patent_id
stringlengths 7
8
| description
stringlengths 125
2.47M
| length
int64 125
2.47M
|
|---|---|---|
11858190 | DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment of the present invention will be described below with reference to the accompanying drawings. An abnormality detection device for injection molding machine according to the present invention stores a physical quantity (a load applied on a servo motor, a speed of the servo motor, a current value of current for driving the servo motor, and a position deviation of the servo motor), which is obtained when a movable part is driven in a normal state and corresponds to time from driving start time or a position of the movable part, of a servo motor, which drives the movable part, as a reference physical quantity in a RAM which is directly readable/writable by a servo CPU and a RAM which is not directly readable/writable by a servo CPU, so as to detect abnormality of the movable part by using the reference physical quantity which is stored in these two RAMs. The RAM which is directly readable/writable by a servo CPU is an internal RAM such as a cash memory which is connected with the servo CPU via an internal bus or an external RAM such as a main memory and a shared memory for servo CPU which is connected via an external bus, that is, a RAM which is readable/writable without intervention of a CPU other than the servo CPU. A RAM which is directly readable/writable by a servo CPU may be accessed in sequence while the servo CPU is controlling a servo motor. Therefore, the RAM is required to be able to meet high speed data reading/writing corresponding to the control for the servo motor and thus, it is necessary to use a memory chip whose access speed is relatively high and whose cost per unit storage capacity is relatively high. Accordingly, only the minimum required storage capacity is often mounted in view of the aspect of cost. On the other hand, the RAM which is not directly readable/writable by a servo CPU is a memory which requires intervention of a CPU other than the servo CPU for reading and writing performed by the servo CPU, that is, a RAM from/to which data cannot be read/written only based on a load instruction or a store instruction which is executed on the servo CPU. When reading/writing of data is performed with respect to such RAM by the servo CPU, the servo CPU exchanges data with another CPU by using a transfer command via an expansion bus or the like and thus, the other CPU with which the servo CPU exchanges data directly reads/writes the data from/to the RAM, generating delay in reading/writing of data. Examples of the RAM which is not directly readable/writable by a servo CPU include a RAM from/to which reading/writing can be directly performed by a CPU performing numerical control, for example. A RAM which is directly used by a numerical control CPU has a relatively large storage capacity so as to be used for numerical control processing. On the other hand, a memory chip whose cost per unit storage capacity is low is often used as the RAM. Thus, a physical quantity detected in the past is stored in two types of RAMs, which are a RAM which is directly readable/writable by a servo CPU (referred to below as a first storage unit) and a RAM which is not directly readable/writable by a servo CPU (referred to below as a second storage unit), as a reference physical quantity in a manner to be associated with time from start of an operation of a movable part or with a position coordinate of the movable part so as to detect abnormality of the movable part by using the reference physical quantity. Accordingly abnormality detection processing taking advantage of each of the RAMs can be performed for the case where operation time of the movable part is short and the case where operation time of the movable part is long, as described below. <Case where Operation Time of Movable Part is Short> In the case where operation time of a movable part is short, the number of points (the number of sampling points) of reference physical quantities to be stored during an operation is small, so that the RAM capacity required for storing reference physical quantities for abnormality detection is small. In this case, as illustrated inFIG.1, abnormality detection is performed by using both of the first physical quantity deviation which is calculated based on a current physical quantity detected from the movable part and a reference physical quantity stored in the first storage unit and the second physical quantity deviation which is calculated based on a current physical quantity detected from the movable part and a reference physical quantity stored in the second storage unit. Since the first physical quantity deviation is calculated based on the reference physical quantity stored in the first storage unit, abnormality can be detected with almost no delay from an occurrence of the abnormality in the case of the abnormality detection performed based on the first physical quantity deviation compared to the case of the abnormality detection performed based on the second physical quantity deviation. <Case where Operation Time of Movable Part is Long> In the case where operation time of a movable part is long, the number of points (the number of sampling points) of reference physical quantities to be stored during an operation is large, so that the RAM capacity required for storing reference physical quantities for abnormality detection is large. In this case, as illustrated inFIG.2, the storage capacity of the first storage unit may be insufficient and abnormality cannot be detected based on the first physical quantity deviation on and after predetermined operation time (the maximum storage time) in this case. However, since the reference physical quantities are stored in the second storage unit as well, abnormality can be detected based on the second physical quantity deviation also on and after the maximum storage time though a certain level of delay is generated. FIG.3is a chief part configuration diagram of an abnormality detection device1for injection molding machine according to an embodiment of the present invention. The abnormality detection device1includes a servo CPU10which is a microprocessor for servo control, a CNC CPU20which is a microprocessor for numerical control, a PMC CPU30which is a microprocessor for programmable machine controller, and a shared RAM40which is directly readable/writable by each of the CPUs. In the abnormality detection device1, information can be transmitted among the microprocessors by selecting mutual input/output via a bus50. To the servo CPU10, a ROM (not illustrated) in which a control program dedicated for servo control for processing of a position loop, a speed loop, and a current loop is stored and a RAM11which is used for temporary storage of data are connected. To the servo CPU10, a servo amplifier12which drives servo motors13for respective axes used for mold clamping, for injection, for screw rotation, for ejector, and the like based on instructions from the servo CPU10is connected. An output from a position and speed detector14attached to the servo motor13for each axis is fed back to the servo CPU10. A current position of each axis is calculated by the servo CPU10based on a feedback signal of a position from the position and speed detector14so as to be updated and stored in a current position storage register (not illustrated) for each axis. FIG.3shows only the servo motor13which drives a mold clamping mechanism and the position and speed detector14which is attached to this servo motor13and detects a position and the like of a movable mold based on a rotation position of this servo motor13. However, respective axes for clamping, for injection, for ejector, and the like have the same configurations as this. Further, to the CNC CPU20, a ROM (not illustrated) in which an automatic operation program for controlling the whole of an injection molding machine and the like are stored and a RAM21which is used for temporary storage of operation data, for example, are connected. To the PMC CPU30, a ROM (not illustrated) in which a sequence program for controlling a sequence operation of an injection molding machine and the like are stored and a RAM31which is used for temporary storage of operation data, for example, are connected. The shared RAM40composed of a nonvolatile memory is a memory which is directly readable/writable by each of the servo CPU10, the CNC CPU20, and the PMC CPU30and is used as a molding data storage memory storing molding conditions and various types of setting values, which are related to an injection molding operation, parameters, macro variables, and the like. In the above-described configuration, the PMC CPU30controls a sequence operation of the whole of an injection molding machine and the CNC CPU20distributes moving instructions to the servo motors13of respective axes based on an operation program, a molding condition stored in the shared RAM40, and the like. Further, the servo CPU10performs servo control such as position loop control, speed loop control, and current loop control based on moving instructions distributed to respective axes and feedback signals of a position and a speed which are detected in the position and speed detector14, as is the case with the prior art, that is, the servo CPU10executes digital servo processing. The above-described configuration is same as that of a control device for injection molding machine of prior art and the abnormality detection device1for injection molding machine according to the present invention is composed of this control device. The abnormality detection device1is different from a control device of the prior art in that the abnormality detection device1stores reference physical quantities in the first storage unit such as the RAM11which is directly readable/writable by the servo CPU10and the second storage unit such as the RAM21which is not directly readable/writable by the servo CPU10in detection of abnormality occurring in a movable part of an injection molding machine so as to detect abnormality of the movable part by using the reference physical quantities stored in these two storage units. Abnormality detection of a movable part is performed based on both of the first physical quantity deviation which is calculated based on a current physical quantity detected from the movable part and a reference physical quantity stored in the first storage unit and the second physical quantity deviation which is calculated based on a current physical quantity detected from the movable part and a reference physical quantity stored in the second storage unit. The first storage unit is directly readable/writable by the servo CPU10. Therefore, through abnormality detection which is performed by calculating the first physical quantity deviation which is a deviation between a reference physical quantity read by the servo CPU10from the first storage unit and a current physical quantity abnormality can be detected with almost no delay from the occurrence of the abnormality. Accordingly it is preferable that the servo CPU10perform processing for calculating the first physical quantity deviation. The second storage unit is not directly readable/writable by the servo CPU10. Therefore, it is necessary to transfer a reference physical quantity read from the second storage unit via another CPU which is capable of performing direct reading/writing with respect to the second storage unit, so as to calculate the second physical quantity deviation which is a deviation between the reference physical quantity read by the servo CPU10from the second storage unit and a current physical quantity. The processing for calculating the second physical quantity deviation may be performed by the servo CPU10or another CPU (the CNC CPU20in the case of use of the RAM21as the second storage unit, the PMC CPU30in the case of use of the RAM31as the second storage unit). Here, as the way to detect a load of a movable part, a load may be detected by configuring a known disturbance load observer in a servo circuit or by preparing a detection unit such as a strain gauge in the movable part. Further, a load may be detected based on driving current of the servo motor13. Alternatively, a load may be detected based on reduction of a speed of the servo motor13occurring when the load is applied in an inverted direction with respect to a traveling direction of the movable part and based on rise of the speed of the servo motor13occurring when the load is applied in the same direction with the traveling direction of the movable part. Alternatively, a load may be detected based on increase of a position deviation of the servo motor13occurring when the load is applied in the inverted direction with respect to the traveling direction of the movable part and based on decrease of the position deviation of the servo motor13occurring when the load is applied in the same direction with the traveling direction of the movable part. FIG.4is a functional block diagram for explaining an operation for detecting abnormality of a movable part in the abnormality detection device1for injection molding machine having the configuration illustrated inFIG.3.FIG.4illustrates a configuration example in which the RAM11inFIG.3is used as a first storage unit110and the RAM21inFIG.3is used as a second storage unit130. The left side from the dotted center line ofFIG.4shows an operation on the servo CPU10side and the right side from the dotted center line shows an operation on the CNC CPU20side. Further, a physical quantity detection unit100and a first abnormality detection unit120inFIG.4are functional means representing functions provided by respectively executing a system program of a physical quantity detection function and a system program of an abnormality detection function on the servo CPU10. Further, a second abnormality detection unit140and a data management unit150are functional means representing functions provided by respectively executing a system program of an abnormality detection function and a system program of a data management function on the CNC CPU20. An operation of the abnormality detection device for injection molding machine according to the present embodiment will be described below in accordance withFIG.4. The physical quantity detection unit100detects a physical quantity such as a position or a speed of the servo motor13based on a feedback signal of a position from the position and speed detector14attached to the servo motor13and a current value of current for driving the servo motor13. The physical quantity detected by the physical quantity detection unit100is stored in the first storage unit110and the second storage unit130and notified to the first abnormality detection unit120and the second abnormality detection unit140. The storage of the physical quantity from the physical quantity detection unit100to the second storage unit130and the notification of the physical quantity to the second abnormality detection unit140are performed via the data management unit150. The second abnormality detection unit140sequentially compares a current physical quantity notified from the physical quantity detection unit100with a reference physical quantity read from the second storage unit130in a manner to associate the current physical quantity and the reference physical quantity with elapsed time in which a movable part operates or an operation position of the movable part. In the case where a deviation obtained through the comparison exceeds a threshold value, the second abnormality detection unit140notifies the first abnormality detection unit120of abnormality In the case where the first abnormality detection unit120is notified of abnormality from the second abnormality detection unit140or in the case where a current physical quantity notified from the physical quantity detection unit100is sequentially compared with a reference physical quantity read from the first storage unit110in a manner that the current physical quantity and the reference physical quantity are associated with elapsed time in which a movable part operates or an operation position of the movable part and a deviation obtained through the comparison exceeds a threshold value, the first abnormality detection unit120notifies the servo amplifier12of an instruction for stopping or decelerating the movable part. The embodiment of the present invention has been described above, but the present invention is not limited only to the example of the above-described embodiment but the present invention can be embodied in various aspects by making appropriate alterations. For example, in one operation of a movable part, a physical quantity detected by the physical quantity detection unit100is stored in both of the first storage unit110and the second storage unit130from the start of the operation of the movable part to the maximum storage time (the maximum number of sampling points) in which storage can be performed in a storage region prepared in the first storage unit110, while a physical quantity detected by the physical quantity detection unit100on and after the maximum storage time until the end of one operation of the movable part is stored in the second storage unit130, in the above-described embodiment. However, in one operation of a movable part, a physical quantity detected by the physical quantity detection unit100may be stored only in the first storage unit110from the start of the operation of the movable part to the maximum storage time (the maximum number of sampling points) in which storage can be performed in a storage region prepared in the first storage unit110, and a physical quantity detected by the physical quantity detection unit100on and after the maximum storage time until the end of the operation of the movable part may be stored in the second storage unit130. In the case of this configuration, physical quantities detected from the start of the operation of the movable part to the maximum storage time (the maximum number of sampling points) may be checked based on reference physical quantities read from the first storage unit110by the first abnormality detection unit120(the servo CPU10) and physical quantities detected on and after the maximum storage time may be checked based on reference physical quantities read from the second storage unit130by the second abnormality detection unit140(the CNC CPU20), Further, in the above-described embodiment, a reference physical quantity obtained by associating a physical quantity detected in a past operation of a movable part with time from start of an operation of the movable part or a position coordinate of the movable part may be directly employed as a reference physical quantity to be stored in the first storage unit110and the second storage unit130. However, as the technique disclosed in Japanese Patent Application Laid-Open No. 2001-030326 and Japanese Patent Application Laid-Open No. 2001-038775, such configuration may be employed that physical quantities for a plurality of times of past operations are stored so as to calculate a reference physical quantity based on the statistic (an average value or the like) calculated based on the physical quantities of a plurality of times of operations. Further, the second abnormality detection unit140operates on the CNC CPU20side in the above description of the example ofFIG.4, but the second abnormality detection unit140may be allowed to operate on the servo CPU10side. The embodiment of the present invention has been described thus far, but the present invention is not limited to the example of the above-described embodiment and may be embodied in other aspects by making appropriate alterations. | 19,753 |
11858191 | DETAILED DESCRIPTION OF THE INVENTION From the state of the art as well as the use in practice, it has been proven that materials such as PET and PA in the outermost layer have proven themselves to achieve the best possible printability and to maintain the highest possible thermal resistance. However, also materials such as PLA or EVOH are far more suitable from the point of view of printability, thermal resistance, further processability than polyolefin-based pipe materials such as PE or PP. Heat resistancemelting temperatureRaw materialDSG (ISO 11357)Homo-PET250° C.PA6220° C.PLA210° C.EVOH (32 mol %)183° C.HD-PE131° C.Homo PP164° C.RawEVAEVAEVArandomCo-PAmaterial28%18%12%LLDPEmLLDPECo-PPPPEVOHPLA6.66PA6Co-PEThomo PETVST (° C.)40-60-70-100-100-100-120-155-160-180-190-210-240-DIN EN507085120120120140175180200210230260ISO 306Printability orPolarityRawSurface tensionmaterial(dyn/cm)PE30-32PP30-32PET43PA43 In order to obtain the sufficient barrier against oxygen or gas, raw materials such as PET, PA, EVOH, PVOH and PV DC have been established. Oxygen barrier65 % rel. humidity80 % rel. humidityRaw materialcm3m2*d*barcm3m2*d*barEVOH (PE 32 mol %)0.51.2EVOH (PE 44 mol %)12.3PVDC (extrusion resin)44PVDC (dispersion1010resin)PAN810PET5050PA63550PVC240240PE-HD25002500PP30003000PE-LD1000010000EVA1800018000 Source: Oxygen permeability at 20° C., measured for various barrier plastics (according to Kyoichiro; from: Joachim Nentwig, Kunststoff-Folien, 3rd edition, 2006. Carl Hanser Verlag; Table 26). But as is known among experts, the barrier property of most of these raw materials is only sufficient if they are appropriately protected against moisture. Therefore, if these raw materials are to provide barrier, they are always used in one of the middle or innermost layers of a film. In order to obtain the best possible sealability, polyolefin-based raw materials, such as PE or PP, or similar, which have the lowest possible sealing temperature or melting temperature, should be used in any case, as is known from practical experience. RawMelting temperature of sealingmaterialmaterials (ASTM D3418)EVA 12%93° C.EVA 18%84° C.POP95° C.mLLDPE118° C.RaCoPP132° C. It is noticeable that the raw materials ideally used to achieve properties such as thermal resistance, printability and the oxygen barrier also have a much higher strength, in particular after biaxial stretching (=biaxial orientation), than polyolefins are only approximately capable of, even despite biaxial stretching. In an optimum layer structure, the oxygen barrier layer should consequently consist of EVOH, PVOH or PA and be disposed in one of the middle or intermediate layers, and the sealant layer, consisting of a heat-sealable polyolefin, in the innermost layer. The outermost layer should be formed by one of the heat-resistant and printable materials ideal for this purpose, such as PET or PA. A closer look at the materials advantageous for properties such as thermal resistance, printability, oxygen barrier, as well as strength, reveals that all materials have various common features, for example, they all have a density of greater than 1.0 g/cm3, they are all polar materials, and they almost all have a melting temperature of more than 170° C. Further consideration of the raw materials to be used preferably as sealant layer also reveals that they all have a density of less than 0.95 g/cm3and a melting temperature <120° C. RawmaterialDensity (g/cm3)PET1.33 to 1.4PA1.12 to 1.14PLA0.124 to 0.125EVOH1.12 to 1.22PE0.89 to 0.96PP0.895 to 0.915 Not all of these raw materials with a density of greater than 1.0 g/cm3are equally ideal for printability, like PA or PET, or thermal resistance, like PET or PA. Nor do they all have an equally high oxygen barrier like EVOH, PVOH or PA, nor are they all equally strength-increasing like PA or PET. But all of them exhibit significantly improved properties in each of the individual properties, and even more so when they are combined in a composite film, particularly after biaxial stretching, than any polyolefin-based raw material. Due to the different optimal characteristics of the raw materials with a density of greater than 1.0 g/cm3with regard to their thermal resistance, printability as well as oxygen barrier and the resulting ideally or preferably division into at least two separate layers, this division results in a further, very positive effect, namely a partly significant increase in the strength and stiffness of the film. This effect becomes more pronounced, the further apart the two layers containing a raw material with a density of greater than 1.0 g/cm3are from each other in the overall composite of the layers. It is therefore necessary to select a layer structure which, on the one hand, comprises at least two independent layers with a density of greater than 1.0 g/cm3, wherein one of these layers forms the outermost layer and the other an intermediate layer. On the other hand, the composite film should contain a heat-sealable layer which forms the innermost layer and consists of a material, preferably a polyolefin, having a density of less than 0.95 g/cm3and a melting temperature of less than 120° C. Although such a layer structure solves the sum of all desired properties (in particular sufficient oxygen and/or water vapor barrier, sealability, thermal resistance, printability and mechanical strength) in an excellent manner, in particular after biaxial stretching, the adjustment or setting of the desired low shrinkage, in particular after biaxial stretching, is not yet solved thereby. This cannot be solved on the raw material side alone, at least not if the film produced has undergone biaxial stretching. This requires a suitable producing process and/or a suitable treatment that fulfills this object. Particularly after stretching, in particular after biaxial stretching, polymers or films made of polymers have a sometimes considerable shrinkage. This shrinkage varies depending on the polymer and is essentially dependent on whether and how much heat or temperature is applied to the film. In other words, the higher the temperature and the longer the exposure time, the higher the shrinkage of the film. Processes and treatments are known from the state of the art which are used for monoaxially stretched films, but also especially for biaxially stretched films, in order to reduce the shrinkage of the stretched films. For monoaxially stretched films in particular, but also for biaxially stretched films, post-treatments are known, i.e. disposed after the stretching process (=orientation process), in which the films are guided over temperature-controlled rolls (so-called tempering rolls) with a wrap being as high as possible. This introduces heat or temperature into the film, i.e. thermally fixes it, and thus reduces the remaining shrinkage. In the stretching (=orientation) of flat films, the so-called tenter frame process, post-treatments (tempering), also known as thermo fixings or heat-settings (thermally fixing), are also known, wherein the film is passed horizontally through a downstream heating oven after stretching and is treated with hot air, thereby reducing the shrinkage. Furthermore, thermal post-treatments following stretching are also known from the so-called triple bubble or multibubble process for tubular films. In this process, the films in tubular form are passed through an oven and treated with temperature, in most cases, as in the tenter frame process, by means of hot air. Alternatively, the film is treated with infrared or hot water vapor in the triple bubble process to reduce the shrinkage caused by stretching. For example, various technologies are known which reduce shrinkage following biaxial stretching by means of temperature application. However, in addition to the level of temperature applied, the time or duration of the temperature effect is also a significant factor here. However, treating the film exclusively with heat/temperature in order not only to reduce the shrinkage in the films, but even to eliminate it completely, is only expedient and sufficient for a few film types. For example, films produced in the tenter frame process, such as BoPET, BoPA or BoPP (Bo=biaxially oriented biaxially stretched), are stabilized by means of a very high heat treatment (thermo fixing) so that they contain very little to no shrinkage. The situation is similar for certain types of film that have been biaxially stretched in the double-bubble process and then thermally fixed by means of tempering rollers or a horizontal hot-air oven. In this case, too, BoPP or BoPA films in particular are often treated or fixed exclusively by means of temperature, and then show no or very little shrinkage. This is mainly due to the fact that, regardless of the stretching process, these types of films are single-type films in which only one type of raw material is used, BoPET (exclusively PET). BoPA (exclusively PA), BoPP (exclusively PP). In this case, a high thermo fixing temperature (fixation temperature) corresponding to the raw material, up to just below the softening point or melting point, can be selected for stabilization, and thus, the shrinkage can be greatly reduced or even eliminated by the temperature treatment alone. Up to now, however, this has been considered impossible for film types consisting of various raw materials, i.e. different types of raw materials, especially for raw materials with widely differing softening or melting temperatures. In practice, for example, no coextruded or biaxially stretched films are known that contain a combination of various raw materials with widely differing softening or melting temperatures and, in addition, have no or only a very slight shrinkage despite stretching. Exceptions to this are isolated multilayer films produced by the tenter frame process or double-bubble process. This essentially involves the following layer structure (from the inside to the outside; HV=adhesion promotor):PP-HV-EVOH—HV-PP Since HomoPP (homopolymeric PP; melting temperature: 155 to 165° C.) is used almost exclusively in combination with EVOH and EVOH types with a high ethylene content, which have a lower melting temperature than those with a low ethylene content (melting temperature: 170 to 180° C.), these composites can indeed be stabilized at similar temperatures almost exclusively by heat treatment, and the shrinkage can be reduced or eliminated. However, these multilayer films based on PP, the majority of which consist of PP, do not exhibit the desired thermal resistance and certainly not the required printability. Since even the most heat-resistant HomoPP types melt at temperatures below 170° C. and PP is also one of the most non-polar raw materials, which is completely unsuitable for printing without further post-treatment, PP is not an ideal raw material to be useed in the outermost layer. In addition, as is well known in the market, these PP-based multilayer films have only very poor or moderate sealability, i.e. a relatively high sealing temperature, due to the PP types used and the fundamentally poorer sealing properties compared to preferred raw materials such as PE. Therefore, these films are conventionally laminated afterwards with PE-based films. Consequently, a multilayer, coextruded and subsequently biaxially stretched film, which comprises a sealant layer with a low melting temperature, which has not been subsequently laminated, which furthermore contains a heat-resistant and printable (polar) outermost layer as well as an oxygen barrier layer located in the intermediate layers, and which has no or minimal shrinkage, is currently not considered to be producible. This is due to the fact that such multilayer composites cannot be produced stably, or at all, at the temperature required to eliminate or reduce shrinkage below 5%, or better still below 3%, without further process measures. Thus, even before the temperature required to eliminate shrinkage is achieved, individual layers in the multilayer composite soften or even melt, inevitably interrupting, or at least massively impairing, the film producing process. When or at what temperature process impairments or even interruptions occur depends essentially on whether and how many layer portions of the entire film composite consist of non-polyolefin-based materials, i.e. temperature-resistant materials, with a density >1.00 g/cm3and a melting temperature greater than 170° C. If the mass proportion of the materials with a density >1.00 g/cm3is more than 40% relative to the total mass of the film's layer structure, the composite film also permits treatment (thermo fixing) at temperatures of 80 to 100° C., and at a mass proportion of 50% and more even beyond that. But even with a high mass proportion of materials with a density >1.00 g/cm3of 40% and more, as long as the film composite contains a sealant layer ofpolyolefin-based raw materials with a density >0.95 g/cm3and with a melting temperature of smaller than 120° C., process impairments or interruptions always occur before a residual shrinkage of less than 5% is reached, respectively in MD and TD, since the temperatures required for thermo fixing the films must be at least between 120 and 150° C., and in this case even materials with a density >1.00 g/cm3and with melting temperatures greater than 170° C. are no longer sufficient to keep the producing process stable. In order not to impair the film producing process, only temperatures that do not completely eliminate shrinkage or shrink can be selected for thermal post-treatment. In order to nevertheless reduce the shrinkage to a minimum or even eliminate it completely, a further process step is required in accordance with the invention. In addition to the treatment of biaxially stretched films with temperature to eliminate shrinkage, a further process step, namely relaxation, is common, especially in the triple-bubble or multibubble process. In this process, the film is allowed to shrink back again in a controlled manner after stretching or orientation; this is known as relaxation and takes place with the introduction of temperature or heat. Relaxation can take place in both directions, i.e. in the production direction or machine direction (MD) as well as in the transversal direction to production (TD). Relaxation can take place equally in both directions (MD and TD) or in a different way (quantitative extend) in one or the other direction. Furthermore, relaxation is also possible in only one direction, i.e. only in MD or TD. The choice of the relaxation direction can always be made independently of each other. In the context of the present invention, the quantitative extend of the relaxation is expressed by the so-called relaxation factor, as defined in more detail below. But even relaxation of the film alone does not sufficiently reduce shrinkage, and in no case can shrinkage even be completely eliminated. This is due to the fact that the films (shrink films/lidding films) are conventionally treated or fixed only at temperatures of max. up to 60 to 80° C. during relaxation, since these relatively low temperatures are already sufficient to achieve controlled shrinkback of the films and to reduce the remaining shrinkage to values by around 10 to 20%, respectively in MD and TD, but at best to >5 to 10% in one of the two directions. Lower shrinkage values have not been achievable so far, since neither the relaxation achievable at these conditions (temperatures) nor the applied temperature are sufficient to reduce the shrinkage to below 5%, respectively in MD and TD. The level of relaxation that can be realized depends essentially on the level of temperature at which the film is treated or fixed. Thus, the highest possible relaxation, which has a further positive effect on the remaining residual shrinkage, i.e. further reduces the residual shrinkage, can only be achieved with correspondingly high temperatures in the film treatment (thermo fixing). In this case, however, the same problem arises again as described previously, namely that when treating films, in particular films containing combinations of raw materials with widely differing melting temperatures, with the temperatures required to eliminate the shrinkage, softening or even melting of individual layers occurs and thus inevitably interrupts, or at least massively impairs, the producing process of the film. When the film is treated with a combination of temperature and relaxation, the temperature range at which the producing process is impaired or interrupted, again depends on the mass proportion of the materials (density >1.00 g/cm3) in the layer structure of the film. Surprisingly, however, the proportion of materials (density >1.00 g/cm3) contained in the film can be significantly lower with appropriate relaxation than with exclusive heat treatment without relaxation. Thus, with appropriate relaxation, treatment at significantly higher temperatures, in any case above 60° C., preferably above 70° C., in particular above 80° C., up to temperatures of 180° C., preferably up to 150° C., in particular up to 120° C., can be applied, with simultaneous reduction of the materials (thermoplastic resin with a density >1.00 g/cm3) to a mass proportion in any case of below 40%, preferably below 30%, in particular below 20%, down to a mass proportion of even less than 10%, relative to the total mass of the layer structure of the film. In this case, the mass proportion of the thermoplastic resin with a density >1.00 g/cm3relative to the total mass of the layer structure of the film is at least 1%, preferably at least 5%. In the method according to the invention, therefore, the temperature of the composite film during relaxation is preferably adjusted or set to one of the following ranges: 60 to 180° C., preferably 60 to 150° C., particularly preferably 60 to 120° C., most preferably 80 to 100° C. It is essential for the method according to the invention that the sum of the relaxation factor in the machine direction (MD) and the relaxation factor in the transverse direction (TD) is at least 0.05 (=5%), preferably at least 0.1 (=10%), preferably at least 0.2 (=20%), in particular at least 0.4 (=40%). Therein, the relaxation factor in the machine direction and the relaxation factor in the transverse direction are each at least greater than 0.00. Consequently, the relaxation factors, in addition to the introduced fixing temperature (temperature of the composite film during relaxation), are decisive factors for reducing or eliminating again the shrinkage introduced during stretching of the film. In the context of the present invention, it has thus proven to be expedient to reduce or relax again in a controlled manner the stretching or elongation of the film introduced during stretching. If the sum of the process steps, including stretching and subsequent relaxation, is considered, a residual stretch or residual elongation is obtained in the film after both process steps. A residual stretch factor can be determined, which is defined in detail in the following and which is based on the ratio of a length of a section of the composite film after stretching and after relaxation to a length of the same section before stretching and before relaxation. Since the residual stretch factor results equally from both processes (stretching and relaxation), it can ideally also be influenced or changed equally by both processes. A closer look at this dependence reveals that even a reduction of the stretch factor under otherwise identical conditions results in an effect similar to a later relaxation of the film, i.e., with lower stretching a very low shrinkage can be achieved even with lower relaxation, and with high stretching a high relaxation is again required to keep the shrinkage low, but surprisingly, basically the influence of the relaxation factor is significantly higher than that of the stretch factor. Nevertheless, it is not the relaxation alone, but rather the sum or factor of both process steps that is decisive. Thus, the residual stretch factor and, of course, the temperature introduced in the relaxation essentially determine whether and how much shrinkage remains in the film. Since not only the relaxation process and the temperature introduced in it, but also the stretching process have a significant influence on the residual shrinkage remaining, and the stretching process is also subject to temperature treatment, the influence from this must also be considered. In fact, an influence can also be seen here, i.e. at low stretching temperatures, without a simultaneous change in other process parameters, there is a higher residual shrinkage than compared with higher stretching temperatures. Compared to relaxation, however, the stretching process is much more sensitive, i.e. the temperatures required to obtain a stable process at all are often within a temperature window of only +/−2 to +/−3° C. Therefore, the temperature range to be varied is smaller or limited in this case. In addition, the influence of the temperature of the composite film during stretching is rather small according to the knowledge of the inventors. The temperature during stretching of the composite film is thus an influencing factor, but not of the same decisive importance as the temperature in the relaxation or else the stretch factor as well as the relaxation factor or the residual stretch factor. A closer look at the process steps and their influence reveals another significant factor, namely the time or duration for which the film is exposed to the individual process steps and the prevailing conditions. However, it turns out that the influence of the time factor in the stretching process is rather negligible compared to the influence of the temperature and the stretch factor. In contrast, it turns out that in the relaxation process, the time (duration) of the relaxation can be of at least equal importance as the relaxation factor and the prevailing temperature. It turns out that the interaction of time (duration) and relaxation factor is less significant than the time (duration) in connection with the temperature, i.e. more precisely, the duration to which the film is exposed to the temperature during relaxation. The longer the duration of the temperature treatment, the greater the influence and thus the reduction in residual shrinkage. However, it also becomes apparent that this cannot be increased indefinitely, but rather that after a certain duration under the influence of temperature, no further increase. i.e. shrinkage reduction, can be realized and a kind of saturation sets in. Much more decisive, however, is the duration for which the film is at least at a minimum under the influence of temperature, so here a duration or dwell time under temperature of at least 2 seconds is required in order to recognize a desired influence. Thus, the method according to the invention may be limited in that the composite film has a temperature in one of the aforementioned temperature ranges for a predetermined period of time during relaxation (a so-called “dwell time under temperature”). Thus, a duration of relaxation or a dwell time during relaxation under temperature must preferably be at least 2 seconds, in particular more than 5 seconds. Thereby, the duration of the relaxation or the dwell time during the relaxation under temperature may be limited to at most 30 seconds, preferably at most 20 seconds, in particular at most 10 seconds. Just as the temperature or the relaxation alone cannot bring about a correspondingly low shrinkage, the dwell time under temperature alone cannot do so. These influencing variables and the effect they achieve are interdependent and influence each other. Thus, the residual shrinkage of the film is low at high temperature treatment and simultaneous high relaxation despite short dwell time under temperature. However, the residual shrinkage of the film is also low with high temperature treatment and long dwell time under temperature despite low relaxation. The remaining residual shrinkage of the film is also low with long dwell time under temperature and high relaxation despite moderate temperature treatment. It is therefore only the combination of these influencing variables that makes it possible to achieve the desired low residual shrinkage of the film. Films according to the inventionRelaxationDwell timefactorResidualFixingLevel ofduringDurationShrinkage afterStretch factor(TD × MD)Level ofstretch factortemperaturefixingrelaxationof dwellstretching and(TD × MD)(%)relaxation(TD × MD)(° C.)temperature(sec)timerelaxation (TD × MD) (%)FILM 1: PET(15%)/HV/PE/HV/PA(20%)/EVOH(5%)/PA(20%)/HV/PE; Percentages by mass of the total mass of the composite film; proportion ofmaterial with a density > 1.0 g/cm3> 50%; fixing temperature = temperature of the composite film during relaxation3.4 × 2.65 × 1↓3.23 × 2.57120→5→19 × 173.4 × 2.640 × 20↑2.04 × 2.08120→5→0 × 0.53.4 × 2.620 × 5→2.72 × 2.4760↓5→17 × 143.4 × 2.620 × 5→2.72 × 2.47180↑5→No stable process3.4 × 2.620 × 5→2.72 × 2.47120→2↓9 × 83.4 × 2.620 × 5→2.72 × 2.47120→9↑0.5 × 0.53.4 × 2.65 × 1↓3.23 × 2.5760↓2↓46 × 423.4 × 2.620 × 5→2.72 × 2.47120→5→2 × 13.4 × 2.640 × 20↑2.04 × 2.08180↑9↑0 × 0Film 2: PET(10%)/HV/PE/HV/PA(10%)/EVOH(5%)/PA(10%)/HV/PE; Percentages by mass of the total mass of the composite film; material with adensity > 1.0 g/cm3< 40%; fixing temperature = temperature of the composite film during relaxation3.4 × 2.65 × 1↓3.23 × 2.57100→5→17 × 183.4 × 2.640 × 20↑2.04 × 2.08100→5→0.5 × 0.53.4 × 2.620 × 5→2.72 × 2.4760↓5→15 × 143.4 × 2.620 × 5→2.72 × 2.47150↑5→No stable process3.4 × 2.620 × 5→2.72 × 2.47100→2↓8 × 83.4 × 2.620 × 5→2.72 × 2.47100→9↑0.5 × 13.4 × 2.65 × 1↓3.23 × 2.5760↓2↓43 × 413.4 × 2.620 × 5→2.72 × 2.47100→5→1.5 × 23.4 × 2.640 × 20↑2.04 × 2.08150↑9↑0 × 0Film 3: PA(10%)/HV/PP/HV/EVOH(5%)/HV/PE; Percentages by mass of the total mass of the composite film; material with a density > 1.0g/cm3< 20%; fixing temperature = temperature of the composite film during relaxation3.5 × 2.85 × 1↓3.33 × 2.7790→5→21 × 243.5 × 2.840 × 20↑2.1 × 2.2490→5→0.5 × 13.5 × 2.820 × 5→2.8 × 2.6660↓5→19 × 223.5 × 2.820 × 5→2.8 × 2.66120↑5→kein stabiler Prozess3.5 × 2.820 × 5→2.8 × 2.6690→2↓9 × 113.5 × 2.820 × 5→2.8 × 2.6690→9↑1 × 1.53.5 × 2.85 × 1↓3.33 × 2.7760↓2↓45 × 473.5 × 2.820 × 5→2.8 × 2.6690→5→2 × 2.53.5 × 2.840 × 20↑2.1 × 2.24120↑9↑0 × 0Film 4: PET(5%)/HV/PE/HV/EVOH(5%)/HV/PE; Percentages by mass of the total mass of the composite film; material with a density > 1.0g/cm3≤ 10%; fixing temperature = temperature of the composite film during relaxation3.5 × 3.05 × 1↓3.33 × 2.9775→5→37 × 343.5 × 3.040 × 20↑2.1 × 2.475→5→1 × 1.53.5 × 3.020 × 5→2.8 × 2.8560↓5→24 × 273.5 × 3.020 × 5→2.8 × 2.8590↑5→kein stabiler Prozess3.5 × 3.020 × 5→2.8 × 2.8575→2↓12 × 143.5 × 3.020 × 5→2.8 × 2.8575→9↑2 × 2.53.5 × 3.05 × 1↓3.33 × 2.9760↓2↓54 × 513.5 × 3.020 × 5→2.8 × 2.8575→5→3 × 43.5 × 3.040 × 20↑2.1 × 2.490↑9↑0 × 0Film 5: PP/HV/EVOH(5%)/HV/PE; Percentages by mass of the total mass of the composite film; material with a density > 1.0 g/cm3≤ 5%; fixingtemperature = temperature of the composite film during relaxation5.0 × 5.05 × 1↓4.75 × 4.9570→5→kein stabiler Prozess5.0 × 5.040 × 20↑3.0 × 4.070→5→9 × 115.0 × 5.020 × 5→4.0 × 4.7560↓5→31 × 345.0 × 5.020 × 5→4.0 × 4.7580↑5→kein stabiler Prozess5.0 × 5.020 × 5→4.0 × 4.7570→2↓28 × 295.0 × 5.020 × 5→4.0 × 4.7570→9↑kein stabiler Prozess5.0 × 5.05 × 1↓4.75 × 4.9560↓2↓37 × 395.0 × 5.020 × 5→4.0 × 4.7570→5→23 × 245.0 × 5.040 × 20↑3.0 × 4.080↑9↑kein stabiler Prozess Thus, in order to solve the defined object, in addition to the ideally applied layer structure with the raw materials preferably contained therein, the combination with the temperatures, process factors, and here in particular the stretch factor, the relaxation factor and the residual stretch factor, as well as the dwell time, at least the duration of the thermal fixation (relaxation), applied in the individual process steps, are of decisive importance. The combination of the features and parameters mentioned above or defined in the independent claims according to the invention has for the first time achieved the goal of producing, and in particular stably producing, a generic composite film by means of coextrusion and without lamination, which, in addition to the properties to be aimed for, such as thermal resistance, printability and oxygen barrier, also has no shrinkage or a shrinkage of less than 5%, preferably less than 3%, in the MD and TD, respectively. It is particularly preferred if the thermoplastic resin contained in the layer (c) or of which the layer (c) consists has a melting temperature of less than 120° C. The increased temperature difference compared to the melting temperature of the outermost layer means that the composite film can be sealed earlier, i.e., already at a lower temperature. In addition, higher numbers of cycles can be achieved during further processing of the composite film. It is also particularly preferred if the thermoplastic resin contained in the layer (a) or of which the layer (a) consists has a melting temperature of more than 170° C. Due to the higher temperature of the outermost layer, higher temperatures can be used in further processing and thus, higher numbers of cycles can be achieved in further processing of the composite film. Furthermore, according to the invention, the layer (a), i.e. the outermost layer, or the thermoplastic resin of the layer (a) can advantageously have a predetermined polarity, which is represented in the shape of the surface tension, given in the unit dyn/cm (dynes per centimeter, a dyne is equal to 10−5N). This value can preferably be >40 dyn/cm, in particular >42 dyn/cm, to enable the best possible printability. According to the invention, it can further be provided in an advantageous embodiment that the outermost layer (a) consists of or contains EVOH. To date, no generic composite film is known from the state of the art in which EVOH has been used as a layer component in the outermost layer (a), or in which the layer (a) would consist of EVOH. Thus, the use of EVOH as a material with an excellent oxygen barrier is known from the state of the art. However, a use for this purpose requires an intermediate layer arrangement of EVOH, since EVOH quickly loses its good oxygen barrier properties due to moisture penetration. Therefore, EVOH has only ever been used as a layer component or layer material surrounded or sandwiched on both sides by protective layers, such as polyolefin or polyamide, some of which have a high water vapor barrier. However, the use of EVOH in generic composite films for a different purpose and in a different way or in a different disposition, for example as an outermost or sealant layer (innermost layer; surface to the good to be packaged), has not been known so far. In contrast, according to the invention, the possibility of deliberately using EVOH in layer (a), i.e. in the outermost layer constituting a surface of the composite film to the outside, is provided. In this context, the outermost layer (a) may contain EVOH or consist thereof. However, when EVOH is provided in the outermost layer (a), the property of EVOH as an oxygen barrier does not play a role. Rather, what matters according to the invention is that the use of EVOH in the outermost layer substantially increases the recyclability of the film compared to composite films that have outermost layers with PA or PET. This is because the EVOH has a lower melting temperature compared to the PA and PET materials previously provided in the outermost layer, so that the difference in the melting temperatures of the outermost layer and the sealant layer (innermost layer) is reduced. Thereby, the overall melting temperature required for recycling can be reduced, which improves the recyclability of the composite film. In addition, the inventors have found that the EVOH in the outermost layer can further improve the mechanical properties, such as stiffness and printability, of the film similar to PET or PA compared to polyolefins, such as PE or PP. For example, the higher melting temperature of the EVOH compared to these polyolefins and the associated greater temperature resistance to the innermost layer (sealant layer) leads to an overall improvement in the further processability of the composite film (number of cycles). The following subject-matter is also disclosed within the scope of this application. The above defined object is solved by the subject-matter defined according to the following numbers.1. Method for producing a multilayered composite film, wherein the method includes at least the following steps:a step of coextruding at least three layers (a), (b) and (c) of whichthe layer (a) forms an outward surface of the composite film;the layer (c) forms a surface of the composite film facing or coming in contact with a good to be packaged: andthe layer (b) is disposed between the layer (a) and the layer (c);wherein the layer (b) consists of a single layer or a plurality of layers (b1, b2, b3, b4, . . . ), preferably two, three or four layers;a step of stretching the coextruded composite film; anda step of relaxing the stretched/oriented composite film:wherein the stretching is bi-axial;wherein a stretch factor in the machine direction or longitudinal direction (MD) is at least 2.0;wherein a stretch factor in the transversal direction (TD) is at least 2.0;wherein the sum of the stretch factor in the machine direction (MD) and the stretch factor in the transversal direction (TD) is at least 5.0;wherein the composite film has a temperature of 70 to 130° C. during stretching;wherein a relaxation factor in the machine direction (MD) is more than 0.00;wherein a relaxation factor in the transversal direction (TD) is more than 0.00;wherein the sum of the relaxation factor in the machine direction (MD) and the relaxation factor in the transversal direction (TD) is at least 0.05 (=5%), preferably at least 0.1 (=10%), preferably at least 0.2 (=20%), in particular at least 0.4 (=40%);wherein the composite film has a temperature of 660 to 180° C., preferably 60 to 150° C., more preferably 60 to 120° C., in particular preferably 80 to 100° C., during relaxation;wherein a dwell time during relaxation, preferably during relaxation under temperature, is preferably at least 2 seconds, in particular more than 5 seconds, or the duration of relaxation is preferably at least 2 seconds, in particular more than 5 seconds;wherein a dwell time during relaxation, preferably during relaxation under temperature, is preferably at most 30 seconds, preferably at most 20 seconds, in particular at most 10 seconds, or the duration of relaxation is preferably at most 30 seconds, preferably at most 20 seconds, in particular at most 10 seconds:wherein a residual stretch factor in the machine direction (MD) is at most 5.0;wherein a residual stretch factor in the transversal direction (TD) is at most 5.0:wherein the layer (a) comprises or consists of a thermoplastic resin having a density of greater than 1.0) g/cm3;wherein the layer (b) or the plurality of the layers (b1, b2, . . . ) each comprises or consists of a thermoplastic resin having a density of greater than 1.00 g/cm3; andwherein the layer (c) comprises or consists of a thermoplastic resin having a density of less than 0.95 g/cm3.2. Method for producing a multilayered composite film, preferably method according to number 1, wherein the method includes at least the following steps:a step of coextruding at least four layers (a), (b), (d), and (c) of whichthe layer (a) forms an outward surface of the composite filmthe layer (c) forms a surface of the composite film facing or coming in contact with a good to be packaged; andthe layer (b) is disposed between the layer (a) and the layer (c);the layer (d) is disposed between the layer (a) and the layer (c), preferably between the layer (a) and the layer (b);wherein the layer (b) consists of a single layer or a plurality of layers (b1, b2, . . . ), preferably two, three or four layers;wherein the layer (d) consists of a single layer or a plurality of layers (d1, d2, . . . ), preferably two, three or four layers;a step of stretching the coextruded composite film; anda step of relaxing the stretched/oriented composite film;wherein the stretching is bi-axial;wherein a stretch factor in the machine direction or longitudinal direction (MD) is at least 2.0;wherein a stretch factor in the transversal direction (TD) is at least 2.0;wherein the sum of the stretch factor in the machine direction (MD) and the stretch factor in the transversal direction (TD) is at least 5.0;wherein the composite film has a temperature of 70 to 130° C. during stretching;wherein a relaxation factor in the machine direction (MD) is more than 0.00;wherein a relaxation factor in the transversal direction (TD) is more than 0.00;wherein the sum of the relaxation factor in the machine direction (MD) and of the relaxation factor in the transversal direction (TD) is at least 0.05 (=5%), preferably at least 0.1 (=10%), preferably at least 0.2 (=20%), in particular at least 0.4 (=40%);wherein the composite film has a temperature of 60 to 180° C., preferably 60 to 150° C., more preferably 60 to 120° C. in particular preferably 80 to 100° C., during relaxation;wherein a dwell time during relaxation, preferably during relaxation under temperature, is preferably at least 2 seconds, in particular more than 5 seconds, or the duration of relaxation is preferably at least 2 seconds, in particular more than 5 seconds;wherein a dwell time during relaxation, preferably during relaxation under temperature, is preferably at most 30 seconds, preferably at most 20 seconds, in particular at most 10 seconds, or the duration of relaxation is preferably at most 30 seconds, preferably at most 20 seconds, in particular at most 10 seconds;wherein a residual stretch factor in the machine direction (MD) is at most 5.0;wherein a residual stretch factor in the transversal direction (TD) is at most 5.0;wherein the layer (a) comprises or consists of a thermoplastic resin having a density of greater than 1.00 g/cm3;wherein the layer (d) or the plurality of the layers (d1, d2, . . . ) each comprises or consists of a thermoplastic resin, preferably a polyolefin, having a density of less than 1.00 g/cm3, preferably less than 0.98 g/cm3;wherein the layer (b) or the plurality of the layers (b1, b2, . . . ) each comprises or consists of a thermoplastic resin having a density of greater than 1.0) g/cm3; andwherein the layer (c) comprises or consists of a thermoplastic resin having a density of less than 0.95 g/cm3.3. Method according to number 1 or 2 above, characterized in thatthe thermoplastic resin of the layer (a) and the thermoplastic resin of the layer (b) are different; orthe thermoplastic resin of the layer (a) is different from the thermoplastic resin of the layer (b) or from all thermoplastic resins of the layers (b1, b2, . . . ); orthe thermoplastic resin of the layer (a) and the thermoplastic resin of the layer (b) are identical; orthe thermoplastic resin of the layer (a) is identical to at least one of the thermoplastic resins of the layers (b1, b2, . . . ).4. Method according to any one of numbers 1 to 3 above, characterized in thatthe thermoplastic resin of the layer (a) has a melting temperature of more than 170° C.; and/orthe thermoplastic resin of the layer (a) has a surface tension >40 dyn/cm, in particular >42 dyn/cm.5. Method according to any one of numbers 1 to 4 above, characterized in thatthe thermoplastic resin of the layer (c) is a polyolefin having a sealing temperature lower than the sealing temperature of the thermoplastic resin of the layer (a); and/orthe thermoplastic resin of the layer (c) is a polyolefin having a melting temperature of less than 120° C.6. Method according to any one of numbers 1 to 5 above, characterized in thatthe thermoplastic resin of the layer (b) has an oxygen permeability of less than 100 cm3/m2·d·bar or the thermoplastic resins of the layers (b1, b2, . . . ) each or in total have an oxygen permeability of less than 100 cm3/m2·d·bar; and/orthe layer (b) has an oxygen permeability of less than 100 cm3/m2·d·bar or the layers (b1, b2, . . . ) each or in total have an oxygen permeability of less than 100 cm3/m2·d·bar.7. Method according to any one of numbers 1 to 6 above, characterized in thatthe stretching is carried out simultaneously or successively in several stages.8. Method according to any one of numbers 1 to 7 above, characterized in thatthe composite film after stretching and relaxation has a shrinkage of less than 0.05 (=5%), preferably less than 0.03 (=3%), in the machine direction (MD); and/orthe composite film after stretching and relaxation has a shrinkage of less than 0.05 (=5%), preferably less than 0.03 (=3%), in the transversal direction (TD); and/orthe composite film after stretching and relaxation preferably has a sum of the shrinkage in the machine direction (MD) and the shrinkage in the transversal direction (TD)(=total shrinkage) of less than 0.05 (=5%).9. Method according to any one of numbers 1 to 8 above, characterized in thatthe thickness of the layer (a) does not exceed 20%, preferably 10%, of the thickness of the entire composite film; and/orthe thickness of the layer (b) or the total thickness of the layers (b1, b2, . . . ) does not exceed 20%, preferably 10%, of the thickness of the entire composite film.10. Method according to any one of numbers 1 to 9 above, characterized in thatthe mass proportion of the layer (a) relative to the total mass of the composite film does not exceed 10%; and/orthe mass proportion of the layer (b) or the sum of the mass proportions of the layers (b1, b2, . . . ) relative to the total mass of the composite film does not exceed 10%.11. Method according to any one of numbers 1 to 10 above, characterized in thatthe sum of the mass proportions of the layer (a) and (b) or of the layer (a) and the layers (b1, b2, . . . ) relative to the total mass of the composite film does not exceed 10%.12. Method according to any one of numbers 1 to 11 above, characterized in thatthe thermoplastic resin of the layer (a) contains or consists of a polyester, preferably a polyethylene terephthalate (PET) or a polylactic acid or a polylactide (PLA), a polyamide (PA), an ethylene-vinyl alcohol copolymer (EVOH), or any mixture thereof.13. Method according to any one of numbers 1 to 12 above, characterized in thatthe thermoplastic resin of the layer (c) comprises or consists of a polyolefin (PO), preferably a polyethylene (PE) and/or a polypropylene (PP), an ethylene-vinyl acetate copolymer (EVA), an ionomer (IO), an ethylene-methyl methacrylate copolymer (EMMA), an ethylene-methacrylic acid copolymer (EMA), or any mixture thereof.14. Multilayered composite film, produced according to any one of numbers 1 to 13 above,wherein the composite film is preferably sheet-like or tubular.15. Multilayered, coextruded, biaxially stretchedloriented, and relaxed composite film, preferably produced by the method according to any one ofnumbers 1 to 13 above, comprising at least three layers (a), (b) and (c), of whichthe layer (a) forms an outward surface of the composite film;the layer (c) forming a surface of the composite film facing or coming in contact with a good to be packaged: andthe layer (b) is disposed between the layer (a) and the layer (c);wherein the layer (b) consists of a single layer or a plurality of layers (b1, b2, b3, b4, . . . ), preferably two, three or four layers;wherein a residual stretch factor of the composite film in the machine direction (MD) is at most 5.0;wherein a residual stretch factor of the composite film in the transversal direction (TD) is at most 5.0;wherein the layer (a) comprises or consists of a thermoplastic resin having a density of greater than 1.00 g/cm3;wherein the layer (b) or the plurality of the layers (b1, b2, . . . ) each comprises or consists of a thermoplastic resin having a density of greater than 1.00 g/cm3; andwherein the layer (c) comprises or consists of a thermoplastic resin having a density of less than 0.95 g/cm3.16. Multilayered, coextruded, biaxially stretched, and relaxed composite film, preferably composite film according to number 15 above, comprising at least four layers (a), (b), (d) and (c), of whichthe layer (a) forms an outward surface of the composite film;the layer (c) forms a surface of the composite film facing or coming in contact with a good to be packaged; andthe layer (b) is disposed between the layer (a) and the layer (c);the layer (d) is disposed between the layer (a) and the layer (c), preferably between the layer (a) and the layer (b);wherein the layer (b) consists of a single layer or a plurality of layers (b1, b2, . . . ), preferably two, three or four layers;wherein the layer (d) consists of a single layer or a plurality of layers (d1, d2, . . . ), preferably two, three or four layers;wherein a residual stretch factor of the composite film in the machine direction (MD) is at most 5.0;wherein a residual stretch factor of the composite film in the transversal direction (TD) is at most 5.0;wherein the layer (a) comprises or consists of a thermoplastic resin having a density of greater than 1.00 g/cm3;wherein the layer (d) or the plurality of the layers (d1, d2, . . . ) each comprises or consists of a thermoplastic resin, preferably a polyolefin, having a density of less than 1.00 g/cm3, preferably less than 0.98 g/cm3;wherein the layer (b) or the plurality of the layers (b1, b2, . . . ) each comprises or consists of a thermoplastic resin having a density of greater than 1.00 g/cm3; andwherein the layer (c) comprises or consists of a thermoplastic resin having a density of less than 0.95 g/cm3.17. Composite film according to any of numbers 14 to 16 above, characterized in thatthe thermoplastic resin of the layer (a) and the thermoplastic resin of the layer (b) are different; orthe thermoplastic resin of the layer (a) is different from the thermoplastic resin of the layer (b) or from all thermoplastic resins of the layers (b1, b2, . . . ); orthe thermoplastic resin of the layer (a) and the thermoplastic resin of the layer (b) are identical; orthe thermoplastic resin of the layer (a) is identical to at least one of the thermoplastic resins of the layers (b1, b2, . . . ).18. Composite film according to any of numbers 14 to 17 above, characterized in thatthe thermoplastic resin of the layer (a) has a melting temperature of more than 170° C.19. Composite film according to any of numbers 14 to 18 above, characterized in thatthe thermoplastic resin of the layer (c) is a polyolefin having a sealing temperature lower than the sealing temperature of the thermoplastic resin of the layer (a); and/orthe thermoplastic resin of the layer (c) is a polyolefin having a melting temperature of less than 120° C.20. Composite film according to any of numbers 14 to 19 above, characterized in thatthe thermoplastic resin of the layer (b) or the thermoplastic resins of the layers (b1, b2, . . . ) each or in total has or have an oxygen permeability of less than 100 cm3/m2·d·bar; and/orthe layer (b) or the layers (b1, b2, . . . ) each or in total has or have an oxygen permeability of less than 100 cm3/m2·d·bar.21. Composite film according to any of numbers 14 to 20 above, characterized in thatthe composite film after stretching and relaxation has a shrinkage of less than 0.05 (=5%), preferably less than 0.03 (=3%), in the machine direction (MD); and/orthe composite film after stretching and relaxation has a shrinkage of less than 0.05 (=5%), preferably less than 0.03 (=3%), in the transversal direction (TD); and/orthe composite film after stretching and relaxation preferably has a sum of the shrinkage in the machine direction (MD) and the shrinkage in the transversal direction (TD)(=total shrinkage) of less than 0.05 (=5%).22. Composite film according to any of numbers 14 to 21 above, characterized in thatthe thickness of the layer (a) does not exceed 20%, preferably 10%, of the thickness of the entire composite film; and/orthe thickness of the layer (b) or the total thickness of the layers (b1, b2, . . . ) does not exceed 20%, preferably 10%, of the thickness of the entire composite film.23. Composite film according to any of numbers 14 to 22 above, characterized in thatthe mass proportion of the layer (a) relative to the total mass of the composite film does not exceed 10%; and/orthe mass proportion of the layer (b) or the sum of the mass proportions of the layers (b1, b2, . . . ) relative to the total mass of the composite film does not exceed 10%.24. Composite film according to any of numbers 14 to 23 above, characterized in thatthe sum of the mass proportions of the layer (a) and layer (b) or of the layer (a) and (b1, b2, . . . ) relative to the total mass of the composite film does not exceed 10%.25. Composite film according to any of numbers 14 to 24 above, characterized in thatthe thermoplastic resin of the layer (a) contains or consists of a polyester, preferably a polyethylene terephthalate (PET) or a polylactic acid or a polylactide (PLA), a polyamide (PA), an ethylene-vinyl alcohol copolymer (EVOH), or any mixture thereof.26. Composite film according to any of numbers 14 to 25 above, characterized in thatthe thermoplastic resin of the layer (c) comprises or consists of a polyolefin (PO), preferably a polyethylene (PE) and/or a polypropylene (PP), an ethylene-vinyl acetate copolymer (EVA), an ionomer (IO), an ethylene-methyl methacrylate copolymer (EMMA), an ethylene-methacrylic acid copolymer (EMA), or any mixture thereof.27. Use of a multilayered composite film according to any one of numbers 14 to 26 above or of a casing made therefrom for packaging a good, preferably for packaging a food product, a luxury food product or a liquid or solid, in particular powdered, good.28. Method according to any one of numbers 1 to 13, composite film according to any one of numbers 14 to 26 or use according to number 27, characterized in thatthe mass proportion of the layer components having a melting temperature of more than 170° C., preferably of the thermoplastic resin of the layer (a) having a melting temperature of more than 170° C. is 1 to <40%, preferably 1 to <30%, preferably 1 to <20%, in particular 5 to <20%, relative to the total mass of the composite film. Supplementary Disclosure and Definitions The method for manufacturing a multilayered composite film according to the invention described herein may be characterized in that it does not comprise a step of laminating, i.e., bonding or conglutination, layers or layer composites. Accordingly, the multilayered composite film described herein according to the invention may be a non-laminated composite film. Length definitions (each based on the machine direction or the transversal direction): L0:=length of a predetermined section of the composite film before stretching; L1:=length of the same section of composite film after stretching and before relaxation: L2:=length of the same section of composite film after stretching and before relaxation: L3:=length of the same section of composite film after stretching and after relaxation; Stretch factor definition: stretch factor V=length L1 of a predetermined section of the composite film after stretching and before relaxation divided by the length L0 of the same section of the composite film before stretching. (V:=L1/L0). Definition of relaxation factor: relaxation factor RL=amount of difference of (the length L3 of a predetermined section of the composite film after stretching and after relaxation and the length L2 of the same section of the composite film after stretching and before relaxation) divided by the length L2 of the same section of the composite film after stretching and before relaxation; (RL=|(L3−L2)|/L2) Definition of residual stretch factor: residual stretch factor RV=length L3 of a predetermined section of the composite film after stretching and after relaxation divided by the length L0 of the same section of the composite film before stretching and before relaxation; (RV=L3/L0)) Preferably, the composite film according to the invention is a multilayered composite film with barrier function or a multilayer barrier film, wherein the barrier property refers to reduced oxygen permeability or reduced water vapor permeability or both. Shrinkage (or heat shrinkage): measured in water at 90° C., preferably within 1 second after immersion, but at least within 10 seconds after immersion. According to the invention, in order to determine the shrinkage (or hot shrinkage), the sample is immersed in water at 90° C. for a predetermined period of time, in particular the aforementioned period of time, and immediately cooled to room temperature with water after removal. The length of a pre-marked section after this treatment is measured, and reference is made to measured length of the same section of the sample before treatment. The resulting length ratio (“shrunk” to “unshrunk”), given as a percentage, defines the shrinkage or shrink. Depending on the direction of the length measurement, the shrinkage is obtained in the longitudinal (MD) and transverse (TD) directions. The total shrinkage is calculated by adding the shrinkage in the longitudinal and transversal directions. Multiple determinations, such as triplicate or quintuplicate determinations, of the length measurements, and the formation of the corresponding average values therefrom, advantageously increase the accuracy of the determination. According to the invention, the shrinkage and the total shrinkage can be determined, in particular according to ASTM 2732. According to the invention, oxygen permeability is measured at 23° C. and 75% relative humidity (ASTMD 1434). The method according to the invention and the composite film according to the invention can preferably be carried out or manufactured using the so-called double-bubble and in particular the triple-bubble method, for which the applicant provides suitable equipment, which is known to the skilled person. Therein, the multilayered composite film can be coextruded from the respective resin melts, for example, by means of a nozzle blow head of the applicant set up for manufacturing composite films with three or more layers, preferably with thermal separation of the individual layers, cooled with a water cooling system of the applicant, reheated, biaxially stretched/oriented (in the machine direction (MD) and in the transversal direction (TD)) by means of an enclosed compressed air bubble and finally relaxed (=heat-set or thermofixed) in a further step in a defined temperature regime. The composite film according to the invention can be a composite film which comprises a barrier against gas diffusion, in particular oxygen diffusion, and/or against water vapor diffusion. Such a manufacturing process is also known to the skilled person from the textbook by Savic, Z., Savic, I., “Sausage Casings”, 1st edition, 2002, VICTUS Lebensmittelindustriebedarf Vertriebsgesellshaft m.b.H., Vienna, Austria, chapter 7, esp. subchapter 4.2, pages 267 to 270. Another way of manufacturing the film according to the invention is by stretching/orienting a coextruded flat film according to the tenter-frame method known to the skilled person. The composite film of the present invention can be advantageously obtained on a device or apparatus or plant of the same applicant for manufacturing tubular food films for food packaging, such as, for example, shrink films or shrink bags, by the jet-blow process, if the device for rapidly cooling thin thermoplastic tubes after their extrusion disclosed in patent specification DE 199 16 428 B4 of the same applicant is additionally used. For this purpose, a corresponding further development according to patent specification DE 100 48 178 84 can also be taken into account. Therein, the tubular film produced from the plastic melt in the nozzle blow head is subjected to intensive cooling, during which the amorphous structure of the thermoplastics from the plastic melt is retained. The tubular film vertically extruded from the plastic melt in the nozzle blow head initially moves without wall contact into the cooling device for cooling, as described in detail in the DE 199 16 428 B4 and DE 100 48 178 B4 publications. In order to avoid repetition, full reference is made to the contents of DE 199 16 428 B4 and DE 100 48 178 B4 with regard to details of the process, structure and operation of this cooling system, which is also referred to as a calibration device. The tubular film then passes through supports in the cooling system, against which the film is supported as a result of a differential pressure between the interior of the tubular film and the coolant, wherein a liquid film or liquid coating is maintained between the film and the supports, so that sticking of the tubular film is precluded. The diameter of the supports thereby influences the diameter of the tubular film, which is why this cooling system of the same applicant is also referred to as a calibration device. According to the invention, polyamide (PA) can be a substance selected from a group consisting of PA of ε-caprolactam or poly(s-caprolactam) (PA6), PA of hexamethylenediamine and adipic acid or polyhexamethyleneadipinamide (PA6.6), PA of ε-caprolactam and hexamethylenediamineladipic acid (PA6.66), PA of hexamethylenediamine and dodecanedioic acid or polyhexamethylenedodecanamide (PA6.12), PA of 11-aminoundecanoic acid or polyundecanamide (PA11), PA of 12-laurinlactam or poly(ω-laurinlactam) (PA12), or a mixture of these PAs or a mixture of these PAs with amorphous PA or with other polymers. The general notation PAx.y is synonymous with PAx/y or PAxy. For the purpose of this application, polyolefin (PO) may be a substance selected from a group consisting of PP, PE, LDPE, LLDPE, polyolefin plastomer (POP), ethylene-vinyl acetate copolymers (EVA), ethylene-methyl methacrylate copolymers (EMMA), ethylene-methacrylic acid copolymers (EMA), ethylene-acrylic acid copolymers (EAA), copolymers of cycloolefins/cycloalkenes and 1-alkenes or cycloolefin copolymers (COC), ionomers (IO) or a mixture or blend thereof. Furthermore, in the context of the present invention, PO also includes a blend of the above PO with ionomers and/or with adhesion promotors. In the context of the present invention, polyester may be used as a layer component for the layer (a). Polyesters are polymers with ester functions in their main chain and may be, in particular, aliphatic or aromatic polyesters. Polyesters can be obtained by polycondensation of corresponding dicarboxylic acids with diols. Any dicarboxylic acid suitable for forming a polyester can be used to synthesize the polyester, in particular terephthalic acid and isophthalic acid, as well as dimers of unsaturated aliphatic acids. As the further component for the synthesis of the polyester, diols can be used, such as: Polyalkylene glycols, such as ethylene glycol, propylene glycol, tetranethylene glycol, neopentyl glycol, hexamethylene glycol, diethylene glycol, polyethylene glycol and polytetramethylene oxide glycol: 1,4-cyclohexanedimethanol, and 2-alkyl-1,3-propanediol. PET, which stands for the polyester polyethylene terephthalate (PET), is particularly preferred. PET can be obtained by polycondensation of terephthalic acid (1,4-benzenedicarboxylic acid) and ethylene glycol (1,2-dihydroxyethane). Another preferred polyester are polylactides or polylactic acids (PLA), which may be included as a layer component in the layers for which a polyester is provided as a layer component. These polymers are biocompatibleibiodegradable and have high melting temperatures or high melting points and good tensile strength, in addition to low moisture absorption. In the context of the present invention, EVOH stands for EVOH as well as for a blend of EVOH with other polymers, ionomers, EMA or EMMA. In particular, EVOH also includes a blend of EVOH and PA or of EVOH and ionomer. Adhesion promotors (HV) may be provided as intermediate layers in the composite film according to the invention and represent adhesive layers that provide good bonding adhesion between the individual layers. In this context, HV can be based on a basic substance or base material, selected from a group, consisting of PE, PP, EVA, EMA. EMMA, EAA and an ionomer, or a mixture thereof. Particularly suitable adhesion promotors (HV) according to the invention are EVA, EMA or EMMA, each with a purity of >99%, preferably >99.9%. According to a further preferred embodiment, layers comprising HV as layer component may also comprise a mixture of PO and HV or a mixture of EVA, EMA, EMMA and/or EAA and HV or a mixture of ionomer and HV or a mixture of a plurality of HV. For the purposes of the present invention, the melting point of a polymer is determined by means of dynamic differential calorimetry or differential thermal analysis in accordance with DIN 51007:2019-04 or DIN EN ISO 11357-1:2017-02. Alternatively, the ASTM D3418 method is also known from the state of the art. For the purposes of the present invention, the softening point of a polymer is determined according to the method for determining the Vicat softening temperature (VST) according to DIN EN ISO 306:2014-03. For the purposes of this invention, printability is measured according to DIN 16500-2:2018-09. For the purposes of the present invention, the designation of a material as a “layer component” means that a layer of the composite film according to the invention comprises this material at least in part. In this context, the designation “layer component” within the meaning of the present invention may in particular include that the layer consists entirely or exclusively of this material. For the purposes of the present invention, “middle” or “intermediate” layer means a layer of the composite film which is disposed between the layer (a) and the layer (c). According to the invention, the layer (a) is the layer which forms an outward surface of the composite film (outermost layer). According to the invention, the layer (c) is the layer which forms a surface of the composite film facing or coming into contact with the good to be packaged (innermost layer). By definition, the layers (a) and (c) of the composite film according to the invention cannot be a “middle” or “intermediate” layer. Preferably, the composite film according to the invention is sheet-like or tubular. Preferably, the composite film is a food film or food casing. The composite film is further preferably suitable for use as a non-heatshrinkable packaging material. Examples of coextruded and biaxially stretched multilayer films with barrier function according to the invention with at least three layers (a), (b) and (c) 3-Layer Structures (a)(b)(c)PAEVOHPO Examples of coextruded and biaxially stretched multilayer films with barrier function according to the invention with at least four layers (a), (b), (d) and (c) 4-Layer Structures (a)(d)(b)(c)PETPOEVOHPOPAPOEVOHPOPETPOPVDCPOPAPOPVDCPOPETPOPAPOPAPOPAPO 5-Layer Structures (a)(d1)(b)(d2)(c)PETPOEVOHHVPOPAPOEVOHHVPOPETPOPVDCHVPOPAPOPVDCHVPOPETPOPAHVPOPAPOPAHVPO 7-Layer Structures (a)(d1)(d2)(d3)(b)(d4)(c)PETHVPOHVEVOHHVPOPAHVPOHVEVOHHVPOPETHVPOHVPVDCHVPOPAHVPOHVPVDCHVPOPETHVPOHVPAHVPOPAHVPOHVPAHVPO 9-Layer Structures (a)(d1)(d2)(d3)(b1)(b2)(b3)(d4)(c)PETHVPOHVPAEVOHPAHVPOPAHVPOHVPAEVOHPAHVPO | 63,886 |
11858192 | DESCRIPTION OF EXAMPLE EMBODIMENTS The present invention is explained below with reference to a sealing device100for a twin-screw extruder. However, the invention is not to be restricted hereby. In particular, the generalisation of the following description to sealing devices for extruders with only one or more than two screws and also the generalization to sealing devices for other machines which have one or more shafts which are to be sealed with respect to a housing, is to be included by the invention, in so far as it falls within the subject of the claims. FIG.1shows a schematic view of the sealing device100for sealing an intermediate space between a housing and a shaft which is rotatably mounted in the housing. The sealing device100has a plate-shaped first body110. The sealing device100can consist substantially of the first body110. However, as explained below by way of example with reference toFIG.2, it can also be constructed from several components. The first body110is formed as a cover plate, i.e. its extent in two directions is greater than its extent in the third direction. The first body110is configured here such that it can be mounted in a secure and flush manner, e.g. by screw connections, riveting, welding or suchlike, on a surface of the housing which is to be sealed. The surface of the first body110, which comes in contact with the housing, can be configured in any desired manner here, as long as it is guaranteed that the contact between housing and first body110is tight such that materials exiting from the housing can not escape along the connection between housing and first body110. In this way, it is achieved that the desired sealing between housing and shaft can also be produced between the first body110and the shaft. The sealing between housing and first body110can take place here in any desired known manner, e.g. by pure press connection of components lying against one another by means of screwing, riveting or suchlike, by additional sealing means, such as for instance rubber sealing elements, or sealing media, such as grease for instance, or else through a welding of first body110and housing. As is explained with reference toFIG.1, further components can also be arranged between the housing and the first body110, as long as the connection of the housing to the first body110(including the further components) is tight as a whole. The first body110can consist here of any sufficiently strong material which is suitable to be formed in the form described further below, and which can be connected to the housing. In particular, the first body110can consist of a metal such as aluminium, for instance. However, the first body110can also be made from a sufficiently hard plastic or from ceramic. In the first body110a (first) opening120is provided, which extends between a rear side and a front side of the first body110. The first opening120is sufficiently large that the shaft projecting out from the housing can be directed through it when the sealing device100or respectively the first body110are connected to the housing. For example, the opening120can have a diameter of 10 to 100 cm or more, for instance 20, 40, 60 or 80 cm. The first opening120therefore allows the shaft to rotate when the sealing device100and the housing of the shaft are connected to one another. Through the fixed and tight connection of housing and first body110a region from which the material which is to be sealed (e.g. a powder, such as chalk, talcum or a colour powder), situated in the housing, can exit, shifts to the intermediate space between first body110and the shaft. Therefore, for sealing, it is sufficient to seal the region of the opening120which is not filled by the shaft. For this, the first body110has a line130or respectively a line system formed by the line130, in which a sealing medium, in particular a gaseous or liquid sealing medium, such as for instance air, water or grease, can be directed to the opening120. The line130can have here any desired cross-section suitable for directing the desired sealing medium, which cross-section can also change in its shape and its area. The diameter of the line130can lie in the range of 1 mm to 20 mm, and can be e.g. 2 mm, 5 mm, 10 mm or 20 mm. The line130has one or more inlets132, via which the sealing medium can be introduced into the line130. InFIG.1, three such inlets132are shown. However, it is self-evident that any desired expedient number can be used, in particular also only one inlet132. The inlets132can be situated both on the front side and also on the rear side of the first body110. The feed of the sealing medium can therefore take place from the exterior, i.e. via the side of the first body110facing away from the housing. However, it can also take place via lines arranged in the housing or in intermediate components. The inlets132are situated then in the side of the first body110facing the housing. The inlets or respectively the inlet132can, however, also be situated on the side of the first body110. From the inlets132, the line130extends via diversions134and divergences or respectively branches136to outlets138, via which the sealing medium can be brought to the shaft which is directed through the opening120. The diversions134and divergences136serve to surround the shaft with the sealing medium in as radially symmetrical a manner as possible. The line130is therefore formed such that the outlets138are arranged radially symmetrically to the shaft axis. Thus, inFIG.1the four outlets138are respectively offset to one another by 90°. The number of the outlets138can be as desired. Preferably it is greater than one, in order to guarantee a uniform feed of sealing medium. However, a sealing device100with only one outlet138is also conceivable. The combination of first opening120and line130, described above, in a plate-shaped first body110constitutes the basic principle of the sealing device100. Hereby, a simple sealing of a shaft rotating in a housing can be achieved. Even if this is not shown below in the figures, this combination can be used alone for an individual shaft. Likewise, it would be possible to accommodate several such combinations in a single sealing plate, in order to seal off several shafts. Alternatively, as explained below with reference toFIG.2, several sealing plates, which are formed in accordance with the first body110, can be mounted over one another (or behind one another), in order to seal off several shafts. For this purpose, as shown inFIG.1, a further (third) opening160can be provided, through which a further shaft can be directed. This further opening160is not, however, provided with outlets138, i.e. no sealing medium can be introduced into the further opening160from the line130provided in the first body110. In addition to the above-mentioned components, a cooling line170can also be provided in the first body110, in order to dissipate frictional heat which has occurred owing to the rotational movement of the shaft. The first body110can be formed in one piece, as shown in the figures, i.e. the first body110is not formed from various components. In particular, the first body110can be produced in an additive manufacturing method, such as 3D printing. This has the advantage that the line130and the openings120,160can have a far more flexible and almost any desired form. In addition, through the dispensing of machining manufacturing techniques, such as drilling or milling, shavings are prevented from blocking the line130entirely or partially. Preferably, the first body110then consists of a metal, aluminium for instance. However, it is also possible to compose the first body110from several components. The line130can then also be produced with machining methods, e.g. by milling on the surface of a component, which is then covered by another component. In order to keep the sealing medium, exiting from the outlets138, within the opening120on the shaft, the opening120is configured such that a (first) sealing means140can be inserted therein, which seals off the opening120completely in the region between first body110and the shaft, without covering the outlets138. A further (second) sealing means can likewise be arranged for example in the opening120(without covering the outlets138), in order to prevent an exiting of the sealing medium from the opening120. However, the opening120can also be sealed off in another way against such an exiting, e.g. by sealing means applied in a flat manner on the first body110, through which the shaft projects, or by a sealing means which is held in its position by a further component or sealing plate. The sealing means140is arranged with respect to the outlets138preferably on the side of the sealing device100facing the housing. It therefore serves as first sealing for material exiting from the housing. The sealing means140can adopt any desired form here which is suitable for sealing off the intermediate space between the first body110and the rotating shaft. For example, the sealing means140can be an O-ring, a radial shaft sealing ring or suchlike or else a combination thereof. Preferably, the sealing means140is configured as a stuffing box, as this permits a readjusting in the event of leakage. The sealing means140typically consists of rubber, caoutchouc or suchlike. The opening120can then be configured e.g. in a graduated manner, in order to enable a pressing in and hence spreading open of the sealing means140against the gradation, whereby the sealing means140is pressed against the rotatable shaft and thus improves the sealing. With a running shaft, it can always occur that the shaft shifts perpendicularly to the rotation axis. This leads to a squeezing of the sealing means140whereby a small leaky region can occur between sealing means140and shaft or between sealing means140and first body110. The material which is to be sealed, situated in the housing, can exit through this region. However, it is then caught by the sealing medium in the opening120. In addition, with provision of a further sealing means on the other side of the outlets138, the sealing medium can be introduced under pressure in the intermediate space between the sealing means. The occurrence of a leaky region at one of the sealing means then leads to the sealing means flowing into the region and hence preventing the material, which is to be sealed, from exiting. Pressure sensors connected to the line can establish the pressure drop connected therewith. This makes it possible to monitor the tightness of the sealing, in order to promptly initiate a repair or a replacement of the sealing device100. However, the sealing means140can also be able to be inserted into the opening120on the side of the sealing device100facing away from the housing, and to be held there e.g. by a gradation. Also in this case an improved sealing is achieved through the combination of sealing medium and sealing means140. The sealing medium is then held in the opening by a further sealing means e.g. lying on the first body110, which is arranged between the first body110and the housing. With the sealing device100shown inFIG.1it is therefore possible to solve the above-mentioned problems. A sealing medium can be directed in a line which is arranged in a sealing plate without machining methods and without lack of space, radially symmetrically into an opening in which it seals the region around a rotatable shaft. In addition, the opening can receive sealing means or can be sealable by sealing means which hold the sealing medium between them. Thereby, a durable and reliable sealing is achieved. FIG.2shows schematically an arrangement of the sealing device100ofFIG.1which is supplemented by further components, on a housing200, e.g. a twin-screw extrusion device. The sealing device100ofFIG.1is suitable for the sealing of a first shaft310and a second shaft320, which in the housing200drive two extruder screws of the extrusion device. In addition to the first body110, described above, with the first opening120, the sealing device100in the example ofFIG.2has a second body410with two second openings420and a third body510, which is configured substantially like the first body110. The first body110is connected here in the direction of the housing200on the third body510and oppositely with the second body410. The sealing device100is connected to the housing200via the third body510. As shown inFIG.2, the individual components can be fastened to one another by means of screw connections. However, any other fastening method is also possible, such as e.g. welding. The first shaft310is directed in the manner described above through the first opening120of the first body110. The first opening120has a gradation in the direction of the housing200, at which the first sealing means140sits firmly. The outlets138of the line130are arranged following thereafter, via which the sealing medium is fed into the opening130. The first shaft310then runs through a second opening420in the second body410and from there to the gearing (not shown). This second opening420(alternatively the first opening120or both openings in cooperation) holds a second sealing means150, which together with the first sealing means140delimits a region of the first opening120and holds the sealing medium therein. This sequence enables a reliable sealing of material which is to be sealed, exiting form the housing200along the first shaft310. A similar sequence of sealing means and line outlets is provided through the interaction of the housing200and of the third body510for the second shaft320. The third body510has a first opening520corresponding to the first opening120of the first body110, through which the second shaft320projects. Third sealing means540, corresponding to the first sealing means140are fixed at a gradation in the first opening520of the third body510. These and fourth sealing means550corresponding to the second sealing means150enclose outlets of a line530, formed in the third body510, opening out in the first opening out in the first opening520of the third body510. The line530of the third body510can be connected here with the line130of the first body110, or can have its own inlet for an (also further) sealing medium. The fourth sealing means550are held here by a recess in the housing200and/or the first opening520of the third body510. The second shaft320then runs further through the third opening160of the first body110and through a further second opening420in the second body410, without having to be sealed once again. From there, the second shaft runs to the gearing (not shown). For the first shaft310a third opening560of the third body510, through which the first shaft310also runs, without being sealed, corresponds to the third opening160of the first body110. The first, second and fourth sealing means140,150,540,550described above can all be of the same type and formed e.g. as an O-ring, radial shaft sealing ring, press seal or stuffing box packing. The sealing means140,150,540,550can, however, also be configured differently, if this were necessary e.g. for reasons of manufacturing technique or for reasons of cost. Likewise, the combination of different sealing types for a sealing means is possible. As with the first body110, the third body510can be produced in one piece by means of additive manufacture, whereas the second body410is preferably manufactured in a conventional manner, as it does not have a branching line system like the first body110and the third body510. The feed to the line inlet132shown on the gearing side in the second body410can be produced here by a bore. However, it is also possible to produce first and third body or else all three bodies in one piece by means of additive manufacture. Through the sealing device, shown inFIG.2, an effective sealing can be achieved for a multi-shaft extrusion device, by the sealing being shifted from the housing of the extrusion device into a sealing plate which is to be fastened on the housing. This is preferably produced by means of 3D printing in order to guarantee a uniform and therefore better sealing feeding in of sealing medium to the shaft. The above-mentioned components of the sealing device can all be realized by means of computer program products which are known in principle and are suitable for additive manufacture, e.g. files for 3D printing, when these are executed on a device for additive manufacture. This makes it possible to produce the sealing devices in a decentralized manner. LIST OF REFERENCE NUMBERS 100sealing device110first body120first opening of the first body130line in the first body132inlet of the line in the first body134diversion of the line in the first body136divergence of the line in the first body138outlet of the line in the first body140first sealing means150second sealing means160third opening of the first body170cooling line200housing310(first) shaft320(second) shaft410second body420second opening510third body520first opening in the third body530line in the third body540third sealing means550fourth sealing means560third opening in the third body | 17,161 |
11858193 | DETAILED DESCRIPTION OF THE DRAWINGS With reference to the figures, the system according to the disclosure, generally designated by the reference numeral1, comprises an apparatus for blow molding plastic containers which comprises a blow molding carousel10which can rotate about a main rotation axis100and is operatively connected, at a first transfer station20, to a feeding line21of preforms50. The preforms50are of the type comprising a preform body51and a preform mouth52. The blow molding carousel10supports, at its peripheral region11, a plurality of forming units12arranged around the main rotation axis100. Each forming unit12comprises a mold13formed by two mold parts13a,13bwhich can move with respect to each other, in order to pass from an open position for feeding the preforms50, and a closed position in which it defines at least one forming cavity. The first transfer station20comprises a transfer carousel23which can rotate about an axis of the transfer carousel101that is parallel to the main rotation axis100. The first transfer station20supports a plurality of grip elements24which are associated with at least one respective grip body25which is designed to pick up at least one respective preform50from the feeding line21in order to feed it to a respective forming cavity. The grip element24comprises a first arm24a, which is supported so that it can rotate by the transfer carousel23in order to rotate on command about a substantially vertical pivoting axis102, and a second arm24b, which extends longitudinally and can slide on command with respect to the first arm24aalong an advancement/retraction direction200which is substantially parallel to its own direction of extension. According to the present disclosure, the grip body25comprises a coupling element25awhich is configured to stably hold the preform50substantially by the preform mouth region52. The coupling element25ais movable on command with respect to the second arm24balong a movement trajectory301which has at least one component that is parallel to the vertical direction. In particular, the coupling element25acan move along the movement trajectory301substantially at the step of disengagement from the preform mouth52. According to a possible practical embodiment, the grip body25is supported so that it can rotate by the second arm24bin order to rotate on command about a tilting axis103which is substantially horizontal and substantially perpendicular to the advancement/retraction direction200substantially at the step of disengagement from the preform mouth52. The angular movement of the grip body25about the tilting axis103determines, in this case, the movement of the coupling element25aalong the movement trajectory301. In particular, as shown inFIGS.3and4, the grip body25is made to rotate about the tilting axis103from a transport and release position, in which the axis of the coupling element25a(which coincides with the axis of the preform50associated therewith) is arranged substantially vertically, to a disengagement position in which the axis of the grip body is inclined with respect to the vertical. This transition is completed as soon as the coupling element25ahas released the respective preform50in the respective forming cavity. According to another possible, and in some applications preferred, embodiment (shown inFIGS.5to7), the grip body25is supported so that it can slide by the second arm24balong a substantially vertical movement direction so as to allow its displacement along the movement trajectory301. During the transition from the transport and release position to the disengagement position, the coupling element25ais furthermore brought to a higher level than to the level where it is in the transport and release position, so as to prevent any interference with the movable mold parts13a,13b. Advantageously (as illustrated in the perspective view ofFIG.4), the coupling element25ais operatively associated with air suction means70and is configured to couple hermetically with the preform mouth52so as to hold the preform50. Specifically, the air suction means70comprise a suction conduit72leading into a suction intake73defined at the coupling element25a. A flow control valve is arranged along the suction conduit72. With reference to the embodiment illustrated inFIG.5, a partial vacuum is generated inside the preform50; with reference to what is shown inFIGS.6and7, instead, the coupling element25acomprises an element which can expand radially on command in order to engage against the internal surface of the preform50substantially at the preform mouth52so as to hold the preform50. In particular, the radially expandable element comprises, for example, retention sectors61which are adapted to transition, on command, from a retracted condition (shown inFIG.6) and an expanded position (shown inFIG.7). Preferably, the movement on command of the retention sectors61from the retracted condition and the expanded condition occurs against elastic means which comprise, for example, an O-ring62. The transition from the retracted condition and the expanded condition can occur by way of the movement of an actuation element63which has a frustum-shaped portion63athat engages a complementarily-shaped surface61adefined on the retention sectors61so that a displacement in the axial direction of the actuation element63determines a displacement in a radial direction (indicated by the arrow300ofFIG.7) of the retention sectors61. The displacement of the actuation element63can be controlled by a pneumatic valve64in contrast with the action of a spring65. There can also be an interconnection spring66that acts between the coupling element25aand the grip body25. With reference to the embodiment shown inFIGS.8and9, it is possible for the coupling device25ato be configured in such a way to hold the preform50by virtue of means that are adapted to provide an air blade90that is directed parallel to a coupling portion25adefined by the preform50. Specifically, the means adapted to provide an air blade90comprise two plate-like elements91and92, mutually spaced apart so as to define an annulus-shaped gap that leads, outward, into an outlet. The outlet is arranged proximate to, advantageously above, the coupling portion25a, so that an air flow, supplied by a supply channel connected to the gap, can generate an air blade that will strike the coupling portion25aand as a consequence, substantially owing to the Bernoulli effect, can ensure the preform50is held without in practice there being any contact between the preform50itself and the coupling element25a. In more detail, the apparatus1comprises a first cam (not shown) which is supported by a supporting structure and can be engaged by at least one first engagement element31associated with the first arm24ain order to control the angular position of the first arm24aabout the pivoting axis102during its rotation about the axis of the transfer carousel101. By way of example, the first arm24acomprises a supporting rocker which is hinged to the transfer carousel23in order to rotate about the pivoting axis102and is provided with a cam follower which defines the first engagement element31and is designed to come into contact with the first cam which is adapted to control the angular position of the supporting rocker about the pivoting axis102. The apparatus1comprises a second cam which is supported by the supporting structure and can be engaged by at least one second engagement element32which is associated with the second arm24bin order to control the longitudinal position of the second arm24bwith respect to the first arm24aalong the advancement/retraction direction200during its rotation about the axis of the transfer carousel101. By way of example, the first arm24adefines a cradle-shaped portion, extending along a direction parallel to the advancement/retraction direction200, which can be engaged slideably by a respective slider portion which is integral with the second arm24b. The apparatus1comprises a third cam which is supported by the supporting structure and can be engaged by at least one third engagement element33which is associated with the grip body25in order to control the angular position of the grip body25with respect to the second arm24babout the tilting axis103during its rotation about the axis of the transfer carousel101. Obviously, the third cam is not envisaged in the embodiments, such as the embodiments shown inFIGS.8and9, wherein the grip body25is supported so that it can slide by the second arm24balong a substantially vertical movement direction, so as to allow its displacement along the movement trajectory302. As already noted, the grip body25is designed to rotate about the tilting axis103after the release of the preform50at the respective forming cavity, so as to facilitate the disengagement of the coupling element25afrom the mold13for the grip bodies shown inFIGS.5to7. In order to enable the third engagement element33to maintain its substantially vertical axis during the tilting of the grip body about the tilting axis103, there is conveniently a kinematic interconnection element40arranged between the second arm24band the grip body25. The kinematic interconnection element40comprises a linkage device41which supports the third engagement element33and is supported by the element24aabout a pivoting axis103ain order to actuate the movement of a linkage42which has, at the ends, two joints41aand43which are connected, respectively, to the linkage device42and to the grip body25. The feeding line21is arranged downstream of a conditioning oven21afor the preforms50. The operation of the apparatus1for blow molding containers, according to the disclosure, is the following. The preforms50, exiting from the conditioning oven21a, are brought to the feeding line21. At the transfer station20, the preforms50are picked up by virtue of the action of the coupling elements25a, which engage with the respective preform at the preform mouth52, by virtue of the action of the air suction/pressure means or via the radially expandable element. The preforms50picked up by the feeding line21are then transferred, during the rotation of the transfer carousel23, to the mold13. During this transfer, the first arm23rotates about the pivoting axis102and the second arm24slides with respect to the first aim24aalong the advancement/retraction direction200. Once the preform50is released into the respective forming cavity, the grip body25is made to rotate about the tilting axis103so as to facilitate the disengagement from the mold13. FIGS.10to16show in more detail possible practical embodiments of the coupling device25shown inFIGS.8and9. In particular, the coupling device25comprises a grip device, generally designated inFIGS.10to16with the reference numeral1′, for the support and movement of preforms50′, which extend along a longitudinal axis100′ and are of the type with an access port51′ which defines, at the rim51a′, an annular radial flaring52′ that lies on a plane of arrangement that is substantially perpendicular to the longitudinal axis100′. According to the present disclosure, the grip device1′ comprises a supporting element2which is operatively associated with an air supply conduit3′ and is connected to at least one air outflow nozzle5′. The at least one nozzle5′ is, in particular, adapted to generate at least one respective flow of air which is designed to arrange itself parallel to at least one portion of the radial flaring52′ of a preform50′ to be held in order to enable the preform50′ to be supported without contact. In practice, the supporting element2′ is configured so as to provide an annular “Bernoulli” sucker which is designed to face, at least partially, toward the radial flaring52′ of a preform50′ to be held. Advantageously, the supporting element2′ comprises a centering body2a′ which is designed to engage at the access mouth51′ of the preform50′ to be supported. Conveniently, the supporting element2′ comprises a delivery port6′, connected to an air delivery conduit4′, which leads, during use, inside the preform50′. The supply conduit3′ and, if present, the delivery conduit4′, are connected to means for supplying compressed air or air under pressure (not shown in the figures). The delivery port6′ is struck, on command, by a flow of air which is adapted to facilitate, if necessary, the disengagement of the preform50′ from the supporting element2′. The grip device1′ comprises actuation means which are configured to force the passage of air through the supply conduit3′ so as to enable the supporting element2′ to hold the preform50′. These actuation means can be configured to force the passage of air also through the delivery conduit4′, when it is necessary to release the preform50′ from the supporting element2′. Conveniently, the supporting element2′ defines a surface, preferably flat,20′, preferably with an annular extension, which is designed to face upward toward the radial flaring52′ of the preform50′. In this specific case, the (or each) nozzle5′ is adapted to convey the respective air flow so as to strike the surface20′ so as to create a partial vacuum that is such as to allow the supporting element2′ to hold the preform Specifically, the partial vacuum is substantially generated exclusively at the annular portion20′ arranged opposite to the radial flaring52′ of the preform. With reference to the embodiment shown inFIGS.10to12, the supporting element2′ comprises two plate-like elements11′,12′ which are arranged mutually facing and which define, between the respective mutually facing faces, a gap that can be passed through by the flow of air that is designed to exit from the at least one nozzle5′. In this case, the nozzle5′ comprises the outlet of the gap directed toward the outside. With reference to such embodiment, the plate-like element11′ arranged above has a greater radial extension than the plate-like element12′ arranged below, so as to define the surface20′ that is designed to face toward the radial flaring52′. Alternatively, as shown inFIGS.13to16, the grip device1′ comprises a supply conduit3′ constituted by a central hollow body30′, which during use is coaxial with the axis100′ of the preform50′ and is connected, by way of a plurality of radial conduits31′, to respective nozzles5′ which lead outward in order to strike the surface20′. Such solution, which is conceptually similar, while providing less holding force, appreciably reduces the amount of air necessary for its operation. So it is possible to use grip devices1′ with a configuration similar to that shown inFIGS.10to12at star conveyors for feeding or unloading, in which rapid displacements are needed with short holding times, and grip devices with a configuration similar to that shown inFIGS.13to16can be used when the preforms50′ are to be held for relatively long periods of time, such as for example while passing through the conditioning oven arranged upstream of a blow-molding station. According to a further aspect, the present disclosure relates to an apparatus for handling preforms50′ of plastic for the production of containers, which comprises a supporting body that can move on command and is associated with a grip device1′ according to one or more of the preceding claims Such supporting bodies can be integrated, as explained above, in star conveyors or manipulators for feeding or unloading preforms, or they can be associated with conveyor elements, for example catenaries, for passing through a conditioning oven. The operation of the grip device1′ according to the disclosure is evident from the foregoing description. In particular, with reference to what is shown inFIG.10, air under pressure, for example generated by a compressor, is sent to the supply conduit3′ of a supporting device2′ according to the disclosure, under which a preform is arranged which is to be held and, optionally, moved. The air flow passing through the supply conduit (shown with the arrow200′) is sent, through the gap between the two plate-like elements11′ and12′, to the nozzle5′ (which extends about the axis100′) so as to generate an air blade that strikes the surface20′ underneath, thus creating a partial vacuum that tends to keep the preform50′ “suspended”, even though there is no contact, from the supporting element2′. When it is necessary to disengage the preform from the supporting element2′, it is possible to supply the air (as indicated by the arrow201′) to the delivery conduit4′, and therefore to the delivery port6′, so as to facilitate the disengagement of the preform40′ from the supporting element2′. In practice it has been found that the disclosure fully achieves the intended aim and objects by providing an apparatus for blow molding containers that makes it possible to feed preforms of different diameters and shapes, since it does not need to engage with the external surface of the preform. The disclosure thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims Moreover, all the details may be substituted by other, technically equivalent elements. In practice the materials employed, provided they are compatible with the specific use, and the contingent dimensions and shapes, may be any according to requirements and to the state of the art. | 17,421 |
11858194 | DESCRIPTION OF THE EMBODIMENTS Embodiments of the present invention will be described below with reference to the drawings. In the embodiments, for the sake of easy understanding, structures and elements other than the main part of the present invention will be described in a simplified manner or omitted. In addition, in the drawings, the same elements are denoted by the same reference numerals. Note that, in the drawings, the thickness, shape, and the like of a container and a preform are schematically illustrated, and do not indicate actual thickness, shape, and the like. First Embodiment <Configuration Example of the Container> First, a configuration example of a container10made of resin according to the present embodiment will be described with reference toFIGS.1A to1C. FIG.1Ais a front view of the container10,FIG.1Bis a bottom view of the container10, andFIG.1Cis a cross-sectional view of the container taken along line Ic-Ic. InFIGS.1A to1C, an axial direction L of the container is indicated by an arrow. The container10is a container used for, for example, infusion of a drug, and is manufactured from a preform20having a bottomed cylindrical shape described later by the stretch blow molding method. The container10includes a body portion11formed in a substantially rectangular shape in a front view, a neck portion12which is formed at the center on an upper side of the body portion11and serves as an entrance and exit of the container10, and a bottom cylindrical portion13which is formed at the center on a lower side of the body portion11and has a closed bottom surface side. A flange14having an annular shape, which is an example of a structure protruding outward in the radial direction of the bottom cylindrical portion13, is formed on the bottom surface of the bottom cylindrical portion13. Note that an opening for infusion or the like may be formed in a bottom surface portion13aof the bottom cylindrical portion13in a later process. The material of the container10is a thermoplastic synthetic resin, and can be appropriately selected according to the application of the container10. Specific examples of types of the material include polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycyclohexanedimethylene terephthalate (PCTA), Tritan ((registered trademark): co-polyester manufactured by Eastman Chemical Company), polypropylene (PP), polyethylene (PE), polycarbonate (PC), polyethersulfone (PES), polyphenylsulfone (PPSU), polystyrene (PS), cyclic olefin polymer (COP/COC), polymethyl methacrylate: acrylic (PMMA), polylactic acid (PLA), and the like. <Description of the Blow Molding Apparatus> Next, a blow molding apparatus100for manufacturing the container10will be described with reference toFIG.2.FIG.2is a block diagram schematically illustrating a configuration of the blow molding apparatus100. The blow molding apparatus100according to the present embodiment is a hot parison type (also referred to as a one-stage type) apparatus that performs blow molding by utilizing residual heat (internal heat quantity) during injection molding without cooling the preform20to room temperature. The blow molding apparatus100includes an injection molding unit110, a temperature adjustment unit120, a blow molding unit130, a taking-out unit140, and a conveyance mechanism150. The injection molding unit110, the temperature adjustment unit120, the blow molding unit130, and the taking-out unit140are disposed at positions rotated by a predetermined angle (for example, 90 degrees) about the conveyance mechanism150. The conveyance mechanism150includes a rotary plate (not illustrated) that rotates about an axis in a direction perpendicular to the sheet of paper ofFIG.2(Z direction). On the rotary plate, one or more neck molds151(not illustrated inFIG.2) for holding the neck portion of the preform20or the container10are disposed at each predetermined angle. The conveyance mechanism150rotates the rotary plate to convey the preform20(or the container10) having the neck portion held by the neck mold151to the injection molding unit110, the temperature adjustment unit120, the blow molding unit130, and the taking-out unit140in this order. The injection molding unit110includes an injection cavity mold and an injection core mold, which are both not illustrated, and manufactures the preform20. An injection apparatus112that supplies a resin material, which is a raw material of the preform, is connected to the injection molding unit110. In the injection molding unit110, the injection cavity mold, the injection core mold, and the neck mold151of the conveyance mechanism150are closed to form a preform-shaped mold space. Then, by pouring the resin material from the injection apparatus112into the preform-shaped mold space, the preform20is manufactured by the injection molding unit110. Note that even when the injection molding unit110is opened, the neck mold151of the conveyance mechanism150is not opened, and the preform20is held and conveyed. The number of preforms20simultaneously molded by the injection molding unit110(i.e., the number of containers10that can be simultaneously molded by the blow molding apparatus100) can be appropriately set. The temperature adjustment unit120includes a temperature adjustment mold (heating pot or temperature adjustment pot)121capable of accommodating the preform20. The temperature adjustment unit120accommodates the preform20in the temperature adjustment mold121, and adjusts the temperature of a stretched portion (body portion or bottom portion) of the preform20manufactured by the injection molding unit110to a temperature suitable for final blowing (for example, about 90 to 100° C. for PET and about 130 to 140° C. (around about 135° C.) for PP). FIG.3Ais a diagram schematically illustrating a configuration example of the temperature adjustment mold121. The temperature adjustment mold121has a space for accommodating a portion (body portion and bottom portion) below the neck portion of the preform20. A plurality of heaters122aand122bfor externally heating the preform20in the axial direction of the preform20is disposed with respect to the temperature adjustment mold121. Therefore, the temperature of the preform20can be changed in the axial direction by changing the temperature of each of the heaters122aand122b. In the present embodiment, the temperature of the heater122aon the neck portion side is set to be higher than the temperature of the heater122bon the bottom portion side. Note that a heating rod (not illustrated) may be inserted into the hollow portion inside the preform20in a non-contact manner to simultaneously adjust the temperature (heat or cool) inside and outside the preform20. Here, the temperature adjustment mold121may have a structure in which a temperature adjustment circuit (heater (temperature adjustment medium flow circuit)) that circulates a temperature adjustment medium having a predetermined temperature (for example, 40 to 80° C.) is incorporated. More preferably, as illustrated inFIG.3B, it is desirable that the temperature adjustment mold includes a pair of split molds (121aand121b) incorporating temperature adjustment circuits (heaters (temperature adjustment medium flow circuits)122aand122b), and has a shape in which the diameter is increased only in an upper part of the space for accommodating the preform20. Furthermore, the depth (length) of the space for accommodating the preform20is set to be substantially the same as the length of the preform20, and is desirably set to, for example, 0.95 to 1.10 times, preferably 1.0±0.02 times the length of the preform20. The preform20is preliminarily blown (stretched by compressed air in the temperature adjustment unit120) using the temperature adjustment molds121aand121billustrated inFIG.3B, so that the preform20is brought into contact with the inner surface of the temperature adjustment mold121and the temperature is adjusted. At this time, only the upper part of the body portion of the preform20is increased in diameter (stretched) to be thin and to be close to the shape of the container10, while the lower part of the body portion and the bottom portion are hardly increased in diameter and substantially the same thickness as the injection molding unit110is maintained. Thus, the container10having favorable quality (appearance and thickness distribution (physical properties)) can be manufactured by final blowing (stretching by compressed air and a stretching rod in the blow molding unit130). That is, by preliminarily blowing the preform20in the temperature adjustment mold121, the distribution status of the temperature, the internal heat quantity, and the thickness of the preform20can be suitably adjusted. Specifically, in the preform20expanded by the final blowing, it is possible to suitably leave a thickness on the bottom portion side where the flange14having an annular shape is formed. The blow molding unit130performs blow molding on the preform20whose temperature has been adjusted by the temperature adjustment unit120to manufacture the container10. The blow molding unit130includes a blow molding mold131corresponding to the shape of the container10, a stretching rod132for stretching the preform20, a blow nozzle (not illustrated), and a lifting mechanism133for lifting a bottom mold60described later. A configuration example of the blow molding mold131will be described with reference toFIGS.4A to4C.FIG.4Ais a view of blow cavity split molds and a bottom mold at a mold opening position,FIG.4Bis a view of the blow cavity split molds at a mold closing position (before rising of the bottom mold), andFIG.4Cis a view of the blow cavity split molds and the bottom mold at a mold closing position (after rising of the bottom mold). The blow molding mold131includes a pair of blow cavity split molds40and40, a pair of accommodation portions (blow cavity fixing plates)50and50, and the bottom mold60. The blow cavity split molds40and40are mold members having a mold space S that defines the shape of the main portion (the body portion11and the bottom cylindrical portion13) of the container10excluding the flange14. The blow cavity split molds40and40are divided by a parting plane along an up-and-down direction (Z direction) inFIG.4A, and are configured to be openable and closable in a left-and-right direction (X direction) inFIG.4A. Bottom mold reception portions41for receiving the bottom mold60are formed below the mold space S of the container in the blow cavity split molds40and40. The bottom mold reception portions41have a cylindrical space communicating with the bottom portion side of the bottom cylindrical portion13of the container10in the mold space S and having an inner diameter larger than that of the bottom cylindrical portion13. A lower side of the bottom mold reception portions41is opened so that the bottom mold60can be inserted from below the blow cavity split molds40and40. A pair of first spacer members42and42are exchangeably attached to the blow cavity split molds40and40, respectively, at an upper step portion of the bottom mold reception portions41communicating with the mold space S. The pair of first spacer members42and42have a halved cylindrical shape as illustrated inFIG.5described later. The pair of first spacer members42and42are respectively attached to the blow cavity split molds40and40using bolts (not illustrated) or the like so that the parting plane matches the parting plane of the blow cavity split molds40and40. The pair of first spacer members42and42have a cylindrical shape when the mold is closed. The inner peripheral surface of the first spacer members42and42defines the protrusion amount of the flange14of the container10(diameter dimension width D of the flange illustrated inFIG.5) and the outer peripheral shape of the flange14. Note that, in the present embodiment, the flange14has a circular shape. The pair of accommodation portions50and50are disposed with the blow cavity split molds40and40interposed therebetween, and accommodate the corresponding blow cavity split molds40. In addition, the accommodation portions50are connected to an opening/closing mechanism (not illustrated) of the blow cavity split molds40and40, and move the blow cavity split molds40and40in the left-and-right direction (X direction) inFIG.4A. In addition, the accommodation portions50ofFIG.4Ainclude a space that allows lifting of the bottom mold60. The bottom mold60is a mold member that is disposed below the blow cavity split molds40and40and defines the shape of the bottom surface of the container10. As illustrated inFIGS.4B and4C, the bottom mold60is coupled to the lifting mechanism133of the blow molding apparatus100, and can move forward and backward by lifting with respect to the blow cavity split molds40and40which are closed. FIG.5is an enlarged view illustrating a mold closing state of the blow cavity split molds40and40and the bottom mold60.FIG.6is an exploded perspective view illustrating a configuration example of the first spacer members42and42and the bottom mold60. The bottom mold60includes a bottom mold main body61, a positioning ring member62, pressing members63having a split ring shape, a second spacer member64, and a stopper member65. The bottom mold main body61is a member that has a coupling portion with the lifting mechanism133and receives a force from the lifting mechanism133with the bottom mold60being in an assembled state. The bottom mold main body61has a stepped cylindrical shape whose outer diameter gradually increases from one end side toward the other end side, and includes a large diameter portion61aand a small diameter portion61b. In the bottom mold main body61, a plurality of bolt holes is opened in a step surface61cthat connects the large diameter portion61aand the small diameter portion61band forms a circumferential shape. A groove61ethat receives the pressing members63is formed in an annular shape along the circumferential direction on the outer periphery of the large diameter portion61a. In addition, the diameter dimension of the small diameter portion61bis set to a dimension corresponding to the inner diameter of the first spacer members42and42, and the small diameter portion61bof the bottom mold main body61can be inserted inside the first spacer members42and42. The end of the small diameter portion61bof the bottom mold main body61forms a bottom mold surface61dfacing the mold space S and upper surfaces41aof the bottom mold reception portions41. In the present embodiment, the bottom mold surface61dhas a flat shape. In a state where the bottom mold60is raised, the preform20is compressed between the upper surfaces41aof the bottom mold reception portions41and the bottom mold surface61dof the bottom mold main body61, whereby the flange14of the container10is molded. The positioning ring member62is a member for positioning the bottom mold60with respect to the blow cavity split molds40and40which are closed. The outer diameter of the positioning ring member62is set to a dimension corresponding to the inner diameter of the bottom mold reception portions41, and the outer peripheral surface of the positioning ring member62is configured to come into contact with the inner peripheral surface of the bottom mold reception portions41when the bottom mold60is lifted. In addition, the inner diameter of the positioning ring member62is set to a dimension corresponding to the outer diameter of the large diameter portion61aof the bottom mold main body61, and the thickness of the positioning ring member62is set to a dimension corresponding to the height of the large diameter portion61aof the bottom mold main body61. Therefore, a lower end of the positioning ring member62is supported by the outer periphery of the large diameter portion61aof the bottom mold main body61. In addition, an upper end of the positioning ring member62is pressed by the pressing members63having a split ring shape fitted in the groove61eformed on the outer periphery of the bottom mold main body61, and the movement in the up-and-down direction is restricted. The second spacer member64is a ring-shaped member and can be replaced with a member having a different thickness. The inner diameter of the second spacer member64is set to a dimension corresponding to the diameter of the small diameter portion61bof the bottom mold main body61. In addition, the second spacer member64is provided with insertion holes at positions corresponding to the bolt holes of the bottom mold main body61. The second spacer member64is inserted into the small diameter portion61bof the bottom mold main body61and fixed in a state of being in contact with the step surface61cof the bottom mold main body61. In addition, the second spacer member64is used to adjust the position of the bottom mold surface61din a state where the bottom mold60is raised. By adjusting the thickness of the second spacer member64, in a state where the bottom mold60is raised, the distance between the upper surfaces41aof the bottom mold reception portions41and the bottom mold surface61dof the bottom mold60illustrated inFIG.5changes, and the thickness dimension (thickness T illustrated inFIG.5) of the flange14of the container10can be adjusted. The stopper member65is a ring-shaped member made of resin. The inner diameter of the stopper member65is set to a dimension corresponding to the diameter of the small diameter portion61bof the bottom mold main body61. Therefore, the stopper member65can be inserted into the small diameter portion61bof the bottom mold main body61. In addition, the stopper member65is provided with insertion holes at positions corresponding to the bolt holes of the bottom mold main body61. As illustrated inFIG.5, the stopper member65is disposed so as to sandwich the second spacer member64with respect to the step surface61cof the bottom mold main body61. The stopper member65comes into contact with the bottom mold reception portions41of the blow cavity split molds40when the bottom mold60is raised, and has a function of preventing damage to the bottom mold60. When assembling the bottom mold60, the positioning ring member62is inserted into the large diameter portion61aof the bottom mold main body61and fixed by the pressing members63having a split ring shape, and then the second spacer member64and the stopper member65are attached to the small diameter portion61bof the bottom mold main body61. Then, the respective members of the bottom mold60are fixed by screwing bolts66disposed to pass through the insertion holes into the bolt holes. Here, the shape of the flange14of the container10can be changed by changing the shape of the pair of first spacer members42and42attached to the blow cavity split molds40and40, and the bottom mold main body61. In addition, the thickness of the flange14of the container10can be adjusted by changing the second spacer member64of the bottom mold60. Furthermore, by changing the shape of the bottom mold surface61dof the bottom mold main body61in the bottom mold60, for example, the bottom surface shape of the bottom cylindrical portion13of the container10can be changed. Referring back toFIG.2, the taking-out unit140is configured to release the neck portion12of the container10manufactured by the blow molding unit130from the neck mold151and take out the container10to the outside of the blow molding apparatus100. <Description of the Blow Molding Method> Next, the blow molding method by the blow molding apparatus100of the present embodiment will be described.FIG.7is a flowchart illustrating processes of the blow molding method. First, in the injection molding unit110, resin is injected from the injection apparatus112into a mold space formed by the injection cavity mold, the injection core mold, and the neck mold151to manufacture the preform20having a bottomed cylindrical shape (step S101). Subsequently, the rotary plate of the conveyance mechanism150rotates a predetermined angle, and the preform20in a state containing the residual heat during injection molding is conveyed to the temperature adjustment unit120. In the temperature adjustment unit120, temperature adjustment for bringing the temperature of the preform20close to a temperature suitable for final blowing is performed (step S102). Here, in the temperature adjustment mold121of the temperature adjustment unit120, the neck portion side is heated to a higher temperature than the bottom portion side in the body portion of the preform20due to the temperature difference between the plurality of heaters122aand122bdisposed in the axial direction. Therefore, the temperature of the body portion of the preform20after the temperature adjustment is higher on the neck portion side than on the bottom portion side. Subsequently, the rotary plate of the conveyance mechanism150rotates a predetermined angle, and the preform20whose temperature has been adjusted is conveyed to the blow molding unit130. When the preform20is disposed at a predetermined position in the blow molding unit130, the blow cavity split molds40and40are closed as illustrated inFIG.8(step S103). In the state illustrated inFIG.8, the bottom mold60is coupled to the lifting mechanism133, and the position of the bottom mold60is at a position retracted downward with respect to the blow cavity split molds40and40. Then, as illustrated inFIG.9, the stretching rod132is inserted into the preform20, and the preform20is slightly stretched only in the vertical direction by lowering the stretching rod132(step S104). Subsequently, as illustrated inFIG.10, blow air, which is an example of a pressurized fluid, is introduced into the preform20through a blow nozzle. At the same time, the stretching rod132is further lowered. Thus, the preform20is blow-molded to expand to the bottom mold reception portions41into the container10(step S105). The temperature of the blow cavity split molds40and40at this time is preferably set to 60° C. or higher. Note that, in the final blowing molding, the medium for pressurizing the preform20is not limited to air, and a gas other than air or a liquid such as water may be used as the pressurizing medium. Here, in the hot parison type blow molding, the preform20is more likely to be deformed as the internal heat quantity (residual heat) of the preform20is larger. As described above, the temperature of the body portion of the preform20after the temperature adjustment is higher on the neck portion side than on the bottom portion side, and the internal heat quantity is larger on the neck portion side than on the bottom portion side in the body portion of the preform20. That is, the body portion of the preform20is more likely to be deformed on the neck portion side than on the bottom portion side because the internal heat quantity is larger. Therefore, when the blow air is introduced into the preform20, in the body portion of the preform20, the neck portion side having a larger internal heat quantity is stretched earlier, and the bottom portion side having a smaller internal heat quantity is stretched later. Thus, the bottom portion side of the preform20is not excessively stretched, and the thickness tends to remain on the bottom surface side of the bottom cylindrical portion13of the container10. After the stretching rod132is raised during the blow molding, the bottom mold60moves and rises in the Z direction, and as illustrated inFIG.11, a portion expanding from the bottom surface side of the bottom cylindrical portion13of the container10is pressed against the bottom mold60. The temperature of the bottom mold60at this time is preferably set to 60° C. or higher. Note that, for the sake of simplicity, the illustration of the stretching rod132is omitted inFIG.11. Then, the preform20is compressed between the upper surfaces41aof the bottom mold reception portions41, the inner peripheral surface of the first spacer members42and42, and the bottom mold surface61dof the bottom mold main body61illustrated inFIG.5. Thus, the bottom surface of the bottom cylindrical portion13of the container10is processed to be flat, and the flange14is formed on the bottom surface of the bottom cylindrical portion13(step S106). When the molding of the flange14of the container10is ended, the blow air is exhausted from the container10and the stretching rod132is pulled out (further raised), and the blow cavity split molds40and40and the bottom mold60are opened (step S107). Thus, the container10after blow molding becomes movable. Subsequently, the rotary plate of the conveyance mechanism150rotates a predetermined angle, and the container10is conveyed to the taking-out unit140. In the taking-out unit140, the neck portion12of the container10is released from the neck mold151, and the container10is taken out to the outside of the blow molding apparatus100(step S108). Thus, the series of processes of the blow molding method is ended. Then, by rotating the rotary plate of the conveyance mechanism150a predetermined angle, the processes of S101to S108described above are repeated. According to the present embodiment, the preform20is stretched by the stretching rod132to blow-mold the container10, and then the bottom mold60is closed to compress the portion of the container10expanding in the bottom mold reception portions41with the upper surfaces41aof the bottom mold reception portions41and the bottom mold surface61dof the bottom mold60. Thus, the solid structure (flange14) protruding in the radial direction can be formed on the bottom surface side of the container10molded by the stretch blow molding method. In addition, in the present embodiment, the shape (thickness, width, and shape) of the solid structure formed on the container10can be changed by replacing the first spacer members42and42, the bottom mold main body61, and the second spacer member64. Therefore, for example, it is possible to easily cope with the case of producing a plurality of types of containers10having different structures in small quantities and in large varieties. Second Embodiment The second embodiment is a modification of the first embodiment, and an example in which a thin film-shaped portion is formed on the bottom surface portion13aexcluding the flange14in the bottom cylindrical portion13of the container10will be described. Note that, in the description of the second embodiment, the same elements as those of the first embodiment are denoted by the same reference numerals, and duplicate description is omitted. The second embodiment is different from the first embodiment in the temperature adjusting process in the temperature adjustment unit120and the blow molding process in the blow molding unit130as described below. FIGS.12A to12Care diagrams illustrating an operation example in the temperature adjustment unit120according to the second embodiment. FIG.12Aillustrates the preform20held and conveyed by the neck mold151. At the bottom portion of the preform20, a gate portion21, which is a gate mark of a hot runner during injection molding, is formed so as to protrude to the outside of the preform20. FIG.12Billustrates a state in which the preform20is accommodated in the temperature adjustment mold121. The temperature adjustment mold121of the second embodiment is similar to the split molds121aand121billustrated inFIG.3B. However, the temperature adjustment mold121of the second embodiment is different from the example ofFIG.3Bin that there is no air clearance hole at the center of the bottom portion facing the gate portion21of the preform20, and the portion at the center of the bottom portion of the temperature adjustment mold121is a curved surface following the shape of the bottom portion of the preform20. In the second embodiment, when the preform20is accommodated in the temperature adjustment mold121, the gate portion21of the preform20comes into contact with the curved surface at the center of the bottom portion of the temperature adjustment mold121. The preform20in the temperature adjustment unit120has residual heat during injection molding and is in a state of being easily deformed. Therefore, the gate portion21in contact with the temperature adjustment mold121can be deformed following the curved surface of the bottom portion of the temperature adjustment mold121. However, also inFIG.12B, the resin of the gate portion21remains at the center of the bottom portion of the preform20, and is in a relatively thick state. After the preform20is accommodated in the temperature adjustment mold121, a heating rod123is inserted into the preform20toward the bottom portion of the preform20as illustrated inFIG.12B. The heating rod123is heated with a heater built in at least above its tip portion. As illustrated inFIG.12C, the heating rod123presses the center of the bottom portion of the preform20from inside. Then, the preform20is sandwiched between the tip portion of the heating rod123and the temperature adjustment mold121, and the resin of the sandwiched portion spreads to the periphery, so that the center of the bottom portion of the preform20becomes thin. As described above, in the temperature adjustment unit120, the thickness of the center of the bottom portion of the preform20can be made thinner than the periphery. In addition, it is desirable to preliminarily blow the preform20before or after the above-described sandwiching processing to deform the preform20into a shape in which the diameter of the upper part of the body portion is increased and the diameter of the lower part of the body portion or the bottom portion is not increased. Furthermore, it is preferable that the temperature of the preliminarily blown preform20is simultaneously adjusted inside and outside by the temperature adjustment mold121and the heating rod123for a predetermined time. Thus, a thickness distribution and a temperature distribution suitable for final blowing can be imparted to the preform20. Then, the preform20described above is conveyed to the blow molding unit130. FIGS.13A and13Bare diagrams illustrating an operation example in the blow molding unit130according to the second embodiment. The operation of the blow molding unit130of the second embodiment is similar to that of the first embodiment up to the processes of S103to S106(FIGS.8to11) ofFIG.7. After the flange14is formed on the bottom surface of the bottom cylindrical portion13in step S106, the stretching rod132lowers toward the bottom mold60as illustrated inFIG.13A. Then, as illustrated inFIG.13B, the bottom surface portion13aof the container10is sandwiched between the stretching rod132and the bottom mold surface61dof the bottom mold60and is pressed and deformed. Thus, a thin film-shaped portion thinner than the periphery is formed at the center of the bottom surface portion13aof the container10. Then, similar to the process of S107inFIG.7, the stretching rod132is pulled out, and the blow cavity split molds40and40and the bottom mold60are opened. Thus, the container10becomes movable from the blow molding unit130. In the blow molding unit130of the second embodiment, after the flange14is formed on the bottom surface side of the container10, the bottom surface portion13aof the container10is pressed and deformed between the stretching rod132and the bottom mold60to form a thin film-shaped portion thinner than the periphery on the bottom surface portion13a. Thus, it becomes easy to form an opening for infusion or the like through the thin film-shaped portion of the bottom surface portion13aby puncture or the like in subsequent processes, and the usability of the container10can be further improved. In the temperature adjustment unit120of the second embodiment, the gate portion21of the preform20is sandwiched between the heating rod and the temperature adjustment mold121, and the resin of the gate portion21is moved to the periphery to thin the center of the bottom portion of the preform20in advance. Thus, processability at the time of forming a thin film-shaped portion on the bottom surface portion13aof the container10is improved, and the yield of the container10can be improved. The present invention is not limited to the above embodiments, and various improvements and design changes may be made without departing from the gist of the present invention. For example, the container10in the above embodiments is merely an example, and the overall shape of the container of the present invention can be variously changed. In addition, the outer peripheral shape of the flange14is not limited to a circular shape, and may be, for example, a polygonal shape or a gear shape. In addition, the solid structure formed on the bottom portion side of the container10is not limited to the flange, and, for example, a structure having a cylindrical shape, a polygonal prism shape, a conical shape, a polygonal pyramid shape, a truncated cone shape, a polygonal frustum shape, a hemispherical shape, or any shape obtained by combining these shapes can be formed. In addition, the bottom surface shape of the container10is not limited to a flat surface, and can be appropriately changed. Additionally, the embodiments disclosed herein are to be considered in all respects as illustrative and not restrictive. The scope of the present invention is indicated not by the above description but by the claims, and it is intended that meanings equivalent to the claims and all modifications within the scope are included. | 33,450 |
11858195 | DETAILED DESCRIPTION OF THE DRAWINGS The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some but not all embodiments of the invention are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. As an initial overview of preferred embodiments of the invention, a flexible packaging laminate is constructed to have a built-in opening and reclose function and a tamper-evidence feature. The laminate is constructed as a multi-layer structure by adhesively laminating a first structure to a second structure, wherein each of the first and second structures comprise one or more layers of flexible material. Pressure-sensitive adhesive is applied to one of the structures before lamination. Once the laminate is formed in this manner, scoring operations are performed on both sides of the laminate, but each scoring operation penetrates only through a part of the thickness of the laminate; in particular, a scoring operation performed on the side of the laminate adjacent the first structure results in penetration through the first structure, but without complete penetration through the second structure, and preferably without any substantial penetration, and more preferably without any penetration, into the second structure. Likewise, the scoring operation performed on the side of the laminate adjacent the second structure results in penetration through the second structure, but without complete penetration through the first structure, and preferably without any substantial penetration, and more preferably without any penetration, into the first structure. The scoring operation also forms the tamper-evidence feature, as further described below. More particularly, with reference toFIG.1, a first phase of the manufacturing process is depicted. A first structure10is advanced from a supply roll12by suitable web driving and handling equipment (not shown) to an optional print station14comprising a printing apparatus, such as a rotogravure printer or the like, for printing graphics and/or indicia on the first structure by applying inks to a surface of the first structure. The first structure10comprises one or more layers of flexible packaging material. Various materials can be used for the layer(s) of the first structure, including polymers such polyesters, polyolefins (including homopolymers and copolymers), polyamides, and others; paper; metal foil; and the like. In a preferred embodiment of the invention, the first structure10includes an outer layer (not illustrated) that is substantially transparent and is reverse-printed in the print station14, i.e., the inks are applied to the surface of the first structure10that is subsequently laminated to another structure, as described below, from the opposite side of the first structure, which will form an exterior of a package constructed from the packaging laminate, the inks are visible through the first structure. As an example, the first structure10can comprise a layer of polyester such as polyethylene terephthalate or the like. Prior to printing the first structure in the print station, the surface of the first structure that is subsequently laminated to the other structure can be treated by a corona discharge or flame treatment apparatus16to render the surface more receptive to the inks and/or to render the surface more readily bondable to the pressure-sensitive adhesive that is subsequently applied to the surface as described below. Alternatively, the first structure10can have already been so treated prior to being wound into the supply roll12, such that the treatment apparatus16is unnecessary. Following the optional corona/flame treatment and/or optional printing operation, and with reference toFIGS.1and1a, the first structure10is advanced to a first adhesive application station18at which a pressure-sensitive adhesive20is applied to the first structure in a predetermined pattern22that recurs at regular intervals along the lengthwise direction of the first structure. The predetermined pattern22is generally in the form of a strip of various forms or shapes. As illustrated, a preferred shape for the strip pattern22is generally U-shaped, for reasons that will become apparent in the description ofFIGS.4-8; however, other shapes for the pattern22can be used, the invention not being limited to any particular pattern. The pattern can include a region23that is free of adhesive and will ultimately form a thumb tab or grasping portion of the first structure10as further described below. It is also possible in alternative embodiments to flood-coat the pressure-sensitive adhesive onto the entire surface of the first structure. The pressure-sensitive adhesive20can comprise various compositions. Pressure-sensitive adhesives form viscoelastic bonds that are aggressively and permanently tacky, adhere without the need of more than a finger or hand pressure, and require no activation by water, solvent or heat. Pressure-sensitive adhesives are often based on non-crosslinked rubber adhesives in a latex emulsion or solvent-borne form, or can comprise acrylic and methacrylate adhesives, styrene copolymers (SIS/SBS), and silicones. Acrylic adhesives are known for excellent environmental resistance and fast-setting time when compared with other resin systems. Acrylic pressure-sensitive adhesives often use an acrylate system. Natural rubber, synthetic rubber or elastomer sealants and adhesives can be based on a variety of systems such as silicone, polyurethane, chloroprene, butyl, polybutadiene, isoprene, or neoprene. When the packaging laminate of the invention is to be used for food packaging, the pressure-sensitive adhesive20generally must be a food-grade composition. Various pressure-sensitive adhesives are approved by the U.S. Food and Drug Administration for use in direct food contact, as regulated by 21 CFR Part 175.300. A preferred food-grade pressure-sensitive adhesive20for use in the present invention is Jonbond 743 available from Bostik Findley. Additives (e.g., particulates or the like) can be added to the pressure-sensitive adhesive20to reduce the tenacity of the bond to the underlying second structure42, if necessary, so that the pressure-sensitive adhesive20readily detaches from the second structure on opening (particularly on the very first opening). When applied in a pattern as opposed to being flood-coated or applied everywhere on the first structure10, the pattern22of pressure-sensitive adhesive20is applied to the first structure10at regular intervals along the first structure10. The spacing or index distance d between the patterns22can correspond to a dimension, such as a length, of packages to be produced from the packaging laminate. The adhesive application station18can comprise any suitable device capable of accurately applying the pressure-sensitive adhesive20to the first structure10in the desired pattern22, at regular intervals along the structure. For example, as shown, the adhesive application station can comprise a gravure roll24that picks up the pressure-sensitive adhesive20from a reservoir26on the outer surface of the roll such that the adhesive fills one or more recessed areas in the surface. A doctor blade28scrapes off excess adhesive so that it remains essentially only in the recessed area(s). The first structure10is contacted by the gravure roll24; a backing roll30provides support on the opposite side of the first structure10. After application of the pressure-sensitive adhesive20, the first structure10is advanced to a dryer31such as an oven or the like, to dry the pressure-sensitive adhesive20. In the case of the pressure-sensitive adhesive20being pattern-applied, the first structure10is then advanced to a second adhesive application station32at which a permanent laminating adhesive34(FIG.1b) is applied to the first structure10in such a manner that a sufficiently large proportion of the surface is covered by the permanent adhesive34to permit the first structure10to be adhesively attached to a second structure42at a downstream laminating station40. The permanent adhesive34does not cover the pressure-sensitive adhesive20. Furthermore, when the pattern of pressure-sensitive adhesive20includes an adhesive-free region to form a thumb tab or grasping portion23as previously noted, the pattern of the permanent adhesive also does not cover the adhesive-free region. Thus, the permanent adhesive34must be applied by an apparatus capable of accurately applying the adhesive in a predetermined pattern, in registration with the pressure-sensitive adhesive20but not covering it or the adhesive-free region if present. A suitable adhesive application device32, as shown, can be a gravure roll24of the type previously described. The permanent adhesive34can comprise various compositions. Suitable examples include two-component polyurethane adhesive systems, such as Tycel 7900/7283 available from Henkel. After the application of the permanent adhesive34, the first structure10is advanced to a dryer33such as an oven or the like. Alternatively, when the pressure-sensitive adhesive20is applied to the entire surface of the first structure10, the steps of applying and drying the permanent adhesive34are skipped. The first structure10is then advanced to a laminating station40, comprising a pair of rolls forming a nip therebetween. The first structure10is passed through the nip along with a second structure42that is advanced from its own supply roll44, and the first and second structures10/42are laminated to each other. The second structure42comprises one or more layers of flexible material, and is coextensive with the first structure10—i.e., the width of the second structure42is substantially equal to the width of the first structure10and the longitudinal edges of the second structure42substantially coincide with the longitudinal edges of the first structure10. The resulting laminate46is then advanced to a reel-up (not shown) where it is wound into a roll for subsequent processing in the second phase of the manufacturing process as described below. Alternatively, it is possible for the reel-up operation to be omitted, such that the laminate is directly advanced to the second phase. With reference toFIGS.2and6, the second phase of the process is now described. A supply roll48of the laminate46formed in the first phase of the process is shown. The laminate is advanced from the supply roll to a first scoring station50at which a first, or outer, score line52(FIG.6) is formed through the thickness of the first structure10. When the pressure-sensitive adhesive20has been pattern-applied, the first score line52is in registration with (i.e., coincides with) the outer perimeter22a(FIG.1a) of the strip-shaped pattern22of pressure-sensitive adhesive20. The first score line52extends substantially through the thickness of the first structure10, but preferably does not extend to any substantial extent into the second structure42, as illustrated inFIG.6. The first scoring station50can comprise a laser54as depicted inFIG.2. The use of lasers for scoring through flexible materials is generally known, for example as described in U.S. Pat. No. 5,158,499, incorporated herein by reference. The depth of the score line formed by the laser can be regulated by regulating the power output or beam intensity of the laser beam, the width or spot size of the laser beam, and the amount of time a given spot on the film surface is irradiated by the beam. These factors generally are selected based on the characteristics of the material being scored. Some materials are more readily scored by lasers than other materials, as known in the art. As noted, the first score line52must be in registration with the outer perimeter22aof the pressure-sensitive adhesive strip20(and the outer perimeter of the thumb tab23, if present). To accomplish this registration, the operation of the laser54is controlled to be synchronized with the advancement of the laminate46. A sensor56disposed adjacent the laminate46can be used for detecting a feature on the laminate whose location in relation to the strip of pressure-sensitive adhesive20is known, and the sensor's output signal can be used by a suitable controller (not shown) for controlling the laser54. The first score line52may also include one or more tear portions65as a tamper-evidence feature. A tear portion65may comprise one or more interrupted areas57in which the first structure10is not cut or scored, and whose uncut condition is readily apparent from a visual inspection of the first structure10. The interrupted areas57are located such that when the flap or outer opening portion86bounded by the first score line52is peeled back to create an opening through the laminate, the first structure10tears through the interrupted areas57to connect the two portions of the first score line52on opposite sides of each interrupted area57. To help ensure that the two portions of the score line will be connected even if the tear line tends to wander in direction, the score line52at the “downstream” side of each interrupted area57can terminate in a U- or V-shaped portion58that extends generally transverse to the direction along which the score line52extends. The “downstream” side refers to the side of the interrupted area57that is located farthest along the downstream direction (generally left-to-right inFIGS.4and5) in which the outer opening portion86is peeled back when opening the package. The first structure10is cut through its thickness along the transverse portions58, similar to the rest of the score line52. Accordingly, even if the tear line wanders to one side or the other, it will connect with the transverse portion58and thereby allow the score line52to continue to sever or separate as the outer opening portion86is peeled farther back. Next, the laminate is advanced to a second scoring station60at which a second, or inner, score line62is formed through the thickness of the second structure42. When the pressure-sensitive adhesive20has been pattern-applied, the second score line62is in registration with (i.e., coincides with) the inner perimeter22b(FIG.1a) of the strip-shaped pattern22of pressure-sensitive adhesive20. The second score line62extends substantially through the thickness of the second structure42, but preferably does not extend to any substantial extent into the first structure10, as illustrated inFIG.6. The second score line62is spaced inwardly of the first score line52so as to define an inner opening portion88of smaller area than the outer opening portion86. As further described below, the inner opening portion88is adhered to the outer opening portion86(either by the permanent adhesive when present, or by the pressure-sensitive adhesive20when it is applied everywhere between the two structures10,42), such that both portions86,88are lifted together when opening the package. As shown inFIGS.4and5, preferably the interrupted areas57are located with respect to the second score line62such that in order to lift the outer opening portion86far enough to just begin lifting the inner opening portion88and thereby begin to create an opening into the package, the interrupted areas57must be torn through. In this regard, the downstream side of each interrupted area57(which coincides with the vertex of the U- or V-shaped transverse score line58) preferably is not farther along the downstream direction, or at least is not substantially farther along the downstream direction, than is the most-upstream portion of the second score line62. The second scoring station60can comprise a laser64. The operation of the laser64is synchronized with the advancement of the laminate in a manner as described above. A sensor66can detect a feature, such as an eye mark, on the laminate whose location in relation to the pressure-sensitive adhesive strip20is known, and the sensor66output can be used for regulating the laser operation so that the second score line62is in registration with the inner perimeter of the pressure-sensitive adhesive strip20. As an alternative to the use of lasers for scoring the laminate, the score lines52,62can be formed in the laminate by mechanical scoring or cutting. For instance, as depicted inFIG.3, a first scoring station50′ can comprise a kiss roll51and backing roll53that form a nip through which the laminate is passed. The kiss roll51comprises a rotary cutting die defining a cutting edge (not shown). The kiss roll acts in conjunction with the backing roll to cut partially through the thickness of the laminate starting from the outer surface of the first structure10, such that the first structure10is substantially scored through while the second structure42is left intact. The second scoring station60′ likewise comprises a kiss roll61and backing roll63for scoring through the second structure42. Additionally, it is within the scope of the invention to laser-score one side of the laminate and to kiss cut or otherwise mechanically score the other side. This can be advantageous, for example, when one of the structures making up the laminate is readily scored by a laser but the other structure is not. For instance, when the first structure10is a polyester such as PET, it can readily be scored with a laser, but if a polyethylene heat seal layer is employed on the opposite side, laser scoring may not be the best choice because polyethylene does not score well with a laser. In this case, kiss cutting or other mechanical scoring can be used to score the inner structure42. After the scoring operations, the laminate46can be sent to a reel-up (not shown) and wound into a roll for subsequent processing. The laminate can also be slit into a plurality of partial widths and wound into multiple rolls. In this latter instance, each partial width would have the recurring patterns of pressure-sensitive and permanent adhesives applied with suitably configured adhesive applicators to the full-width material, and would have the recurring score lines formed by suitably configured scoring devices acting on either the full-width laminate prior to slitting or acting on each partial-width portion after slitting. An advantage of the invention, versus the formation of a web having discrete labels applied to a partial portion of the web surface as in the prior art, is that the laminate has a uniform thickness throughout (because the first and second structures are coextensive) and therefore winds well into good-quality rolls. In contrast, a web with labels centrally located in the width of the web tends to produce wound rolls that are soft in the radial direction at the two ends of the roll where the labels are not present. Additionally, the web with labels is much thicker than laminates made in accordance with the invention, and hence the laminates of the invention can achieve a greater square footage per roll of a given diameter. As already noted, a further drawback to the use of labels is the necessity of applying the labels to the web in an “off-line” process, which often entails shipping a roll of the web to a converter that applies the labels and then ships the roll back to the package manufacturer. In the process of the invention, the manufacture of the laminate and the incorporation of the opening/reclose and tamper-evidence features in the laminate are conducted in an in-line fashion as part of the same overall process. The process of the invention thus is much more efficient and less costly. Additionally, the invention avoids other drawbacks associated with the use of labels. More specifically, pressure-sensitive adhesive labels typically require a release liner that is peeled off and thrown away, which represents waste, and create a potential choke hazard. Furthermore, there is the additional waste of the skeleton material left over after die-cutting the labels from the label web material. The present invention eliminates such waste and attendant costs. Some possible applications for the resulting laminate are now explained with reference toFIGS.4-11.FIGS.4and5show a flexible package70. The package includes an outer wrapper74that envelopes the package contents and is sealed to enclose the contents. The outer wrapper74comprises a packaging laminate made by a method in accordance with the invention, such as the laminate46previously described. The outer wrapper74is manipulated into a tubular shape and the longitudinal edges of the wrapper74are sealed together by a suitable sealant material to form a longitudinal seal (not shown), typically adjacent the bottom surface of the package. The opposing portions of the wrapper74are sealed together along transverse seal lines76,78adjacent the opposite ends of the tubular wrapper. The ends of the wrapper74can be gusseted if desired, as known in the art. In the illustrated package, the portion of the outer wrapper74having the score lines52,62is provided to be on the top surface of the package. The area of the wrapper74bounded by the score lines can constitute any fraction of the total top surface of the package, but advantageously the area is a majority of the total surface area of the top surface. Based on the previous description of the laminate46and its formation process, it will be appreciated that the presence of the score lines52,62has little or no impact on the barrier function of the outer wrapper74because each score line extends only partially through the total thickness of the wrapper74and the score lines are not aligned with each other. Additionally, the pressure-sensitive adhesive20fills the space between the score lines so that even if the score lines overlap somewhat in the thickness direction, there is still no open route between them. Furthermore, the score lines typically have a small width, on the order of a few thousandths of an inch. Various materials can be used for the construction of the outer wrapper74. With reference toFIG.6, in the illustrated embodiment, the first structure10that forms the outer surface of the wrapper74comprises a single layer80of flexible material. The layer80can comprise various materials. A preferred material is a polyester such as polyethylene terephthalate (PET). As noted, the PET layer can be reverse-printed if desired, although alternatively it can be printed on its exterior and covered by an over-lacquer (not shown). The second structure42forming the inner surface of the wrapper74comprises a barrier layer82and a sealant layer84. The sealant layer84constitutes the innermost surface of the wrapper74, and can comprise various sealant materials such as heat seals or cold seals. Heat seals generally are preferred because they provide stronger seals than cold seals typically are capable of achieving. Any suitable heat seal materials can be employed, such as polyethylene, polypropylene, ionomer resins such as SURLYN®, or others. The barrier layer82can comprise any of various barrier materials including barrier polymer films such as: ethylene vinyl alcohol copolymer (EVOH), polyamide, and the like; metallized polyolefin films such as polyethylene, polypropylene, oriented polypropylene, and the like; AlOx-coated polymer films; SiOx-coated polymer films; metal foil; and others. The barrier layer82and sealant layer84can be joined in various ways, including adhesive lamination, extrusion lamination, or coextrusion. Advantageously, the laminate includes a metallization layer or a metal foil layer between the first structure10and the second structure42, for example by providing a metallization layer85on the surface of the layer82that faces the first structure10. This is beneficial in enhancing the barrier performance of the laminate as already noted. Additionally, however, the metallization layer or85metal foil layer can also be helpful when a laser is used for scoring the second structure42. In particular, when the sealant layer84comprises polyethylene, which is not as readily scored by laser as some other materials such as polyester, it can be difficult to employ a sufficiently high laser energy to score through the polyethylene sealant layer without scoring through the laminate more deeply than desired. In some cases, the entire thickness of the laminate may be scored through, which is undesirable. The metallization layer or metal foil layer can be helpful in “tuning” the laser to penetrate only up to the metallization layer85or foil layer. The function of the opening/reclose and tamper-evidence features provided by the pattern-applied adhesives and the score lines will now be described. With reference toFIGS.4and6, the package70is shown in a closed condition, for example as initially filled and sealed in a packaging plant. On the top surface of the outer wrapper74, the first or outer structure10is adhesively joined to the second or inner structure42via the permanent adhesive34. The first score line52bounds an outer opening portion86of the outer structure10. In this embodiment, the outer opening portion86has a generally U-shaped perimeter having three sides defined by the score line52, and is attached to the remainder of the outer wrapper74along a fourth side (i.e., an imaginary line extending between the free ends of the two legs of the U-shaped score line52). The second score line62is generally parallel to the first score line52, but is spaced inwardly of the outer score line so as to define an inner opening portion88of smaller area than the outer opening portion86; the second score line62can be a closed curve such as a rectangle, or can be generally U-shaped like the first score line52, as desired. In any event, there is a marginal region90of the outer opening portion86that extends beyond the edge of the inner opening portion88. The pressure-sensitive adhesive20is disposed between this marginal region90and an underlying surface92of the inner structure42. The outer opening portion86and inner opening portion88are permanently joined by the permanent adhesive34when present, or by the pressure-sensitive adhesive when it is applied everywhere between the structures. The first score line52includes the interrupted areas57and transverse score lines58as previously described. Prior to initial opening of the package, the uncut condition of the interrupted areas57is readily apparent, such that the consumer can see that the package has not yet been opened. When the outer opening portion86is detached from the outer wrapper along the first score line52and is peeled back as inFIG.5, the outer layer of the wrapper tears through the interrupted areas57. The inner opening portion88remains affixed to the outer opening portion and comes with it, thereby creating an opening94in the top surface of the outer wrapper74as defined by the second score line62. The outer and inner opening portions essentially form a flap that remains attached along a hinge line defined between the free ends of the two legs of the U-shaped score lines. The package is reclosable by re-attaching the pressure-sensitive adhesive20to the surface92of the inner structure42to restore the package to a closed condition as shown inFIG.6. It will, however, be readily apparent that the package has already been opened, because the film will be torn through the tear portions65. No amount of care in replacing the flap in its original position can erase the fact that the interrupted areas have been torn through. Accordingly, the invention provides a reliable tamper-evidence feature that is not easily circumvented. Furthermore, in some embodiments, the outer structure10can be substantially non-transparent or opaque without compromising the functionality of the tamper-evidence feature; this is in contrast to some prior-art structures in which the outer structure must be transparent because the tamper-evidence feature is formed in the inner structure and is covered by the outer structure. The non-transparent or opaque character of the outer structure10can be a characteristic of the film material itself, or can be achieved by a coating of ink or the like on the film. The outer structure10preferably has a greater affinity for bonding with the pressure-sensitive adhesive20than does the surface92of the inner structure42, and hence the pressure-sensitive adhesive20is detached from the surface92and remains attached to the marginal region90of the outer opening portion86as shown inFIGS.5and7. The greater bonding affinity of the outer structure10can be achieved in various ways. When the outer structure comprises a layer of PET and the layer82of the inner structure to which the pressure-sensitive adhesive is attached comprises a polyolefin such as polypropylene, oriented polypropylene, or metallized oriented polypropylene, the PET will naturally have a greater affinity for bonding to the adhesive than will the polyolefin layer. Additionally or alternatively, the surface of the outer structure10can be treated, as previously noted, by corona discharge or flame treatment, to increase the surface energy and enhance the bonding affinity. It is also possible, as already noted, to control the bond strength of the pressure-sensitive adhesive to the layer82by including an additive in the adhesive to reduce the bond strength, if desired. Although it is preferred to have the pressure-sensitive adhesive be applied to the outer structure and to remain on the outer structure upon opening, it is also within the scope of the invention to apply the pressure-sensitive adhesive to the inner structure and to remain on the inner structure upon opening. This is less preferred, however, because of the greater tendency for crumbs or the like from the contained products to become adhered to the pressure-sensitive adhesive and thereby reduce its adhesiveness with repeated openings and reclosings. It is believed that this tendency is reduced when the pressure-sensitive adhesive remains with the outer structure, since it is out of the way of the package opening when products are being removed. It will be appreciated from the above description that laminates made in accordance with the invention provide a tamper-evidence function for a package because after opening it is impossible to replace the opening portions86,88in such a way as to completely restore the package to its original unopened condition, as previously noted. When printing is included on the laminate, it is even more noticeable when the package has been opened because it is difficult to achieve perfect registration of the printed matter across the score line when reclosing the package. The printing on the laminate can include text adjacent to the interrupted areas57of the first score line52, calling the consumer's attention to the presence of the interrupted areas and indicating that if they are torn through at a tear portion65, the consumer should not purchase the package. The laminates made in accordance with the invention can be used for forming other types of packages or tamper-evidence features. For instance,FIG.8shows a stand-up pouch100constructed from the laminate46as described above. The first score line52and second score line62are formed in a side wall of the pouch. The opening/reclose and tamper-evidence features operate in a manner similar to that described above. An alternative form of a thumb “tab,”25is included, wherein a corner portion of the outer flap defined by the first score line52is left free of pressure-sensitive adhesive20. The packages illustrated inFIGS.9,10and11show other stand-up pouches100with alternative types of tamper-evidence features. In particular, the stand-up pouch100ofFIG.9includes a tab25that extends from an edge of outer portion86. Preferably, tab25is defined by first score line52and is free from pressure sensitive adhesive20or lamination to the second structure42. The end of the tab25is then attached or anchored to a portion of the outer layer74or along the transverse seal line76. The tab25illustrated inFIG.9may also include an indentation55between the outer portion86and where the end of tab25is attached to the stand-up pouch100. By forming the tab25in this way, a user may easily access an underside of the tab25with a finger and open the stand-up pouch100by pulling the tab generally along the downstream direction (generally top-to-bottom inFIGS.8-10). By pulling on the tab25in this way, the tab25will tear at or near the indentation55, or tear portion65, and allow the stand-up pouch100to open. Thus, the stand-up pouch100cannot be opened without introducing a tear into the tab25thereby creating a tamper-evidence feature that is clearly visible. The stand-up pouch100ofFIGS.10and11show other embodiments of tab25with a tamper-evidence feature. InFIG.10, tab25also is defined by first score line52and extends from an edge of outer portion86. The end of the tab25is attached or anchored to a portion of the outer layer74or along the transverse seal line76and is free from pressure sensitive adhesive20or lamination to the second structure42. The tab25inFIG.10includes a prong59extending from a side of the tab25between the outer portion86and where the end of tab25is attached to the stand-up pouch100. The presence of prong59facilitates the task of a user tearing through a portion of the tab25at a tear portion65before opening the stand-up pouch100by providing a surface that is easily grasped. The embodiment inFIG.11includes two tabs25that include tear portions65in addition to a thumb tab23. Both tabs23and25also are defined by first score line52and extend from an edge of outer portion86and are free from pressure sensitive adhesive20or lamination to the second structure42. The end of tabs25are attached or anchored to a portion of the outer layer74or along the transverse seal line76. In use, tab23may be used to open the pouch100and to assist in tearing through tear portions65of tabs25. It should be noted that the terms “line of weakness” and “score line” as used herein refer either to a complete cutting through the thickness of one or more layers of the laminate or to a partial cutting through of the thickness of such layer(s) allowing the layer(s) to be severed along the score line. The packages described above are formed by completely enveloping the contents in the flexible laminate. Alternatively, however, it is within the scope of the invention to employ the flexible laminate as a lidding stock for forming flexible lids that can be secured (e.g., by heat-sealing or the like) to a flange of a tray or other container that contains the contents. In this manner, the lid includes a built-in opening and reclose feature as previously described. For instance,FIG.12shows a package110comprising a container body112having a side wall114and a flange116extending from the upper edge of the side wall. The container body112can comprise various materials (e.g., polymer, paper, foil, etc.) and can be formed by various methods (e.g., thermoforming, molding, etc.). The open top of the container body is closed by a lid118formed of a flexible laminate46in accordance with the invention. The lid is sealed to the flange116by any suitable technique, such that the lid is firmly attached to the flange. The lid includes an opening/reclose feature formed by a first score line52and a second score line62and pressure-sensitive adhesive20, and a tamper-evidence feature as previously described. The package110also includes a thumb “tab”25generally as described in connection withFIG.8; alternatively, a thumb tab of the type shown inFIGS.4and5can be used. Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | 36,428 |
11858196 | DETAILED DESCRIPTION The invention of the present disclosure relates to magnetic ink compositions. In particular, the invention of the present disclosure relates to magnetic ink compositions containing magnetic iron oxide nanoparticles for a variety of applications, such as printed electronics, among others. For example, the magnetic ink compositions may be used to produce tunable and/or reconfigurable fully-printed RF components and devices, such as inductors, antennas, and phase shifters, among other things. The magnetic ink compositions may be inkjet-printed as magnetic films. The magnetic ink compositions may be mixed with a polymeric resin and printed to form freestanding magnetic substrates. Other components may be printed onto the magnetic films and/or freestanding magnetic substrates to form fully printed, magnetically controlled RF devices. The magnetic ink compositions may be used to produce fully-printed RF components and devices that may be tuned and/or reconfigured upon application of an external magnetic field. For example, an inductor may be inkjet-printed on top of an inkjet-printed magnetic film to produce a tunable fully-printed inductor. A tuning of about 24% may be observed upon application of an external magnetic field to the tunable fully-printed inductor. An adjustable capacity of greater than about 20% for a fully-printed inductor is unprecedented, as conventional magnetic inks only exhibit about 0.8% tuning. The magnetic ink compositions may be mixed with, for example, a photocurable polymeric resin to form a magnetic substrate with magnetic iron oxide nanoparticles embedded therein. The magnetic substrate may be used to fabricate a linear patch antenna that may be tuned for its frequency upon application of a magnetic field. These are provided as non-limiting examples, as other tunable and reconfigurable fully-printed microwave/RF devices and components may be realized with the magnetic ink compositions. Definitions The terms recited below have been defined as described below. All other terms and phrases in this disclosure shall be construed according to their ordinary meaning as understood by one of skill in the art. As used herein, “adding” refers to any process and/or method of placing one component in or on another component, joining one or more components with another component, and/or bringing two or more components together, as in contacting. The components may be in contact or in immediate/close proximity. Adding may include one or more of pouring, dumping, mixing, depositing, providing, placing, putting, inserting, injecting, introducing, dropping, contacting, and any other methods known in the art. As used herein, “contacting” refers to the act of touching, making contact, or of bringing to close or immediate proximity, including at the cellular or molecular level, for example, to bring about a physiological reaction, a chemical reaction, or a physical change (e.g., in solution, in a reaction mixture, in vitro, or in vivo). Contacting may refer to bringing two or more components in proximity, such as physically, chemically, electrically, or some combination thereof. Mixing is an example of contacting. As used herein, “heating” refers to increasing to or at a temperature. For example, heating may refer to exposing or subjecting any object, material, etc. at or to a temperature that is greater than a current or previous temperature. Heating may also refer to increasing a temperature of any object, material, etc. to a temperature that is greater than a current or previous temperature of the object, material, etc. As used herein, “separating” refers to any process of removing a substance from another. The process may employ any technique known in the art suitable for separating. Centrifugation, filtration, and evaporation are examples of separating. Magnetic Iron Oxide Nanoparticles FIG.1is a flowchart of a method of making magnetic iron oxide nanoparticles, according to one or more embodiments of the present disclosure. As shown inFIG.1, the method100may comprise one or more of the following steps: mixing101a carboxylic acid with an aqueous solution of an iron compound to form a mixture; heating102the mixture to or at a select temperature; adding103a base to the mixture upon reaching the select temperature to form magnetic iron oxide nanoparticles; and separating104the magnetic iron oxide nanoparticles from one or more residual species. The step101includes contacting a carboxylic acid with an aqueous solution of an iron compound to form a mixture. In this step, one or more of a carboxylic acid, iron compound, and water are brought into physical contact and/or immediate or close proximity, sequentially and/or simultaneously, in any order. For example, the carboxylic acid may be contacted with, or added to, an aqueous solution containing the iron compound to form the mixture. The contacting of the carboxylic acid to the aqueous solution containing the iron compound may optionally proceed under stirring. The carboxylic acid can be a short chain carboxylic acid having 1-3 carbons and salts thereof. In an embodiment, the carboxylic acid may include one or more of acetic acid, carbonic acid, formic acid, propionic acid, butyric acid, pentanoic acid, and salts thereof. In preferred embodiments, the carboxylic acid includes acetic acid. The iron compound may include any iron salt or hydrated iron salt. For example, the iron compound may include, but is not limited to, one or more of iron (II) chloride, iron (III) chloride, iron (II) fluoride, iron (III) fluoride, iron (II) bromide, iron (III) bromide, iron (II) iodide, iron (III) iodide, iron (II) nitrate, iron (III) nitrate, iron (II) acetate, iron (III) acetate, iron (II) sulfate, iron (III) sulfate, iron (II) oxalate, and iron (III) oxalate. In an embodiment, the iron compound may include one or more iron chlorides, such as one or more of iron (II) chloride and iron (III) chloride. In an embodiment, the iron compound includes iron (II) chloride and iron (III) chloride. The step102includes heating the mixture to or at a select temperature. In this step, the mixture containing the carboxylic acid, iron compound, and water may be heated to or at a select temperature. In an embodiment, the heating of the mixture may proceed slowly. In an embodiment, the heating of the mixture may proceed slowly, optionally under stirring. The select temperature may range from about 50° C. to about 120° C. In preferred embodiments, the select temperature is about 90° C. The step103includes adding a base to the mixture upon reaching the select temperature to form magnetic iron oxide nanoparticles. In this step, once the mixture is heated to or at about the select temperature, such as about 90° C., the base may be added to the mixture. The base may include any suitable base, such as metal hydroxides, metal oxides, metal alkoxides, ammonia, and derivatives thereof. For example, in an embodiment, the base is sodium hydroxide. In an embodiment, the addition of the base to the mixture may result in a black colloidal solution. The presence of the carboxylic acid and the addition of the base upon reaching about the select temperature may facilitate the formation of small magnetic iron oxide nanoparticles suitable for the magnetic ink composition. The higher temperatures may increase the reaction rate such that large amounts of nuclei are formed in a short period of time, leading to the formation of small nanoparticles. For example, the base and carboxylic acid may, under the reaction conditions, disassociate or break the precipitates for the formation of uniform and/or disperse iron oxide nanoparticles. In some embodiments, the mixture may, upon adding the base, be refluxed for a period of time (e.g., about 10-15 minutes). The step104is optional and includes separating the magnetic iron oxide nanoparticles from one or more residual species. In this step, the solution of magnetic iron oxide nanoparticles may be centrifuged, optionally followed by washing with one or more solvents, such as water and an alcohol (e.g., ethanol) to obtain the iron oxide nanoparticles. Iron-Oxide Nanoparticle-Based Magnetic Ink Compositions Embodiments of the present disclosure describe an ink composition comprising a plurality of magnetic iron oxide nanoparticles in a solution containing one or more of a carrier (e.g., solvent) and a surface tension adjusting agent. In an embodiment, the plurality of magnetic iron oxide nanoparticles may be dispersed and/or suspended in the solution containing one or more of the carrier and the surface tension adjusting agent. For example, in an embodiment, the plurality of magnetic iron oxide nanoparticles may be uniformly (e.g., substantially uniformly) dispersed, suspended, and/or mixed in the solution containing one or more of the carrier and the surface tension adjusting agent. The plurality of magnetic iron oxide nanoparticles may include any suitable iron oxide nanoparticle with magnetic properties. In an embodiment, the plurality of magnetic iron oxide nanoparticles may include magnetic iron oxide nanoparticles prepared according to any of the methods described herein. In an embodiment, the plurality of magnetic iron oxide nanoparticles include one or more of Fe3O4nanoparticles and Fe2O3nanoparticles. In an embodiment, the plurality of magnetic iron oxide nanoparticles include Fe3O4nanoparticles. In an embodiment, the plurality magnetic iron oxide nanoparticles include Fe2O3nanoparticles. The plurality of magnetic iron oxide nanoparticles may be uniform (e.g., substantially uniform) in size and/or shape, such as spherical, cubic, and/or elongated. An average diameter of the plurality of magnetic iron oxide nanoparticles may range from about 1 nm to about 50 nm. In an embodiment, an average diameter of the plurality of magnetic iron oxide nanoparticles may range from about 15 nm to about 20 nm. In other embodiments, the average diameter may be less than about 1 nm and/or greater than about 50 nm. A concentration/loading of the magnetic iron oxide nanoparticles may be greater than or equal to about 1 wt %. In an embodiment, a concentration/loading of the magnetic iron oxide nanoparticles may be about 10 wt %. The carrier may include any carrier suitable for dispersing, suspending, and/or mixing the magnetic iron oxide nanoparticles. For example, in an embodiment, the carrier includes water. In an embodiment, the carrier includes deionized water. In an embodiment, the carrier includes water-compatible solvents, which may include, but are not limited to, alcohol (e.g., ethanol, methanol, propanol), glycol (ethylene glycol, 1,2-Butanediol, 1,3-Butanediol, 1,4-Butanediol, 1,3-Propanediol, 1,5-Pentanediol, propylene glycol, triethylene glycol, glycerol), and other such solvents. The surface tension adjusting agent may optionally be included to adjust a surface tension of the ink composition and/or providing stable jetting performance. In an embodiment, the surface tension adjusting agent includes an alcohol. For example, the surface tension adjusting agent may include one or more of methanol, ethanol, propanol, Triton X-100, centrimonium bromide (CTAB), sodium dodecyl sulfate (SDS), and other such agents. In an embodiment, the surface tension adjusting agent is ethanol. The alcohol is provided as an example of a suitable surface tension adjusting agent and shall not be limiting as any suitable surface tension adjusting agent known in the art may be used herein. FIG.2is a flowchart of a method of making a magnetic ink composition, according to one or more embodiments of the present disclosure. The method200may comprise one or more of the following steps: contacting205magnetic iron oxide nanoparticles with a carrier to form an iron oxide nanoparticle-based magnetic ink; adding206one or more surface tension adjusting agents to the iron oxide nanoparticle-based magnetic ink; and filtering207the iron oxide nanoparticle-based magnetic ink. The step205includes contacting magnetic iron oxide nanoparticles with a suitable carrier to form an iron oxide nanoparticle-based magnetic ink. In this step, the magnetic iron oxide nanoparticles may be brought into physical contact and/or immediate or close proximity to the one or more carriers sufficient to form the iron oxide nanoparticle-based magnetic ink. The contacting may be sufficient to disperse, suspend, and/or mix the magnetic iron oxide nanoparticles in the carrier. The contacting may optionally proceed under stirring. A content of the magnetic iron oxide nanoparticles may generally be greater than about 0 wt %. For example, in an embodiment, a content of the magnetic iron oxide nanoparticles may be greater than about 1 wt %. In an embodiment, a content of the magnetic iron oxide nanoparticles may be about 10 wt % or greater. The magnetic iron oxide nanoparticles may include any of the magnetic iron oxide nanoparticles prepared according to the methods of or described in the present disclosure. The carrier may include any of the carriers of the present disclosure. For example, in an embodiment, the carrier includes water. In an embodiment, the carrier includes deionized water. The amount of carrier used in this step may be varied in order to adjust a viscosity of the iron oxide nanoparticle-based magnetic ink, which may depend on the concentration of the magnetic iron oxide nanoparticles. For example, in an embodiment, the amount of carrier may be increased (e.g., added to the ink) to reduce a viscosity. In an embodiment, the amount of carrier may be decreased (e.g., removed by evaporation, etc.) to increase a viscosity. In an embodiment, the viscosity can be adjusted by adding a viscofier, such as HEC, 2-HEC, 2,3-butanediol, glycerol, ethylene glycol, and combinations thereof. The viscosity may be less than about 20 cP. In many embodiments, the viscosity may be less than about 12.5 cP. For inkjet printing, the viscosity may range from about 1-10 cps. For example, in preferred embodiments, the viscosity may be about 2 cP. The step206is optional and includes adding one or more surface tension adjusting agents to the iron oxide nanoparticle-based magnetic ink. The adding may proceed by contacting. In an embodiment, the adding may optionally proceed under stirring. For example, a duration of the stirring may range from about 1 min to about 48 h. In an embodiment, a duration of the stirring may be about 24 h. Any of the surface tension adjusting agents of the present disclosure may be used herein. For example, in an embodiment, the surface tension adjusting agents include one or more alcohols, such as methanol, ethanol, and/or propanol. In an embodiment, the surface tension adjusting agents include ethanol. The surface tension adjusting agents may be added to the iron oxide nanoparticle-based magnetic ink to adjust the surface tension of the ink to a suitable range, such as a range suitable for stable jetting performance. For example, the surface tension of the iron oxide nanoparticle-based magnetic ink may range from about 20 to about 350 mN m−1. In many embodiments, the surface tension may range from about 40 to about 65 mN m−1. In preferred embodiments, the surface tension may be about 44 mN m−1. The step207is optional and includes filtering the iron oxide nanoparticle-based magnetic ink. In this step, the iron oxide nanoparticle-based magnetic ink may be subjected to filtration to separate oversized particle aggregates. In an embodiment, it may be desirable to subject the iron oxide nanoparticle-based magnetic ink to filtration in order to avoid clogging and/or blockage during jetting and/or printing. Oversized particle aggregates may be defined according to the printing application and/or apparatus used for printing. In some embodiments, oversized particle aggregates include particle aggregates greater than about 450 nm in size. For example, 0.45 μm polypropylene Whatman paper may be used for the filtering. These shall not be limiting as other techniques known in the art suitable for filtering may be used herein. FIG.3is a flowchart of a method of making a magnetic ink composition, according to one or more embodiments of the present disclosure. As shown inFIG.3, the method300may comprise one or more of the following steps: contacting301a carboxylic acid with an aqueous solution of an iron compound to form a mixture; heating302the mixture to or at a select temperature; adding303a base to the mixture upon reaching the select temperature to form magnetic iron oxide nanoparticles; separating304the magnetic iron oxide nanoparticles from one or more residual species; contacting305the magnetic iron oxide nanoparticles with a carrier to form an iron oxide nanoparticle-based magnetic ink; adding306one or more surface tension adjusting agents to the iron oxide nanoparticle-based magnetic ink; and filtering307the iron oxide nanoparticle-based magnetic ink. In an embodiment, the method may comprise one or more of the following steps: mixing acetic acid with an aqueous solution of iron (II) chloride and/or iron (III) chloride to form a mixture, heating the mixture to or at a select temperature, wherein the select temperature is about 90° C., adding sodium hydroxide to the mixture upon reaching the select temperature to form magnetic iron oxide nanoparticles, separating the magnetic iron oxide nanoparticles from one or more residual species, and dispersing the magnetic iron oxide nanoparticles in deionized water to form an iron oxide nanoparticle-based magnetic ink. Printing Iron-Oxide Nanoparticle-Based Magnetic Ink Compositions FIG.4is a method of printing a magnetic ink composition, according to one or more embodiments of the present disclosure. As shown inFIG.4, the method400may comprise printing401one or more layers of an iron oxide nanoparticle-based magnetic ink onto a substrate; and heating402the printed substrate to or at a select temperature sufficient to dry the printed substrate. Any of the iron oxide nanoparticle-based magnetic inks of the present disclosure may be used herein. The method may be used to form, among other things, magnetic substrates including a magnetic film on a surface of a substrate, wherein the magnetic film includes magnetic iron oxide nanoparticles. The step401includes printing one or more layers of an iron oxide nanoparticle-based magnetic ink on a substrate. In many embodiments, the printing includes inkjet printing. For example, the printing may proceed by ejecting one or more droplets of the magnetic ink from a suitable printer, such as a 2D printer and/or 3D printer, onto the substrate in any form or pattern, such as dots and/or lines. In an embodiment, the printing may proceed by vertically dropping or ejecting droplets of the magnetic ink. In an embodiment, the printer may include a drop-on-demand piezeoelectric ink-jet nozzle. The printing may proceed continuously (e.g., substantially continuously) or non-continuously (e.g., substantially non-continuously), optionally under constant printing conditions. The printing may include printing at least one layer of the iron oxide nanoparticle-based magnetic ink on the substrate. In many embodiments, the printing may include printing at least about 2 overlayers, preferably about 5 overlayers, of the iron oxide nanoparticle-based magnetic ink to, for example, achieve a uniform or substantially uniform density of the nanoparticles. The number of layers of the iron oxide nanoparticle-based magnetic ink printed on the substrate may be selected to achieve a desired thickness. For example, a thickness of the iron oxide nanoparticle-based magnetic ink may be increased by increasing the number of printed layers and/or decreased by decreasing the number of printed layers. In addition or in the alternative, the drop spacing may be adjusted to achieve a desired thickness of the printed lines. The printed magnetic ink may not exhibit any coffee-ring effects and/or line bulging. The printing and/or ejection of ink may be characterized by, among other things, one or more of a drop volume, jetting velocity of ejected droplets, cartridge print height, and drop spacing. In an embodiment, the drop volume may be about 10 pL. In an embodiment, the jetting velocity of ejected droplets may be about 3.3 m s−1. In an embodiment, the cartridge print height may be about 0.3 mm. In an embodiment, the drop spacing may be about 40 μm. In other embodiments, one or more of the drop volume, jetting velocity of ejected droplets, cartridge print height, and drop spacing may be greater or less than the values described herein. The substrate may include any suitable substrate for printing the iron oxide nanoparticle-based magnetic ink. For example, the substrate may include one or more of PI, PET, PEN, glass, and other 3-D printed substrates, such as those formed from acrylic and/or molten plastic (acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), etc.) based materials. In an embodiment, the substrate is glass. The step402includes heating the printed substrate to or at a select temperature sufficient to dry the printed substrate. In this step, the printed substrate is treated by heating the printed substrate and/or an environment in which the printed substrate is present to or at a select temperature sufficient to solidify and/or dry the iron oxide nanoparticle-based magnetic ink. In many embodiments, the select temperature is about 80° C. In other embodiments, the select temperature may be less than or greater than about 80° C. The heating may proceed for any duration suitable for drying and/or solidifying the printed iron oxide nanoparticle-based magnetic ink. Fully/Partially Printed Tunable/Reconfigurable RF Devices/Components Based on the Iron Oxide Nanoparticle-Based Magnetic Inks The iron oxide nanoparticle-based magnetic inks of the present disclosure may be printed according to the methods of the present disclosure and incorporated into tunable and/or reconfigurable RF devices and/or components. The RF devices and/or components may be fully and/or partially printed (e.g., inkjet printed). In an embodiment, the tunable and/or reconfigurable RF devices and/or components are fully printed to form a fully printed tunable inductor. For example, embodiments of the present disclosure describe a tunable and/or reconfigurable inductor including the printed iron oxide nanoparticle-based magnetic ink, which may be printed as a film, among other forms, according to the methods of the present disclosure. In an embodiment, a tunable inductor may be fabricated on a top of an inkjet-printed magnetic film prepared from the iron oxide nanoparticle-based magnetic inks of the present disclosure. For example, the iron oxide nanoparticle-based magnetic ink may be inkjet printed on a substrate, such as a plastic substrate, with one or more overprinted layers and then dried via heating at about 80° C. for about 30 min to form a printed magnetic film. After printing the magnetic film, a tunable inductor may be printed on the inkjet printed film. For example, in an embodiment, one or more layers of silver-organo-complex (SOC) based silver ink may be printed and cured (e.g., using infrared (IR) heating) to obtain a fully printed tunable inductor. Optionally, the fully printed tunable inductor may be supported on any suitable substrate, such as FR-4 board. Functionalized Iron Oxide Nanoparticle-Based Magnetic Ink Compositions Embodiments of the present disclosure further describe an ink composition comprising a mixture containing one or more of a plurality of functionalized magnetic iron oxide nanoparticles, a photocurable polymeric resin, and a solvent. The magnetic iron oxide nanoparticles may include any of the magnetic iron oxide nanoparticles of the present disclosure. For example, in an embodiment, the magnetic iron oxide nanoparticles may include one or more of Fe3O4nanoparticles and Fe2O3nanoparticles. The photocurable polymeric resin and the solvent may include any suitable polymer with photocurable capabilities dissolved in a suitable solvent, such as an organic solvent. For example, in an embodiment, the photocurable polymeric resin may include SU8, an epoxy dissolved in organic solvents, such as cyclopentanone. The SU8 may be cross-linked through polymerization by UV exposure to make solid films (e.g., thick solid films). In many embodiments, the photocurable polymeric resin may be present in low amounts (e.g., with a low wt %) and/or with a low viscosity solvent composition. The photocurable polymeric resin may be solidified (e.g., immediately solidified) upon exposure to, for example, ultraviolet light, among other wavelengths of light. The photocurable polymer resin may include UV-curable resins based on acrylated epoxies, acrylated polyesters, acrylated urethanes, acrylated silicones, and other such resins. The magnetic iron oxide nanoparticles should be compatible with the polymer and solvent of the photocurable polymeric resin such that it may be incorporated into and/or embedded in the matrix. To be compatible with the photocurable polymeric resins, the magnetic iron oxide nanoparticles may be functionalized such that the magnetic iron oxide nanoparticles may be combined with one or more of the photocurable polymeric resins. The magnetic iron oxide nanoparticles may be functionalized with any element or compound suitable for embedding the nanoparticles in the photocurable polymeric resin. For example, in many embodiments, the magnetic iron oxide nanoparticles may be functionalized with oleic acid, which is compatible with a large number of organic solvents, including, for example, cyclopentanone. The oleic acid may be physically sorbed (e.g., adsorbed) onto a surface of the magnetic iron oxide nanoparticles such that the long chain of the oleic acid may interact with the organic solvent. In other embodiments, the magnetic iron oxide nanoparticles may be functionalized with one or more of oleic acid, elaidic acid, oleylamine, oleamide, and oleyl alcohol. FIG.5is a flowchart of a method of making functionalized iron oxide nanoparticle-based magnetic ink compositions, according to one or more embodiments of the present disclosure. As shown inFIG.5, the method may comprise one or more of the following steps: contacting501one or more of magnetic iron oxide nanoparticles, a first solvent, and a functionalizing agent to form a solution; mixing502the solution sufficient for the functionalizing agent to sorb on a surface of the magnetic iron oxide nanoparticles; removing503excess functionalizing agent; and contacting504the functionalized magnetic iron oxide nanoparticles with a photocurable polymeric resin to form a functionalized iron oxide nanoparticle-based magnetic ink. The step501includes contacting one or more of magnetic iron oxide nanoparticles, a first solvent, and a functionalizing agent to form a solution. The contacting may proceed by bringing one or more of the magnetic iron oxide nanoparticles, first solvent, and functionalizing agent into physical contact and/or immediate or close proximity, sequentially and/or simultaneously, in any order. In an embodiment, the magnetic iron oxide nanoparticles may be dispersed in the first solvent, followed by addition of the functionalizing agent. The magnetic iron oxide nanoparticles may include any of the magnetic iron oxide nanoparticles of the present disclosure, either in dry or wet form, preferably wet form. The first solvent may include any solvent suitable for dispersing and/or functionalizing the magnetic iron oxide nanoparticles. For example, the first solvent may include an alcohol solvent, such as ethanol, methanol, propanol, butanol, pentanol, and other such solvents. The functionalizing agent may include any functionalizing agent compatible with a desired solvent, such as solvents in which the photocurable polymeric resin is dissolved (e.g., organic solvents). For example, the functionalizing agent may include one or more of oleic acid, elaidic acid, oleylamine, oleamide, and oleyl alcohol. The step502includes mixing the solution sufficient for the functionalizing agent to sorb on a surface of the magnetic iron oxide nanoparticles. The mixing may include any technique sufficient for the functionalizing agent to sorb onto a surface of the magnetic iron oxide nanoparticles. For example, the mixing may be achieved by stirring, among other techniques known in art, for a select duration. The duration of the mixing may range from about 1 min to about 48 h. In an embodiment, the duration of the mixing is about 24 h. The functionalizing agent may be physically and/or chemically sorbed (e.g., absorbed and/or adsorbed) onto a surface of the magnetic iron oxide nanoparticles. In many embodiments, the functionalizing agent may be physically absorbed onto a surface of the magnetic iron oxide nanoparticles such that the functionalizing agent is available to interact with the desired solvent (e.g., the solvent in which the photocurable polymeric material is dissolved). In this way, the functionalized iron oxide nanoparticles may be compatible with the photocurable polymeric resin matrix. The step503is optional and includes removing excess functionalizing agent, if necessary. In this step, it may be desirable to remove, among other things, excess functionalizing agent from the mixture, which may contain one or more of functionalized magnetic iron oxide nanoparticles, magnetic iron oxide nanoparticles, first solvent, and functionalizing agent. The removing may include one or more of centrifuging and washing with a solvent, such as ethanol. For example, in an embodiment, the mixture may be centrifuged (e.g., at about 4000 rpm for about 2 min) and washed with ethanol about 2-3 times to remove any excess oleic acid. In an embodiment, the removing may further comprise removing one or more of magnetic iron oxide nanoparticles, first solvent, and functionalizing agent to, for example, obtain functionalized magnetic iron oxide nanoparticles. The step504includes contacting the functionalized magnetic iron oxide nanoparticles with a photocurable polymeric resin to form a functionalized iron oxide nanoparticle-based magnetic ink. Any of the photocurable polymer resins of the present disclosure may be used herein. In an embodiment, the photocurable polymeric resin may be dissolved in a second solvent, such as organic solvents (e.g., cyclopentanone). In an embodiment, one or more of magnetic iron oxide nanoparticles, first solvent, and functionalizing agent may be present during the contacting. In an embodiment, one or more of magnetic iron oxide nanoparticles, solvent, and functionalizing agent may not be present during the contacting. The contacting may proceed by bringing the functionalized magnetic iron oxide nanoparticles, photocurable polymeric resin, and second solvent into physical contact and/or immediate or close proximity. For example, in an embodiment, the contacting may proceed by mixing using stone mortar and pestle. The functionalized magnetic iron oxide nanoparticles and photocurable polymeric resin may be mixed at a 1:100 wt % ratio to a 100:1 wt % ratio. In an embodiment, the functionalized magnetic iron oxide nanoparticles and photocurable polymeric resin may be mixed at a 50:50 wt % ratio. In an embodiment, the functionalized iron oxide nanoparticle-based magnetic ink may be in a form of an ink paste. Printing Functionalized Iron Oxide Nanoparticle-Based Magnetic Inks FIG.6is a flowchart of a method of printing a magnetic ink composition, according to one or more embodiments of the present disclosure. As shown inFIG.6, the method600may comprise printing601a functionalized iron oxide nanoparticle-based magnetic ink composition containing functionalized magnetic iron oxide nanoparticles and a photocurable polymeric resin onto a removable substrate, heating602the printed magnetic ink composition to or at a select temperature for a select duration, curing603the printed magnetic ink composition sufficient to solidify the mixture; and optionally removing604the removable substrate. The method may be used to form, among other things, freestanding magnetic substrates including magnetic iron oxide nanoparticles embedded in a polymeric material. The freestanding magnetic substrates formed according to the methods of the present disclosure may be used to form tunable, fully printed microwave or RF devices, among other things. The step601includes printing a functionalized iron oxide nanoparticle-based magnetic ink onto a removal substrate. The functionalized iron oxide nanoparticle-based magnetic ink may include any of the magnetic ink compositions of the present disclosure. For example, in an embodiment, the functionalized iron oxide nanoparticle-based magnetic ink may contain one or more of functionalized magnetic iron oxide nanoparticles and a photocurable polymeric resin. In an embodiment, the functionalized iron oxide nanoparticle-based magnetic ink may further contain one or more residual species, such as one or more of magnetic iron oxide nanoparticles, solvent, and functionalizing agent. The removable substrate may be used as a support until the magnetic substrate is solidified (e.g., after curing). For example, the removable substrate may include an FR-4 board with sacrificial paper on a backside. This shall not be limiting as any other material known in the art may be used as a removable substrate. Depending on a viscosity of the magnetic ink composition, the magnetic ink composition may be provided in the form of a paste. In an embodiment, a slot may be created on the removable substrate to facilitate printing of the magnetic ink composition to achieve a desired magnetic substrate thickness. In an embodiment, the printing may proceed by a manual screen-printing technique, such as a squeegee, to print the magnetic ink paste on the removable substrate. For example, the magnetic ink paste may be printed by filling (e.g., pouring, depositing, dropping, applying, etc.) the slot created on the removable substrate with the magnetic ink paste, optionally with the use of a squeegee or other similar instrument. Any thickness of the magnetic substrate to be formed may be achieved by varying a depth of the slot. The step602includes heating the printed magnetic ink composition to or at a select temperature for a select duration. The heating may include heating the printed magnetic ink composition and/or an environment in which the printed magnetic ink composition is present to or at the select temperature. The select temperature may include any suitable temperature. In many embodiments, the select temperature may be about 80° C. In other embodiments, the select temperature may be less than about and/or greater than about 80° C. The select duration may include any suitable duration. In many embodiments, the select duration may be about 15 min. In other embodiments, the select duration may be less than or more than about 15 min. The step603includes curing the printed magnetic ink composition sufficient to solidify the mixture and obtain, for example, a freestanding magnetic substrate. The curing may include any wavelength of light, which may depend on the selection of the photocurable polymeric resin. In some embodiments, the curing may include ultraviolet (UV) and/or infrared (IR) curing. The curing may proceed for any suitable time, such as about 15 minutes. The freestanding magnetic substrate may include functionalized iron oxide nanoparticles embedded in the polymeric matrix. In an embodiment, a fully inkjet-printed linear patch antenna including the freestanding magnetic substrates of the present disclosure In some embodiments, steps601to603may proceed one or more times. For example, the slot created in the removable substrate may be filled with the magnetic ink paste in one or more cycles, wherein in each cycle, the ink is printed601, heated602, and cured603. The step604is optional and includes removing the removable substrate. The removing may include one or more of cutting the removable substrate from the edges and/or immersing the removable substrate in a warm bath, such as a warm water bath (e.g., for about 10 min). Fully/Partially Printed Tunable/Reconfigurable RF Devices/Components Based on the Iron Oxide Nanoparticle-Based Magnetic Inks The functionalized iron oxide nanoparticle-based magnetic inks of the present disclosure may be printed according to the methods of the present disclosure and incorporated into tunable and/or reconfigurable devices and/or components. The RF devices and/or components may be fully and/or partially printed. In an embodiment, the functionalized iron oxide nanoparticle-based magnetic inks are fully printed to form tunable and reconfigurable passive microwave components. For example, embodiments of the present disclosure describe printed linear patch antennas including the functionalized iron oxide nanoparticle-based magnetic ink described herein and which may be printed as freestanding magnetic substrates according to the methods of the present disclosure. In an embodiment, a smoothening layer may be inkjet printed and cured on a top and bottom surface of the freestanding magnetic substrate. In an embodiment, one or more layers of a silver-organo-complex (SOC) silver ink may be printed and cured using, for example, IR heating to obtain the patch antenna. The SOC ink is more fully described in WO 2017/103797 A1, which is hereby incorporated by reference in its entirety. The following Examples are intended to illustrate the above invention and should not be construed as to narrow its scope. One skilled in the art will readily recognize that the Examiners suggest many other ways in which the invention could be practiced. It should be understand that numerous variations and modifications may be made while remaining within the scope of the invention. Example 1 The field of printed electronics is still in its infancy and most of the reported work is based on commercially available nanoparticle-based metallic inks. Although fully printed devices that employ dielectric/semiconductor inks have recently been reported, there is a dearth of functional inks that can demonstrate controllable devices. The lack of availability of functional inks is a barrier to the widespread use of fully printed devices. For radio-frequency electronics, magnetic materials have many uses in reconfigurable components, but rely on expensive and rigid ferrite materials. A suitable magnetic ink can facilitate the realization of fully printed, magnetically controlled, tunable devices. The present Example describes the development of an iron oxide nanoparticle-based magnetic ink. First, a tunable inductor was fully printed using iron oxide nanoparticle-based magnetic ink. Furthermore, iron oxide nanoparticles were functionalized with oleic acid to make them compatible with a UV-curable SU8 solution. Functionalized iron oxide nanoparticles were successfully embedded in the SU8 matrix to make a magnetic substrate. The as-fabricated substrate was characterized for its magnetostatic and microwave properties. A frequency tunable printed patch antenna was demonstrated using the magnetic and in-house silver-organo-complex inks. This was a step toward low-cost, fully printed, controllable electronic components. The iron oxide nanoparticle-based magnetic ink was completely characterized for its material properties, and then its utility was demonstrated through fully printed, magnetically controllable RF devices. A simple solution method to synthesizing well-dispersed, uniform, magnetic, iron oxide NPs was adopted. These iron oxide NPs were used for ink-formulation and then used to demonstrate the fully inkjet-printed tunable inductor. These iron oxide nanoparticles were also used with the aim of making freestanding magnetic substrates. SU8 polymer was selected to develop thick substrates, a polymeric resin materials that can immediately solidify on exposure to a low-cost UV lamp. This SU8 solution was cross-linked through polymerization by UV exposure to make thick solid films. Through functionalization of iron oxide nanoparticles with oleic acid (to make it compatible with a UV-curable SU8 solution), the functionalized iron oxide nanoparticles were successfully embedded in the SU8 matrix, creating a freestanding, magnetic substrate. The magnetic ink was characterized for its magnetic and high frequency properties. Finally, a patch antenna was printed on the magnetic substrate with an in-house silver ink; the printed antenna was tuned for its frequency by applying magnetic fields across it. This first demonstration of a fully printed controllable RF device was an important milestone for the next generation of low-cost tunable and reconfigurable components that can be completely realized through additive manufacturing. Experimental Section Chemicals: Iron (II) chloride tetrahydrate (FeCl2·4H2O, reagent plus, 98%), iron (III) chloride hexahydrate (FeCl3·6H2O, ACS, 97-102%), sodium hydroxide (NaOH, Sigma Aldrich), acetic acid (CH3COOH, ACS reagent, ≥99.7%), oleic acid [CH3(CH2)7CH═CH(CH2)7COOH, technical grade, 90%], SU8 2002 (MicroChem), and ethanol (absolute, VWR Chemicals) were used as they were received, without further purification. Synthesis of Iron Oxide NPs: As in a typical synthesis process, 0.01 M iron (II) chloride (≈0.596 g) and 0.02 M iron (III) chloride (≈1.621 g) were dissolved in about 300 mL of DI water, followed by mixing of about 1 mL of acetic acid. The resulting solution was then slowly heated in a three-necked refluxing pot while stirring (1000 rpm). When the temperature reached about 90° C., about 2 g of NaOH was added. This resulted in a black solution, indicating the formation of Fe3O4NPs. In this reaction condition, sodium hydroxide acted as a basic source and acetic acid to break the precipitates for the formation of uniform and disperse Fe3O4NPs. After about 10-15 min of refluxing, the black colloidal solution was obtained followed by centrifugation at about 3000 rpm for about 2 min, and washing with deionized water and ethanol. Ink Formulation and Inkjet Printing Using Iron Oxide NPs: The as-prepared iron oxide NPs were formulated as ink in about 3 mL of deionized water. Initially, the ink exhibited a high surface tension (SFT) of ≈63 mN m−1which was adjusted with the addition of about 10 vol % of ethanol. After the addition of ethanol, ink exhibited an SFT of ≈44 mN m−1, which was good for stable jetting performance, as shown inFIGS.7A-7B. The resulting solution was then stirred for about 24 h. Subsequently, the formulated iron oxide ink was filtered by 0.45 μm polypropylene (PP) Whatman paper before jetting. The observed viscosity of as-formulated ink for ink jet printing was ≈1.74 cP, using a spindle speed of about 100 rpm and shear rate of about 132 s−1at about room temperature. However, the SU8 embedded iron oxide nanoparticles were showing the viscosity of about 37.8 cP, using a spindle speed of about 100 rpm and shear rate of about 132 s−1at about room temperature. The iron oxide dot and line patterns were directly printed on glass substrate using a drop-on-demand piezoelectric ink-jet nozzle (manufactured by Dimatix) with a diameter of 16 μm; the drop volume was about 10 pL. The uniform and continuous ejection of droplets was achieved by adjusting various wave forms while applying a firing voltage of 33.2 V at a 5 kHz printer velocity, as shown inFIG.8. The jetting velocity of ejected droplets was ≈3.3 m s−1and the cartridge print height was ≈0.3 mm. The thickness of as-printed lines was varied by the number of overprinting layers using about 40 μm drop spacing. Functionalization of Iron Oxide NPs and Their Ink Formulation: For functionalization, the wet form of iron oxide NPs was dispersed in about 50 mL of ethanol, followed by the addition of about 0.2 mL of oleic acid. The resulting solution was then stirred for about 24 h to ensure the physical absorption of oleic acid molecules on surfaces of iron oxide NPs. After stirring, the resulting solution was centrifuged at about 4000 rpm for about 2 min and washed with ethanol about 2-3 times cycle−1to remove access oleic acid molecules. The resulting functionalized iron oxide NPs were then ready to mix with the SU8 2002 solution. Fabrication of a Printed Antenna on Magnetic Substrate: An in-house SOC ink was utilized in this work to print an antenna on magnetic substrate. The SOC ink produced smooth and dense films; it was stable and transparent. The antenna was printed on magnetic substrate (t≈1500 μm) using eight layers of AOC ink at about 30 μm drop spacing with a 10 pL Dimatix DMP2831inkjet printer. A low-cost250W IR lamp was used to cure the ink by placing the substrate under the lamp for about 5 min after each printed layer. The maximum measured temperature of the substrate was about 80° C. Characterization: The structural properties were examined using scanning electron microscopy (Zeiss Merlin with Gemini 2 column) and transmission electron microscopy (FEI Titan G2 80-300 kV equipped with a 2 k×2 k CCD camera model US4000, Gatan, Inc.). The elemental quantification was examined with EDS equipped with FEI Nova Nano. In addition, the thicknesses and uniformity of printed features on substrates were measured using a surface profiler (Veeco Dektak 150). The crystallinity of the iron oxide powders was examined by X-ray diffraction (Bruker D8 Advance) in the range of 20°-70° at 40 kV. Furthermore, the UV-vis absorption spectrum of the ink was obtained using a UV-vis spectrophotometer (Cary 100 UV-vis-NIR) with a standard 1 cm liquid cuvette and a background calibration that was run using ethanol. The chemical functionalization was characterized by FTIR spectrometers (Nicolet 6700). The FTIR sample was prepared using KBr pellet method. ≈0.1-1.0% sample was well mixed into ≈200 mg fine KBr powder and then finely pulverized using stone mortar and pestle. After pulverization, the resultant powder was placed in to a pellet-forming die for making transparent pellets. In order to correct the infrared light scattering loses in the pellet, a background measurement was done on a pellet holder with a pellet of KBr only. Finally, the sample was loaded and its measured infrared spectrum was recorded. Furthermore, viscosities of the inks were measured using a Brookfield Rheometer (DV3T). The surface tensions of the inks were measured by using a KRUSS DSA100 based on pendant drop method. The particle size analysis of the ink was done using Zetasizer (Malvern Instrument). Before analysis, ink was diluted ten times with DI water. The magnetic properties of iron oxide nanoparticles were examined by SQUID-VSM. Synthesis and Functionalization of Iron Oxide NPs Iron oxide NPs were prepared at about 90° C. with iron (II) chloride, iron (III) chloride, NaOH, and acetic acid using the hot-injection solution method for about 30 min, without the use of any complex reagents. The presence of acetic acid and addition of sodium hydroxide at heating temperature played an important role in the formation of small iron oxide NPs. If sodium hydroxide was added to the boiling solution with the presence of acetic acid, higher temperatures generally caused faster reaction rates, generating large amounts of nuclei in a short time and leading to the formation of small nanoparticles. Iron oxide NPs usually possess typical magnetic behavior at about room temperature (RT). To the best of present knowledge, there is no report of any iron oxide NP-based ink formulation for inkjet printing. Several significant issues related to magnetic ink formulation must be addressed. For example, magnetic materials should be nanoparticle sized and be well dispersed during formulation, ink viscosity and surface tension must be suited for inkjet printing, and ink must contain the appropriate concentration and a carrier vehicle (solvent). In the field of printed electronics, similar to other emerging electronic technologies, new materials and processing methods are required for their continually improving development and performance. The as-prepared iron oxide NPs showed good dispersion with deionized (DI) water and were successfully utilized as a solvent for inkjet printing. To be compatible with SU8 polymeric resin, iron oxide required functionalization on the surfaces of nanoparticles. SU8 2002 manufactured by Micro-Chem is usually composed of an epoxy that is dissolved into an organic solvent (e.g., cyclopentanone). Oleic acid was successfully used as a molecule for functionalization of iron oxide nanoparticles. The selection of oleic acid was due to its compatibility with cyclopentanone of SU8 polymeric resin in addition to many common organic solvents. Furthermore, the choice of SU8 was also due to its low wt % of resin with low viscosity solvent composition and its photocuring capability. A number of other photocurable polymeric resins were available but due to their high content of resin (>99%) and high viscosity, it may be very challenging to embed the nanoparticles in those resins. Thus, for compatibility with SU8 2002, iron oxide nanoparticles were functionalized with oleic acid, as shown inFIG.9A. The physical adsorption of oleic acid molecules on the surfaces of iron oxide NPs led to compatibility with the SU8 matrix, as the long chain of oleic acid interacted with the organic solvent. Subsequently, these SU8-mixed nanoparticles were pre-heated at about 80° C. for about 15 min, followed by UV curing with a wavelength of about 365 nm for about 30 min to solidify the mixture.FIGS.9B-9Gshow the scanning electron microscopic (SEM) images and energy-dispersive spectroscopic (EDS) spectrum taken from the as-prepared, functionalized, SU8-mixed iron oxide NPs. The SEM image (FIGS.9B,9C) shows that the NPs are almost spherical shape; they were uniformly grown at a high density with an average diameter of about 15-20 nm. It should be noted that due to charging effect and magnetization of iron oxide nanoparticles, high-resolution images were difficult to capture. The EDS spectrum (FIG.9E) demonstrates that the as-prepared NPs are made of Fe and O only, and the atomic ratio of Fe and O is ≈3:4. In contrast to pure iron oxide NPs, the oleic acid functionalized sample (FIG.9F) shows the carbon content in addition to Fe and O, which confirmed the functionalization on the surfaces of iron oxide NPs. The SU8 mixed iron oxide NPs (FIG.9G) show even higher carbon content, primarily due to SU8 molecules. The SU8-mixed, iron oxide morphology (FIG.9D) confirmed that nanoparticles were well-embedded in the SU8 matrix. The particle's size and shape were further confirmed by its corresponding transmission electron microscopic (TEM) images.FIGS.10A-10Cshow TEM image, high-resolution TEM (HRTEM) image, and selected area diffraction (SAED) pattern of (FIG.10A) pure, (FIG.10B) functionalized, and (FIG.10C) SU8-mixed iron oxide NPs. From the TEM images, it was confirmed that nanoparticles were in various shapes such as spherical, cubic, and elongated. Such shapes are common in iron oxide nanoparticles during the nucleation and growth formation. The functionalization of iron oxide was also visualized by an HRTEM image (FIG.10B2), showing ≈2-3 nm of carbon shell on the core of the nanoparticles. Furthermore, the HRTEM image (FIG.10C2) of the SU8-mixed sample showed a thick boundary of the SU8 carbon-coated matrix, in which iron oxide nanoparticles were suspended. The SAED patterns (FIGS.10A3-10C3) for all the samples, confirmed the polycrystallinity phase of as-grown iron oxide NPs, corresponded to the cubic spinel structure. Due to thick boundary of SU8 matrix, the intensity of SAED pattern was faded which further confirmed that iron oxide nanoparticles were embedded in the SU8 matrix. It should be noted that TEM analyses were only for morphological characterization purpose. However, functionalization and embedding could be efficiently confirmed by Fourier transform infrared (FTIR) analysis. Chemical Nature and Crystalline Phase of Iron Oxide NPs The quality and chemical composition of (a) as-synthesized, (b) oleic acid functionalized, and (c) SU8-mixed ironoxide NPs were further examined by FTIR spectroscopy in transmission mode and are shown inFIG.11A. In the as-synthesized sample, weak adsorption bands appeared at 3412 and 1587 cm−1as well as a strong adsorption band at 581 cm−1. The weak adsorption bands were attributed to the stretching vibration and bending vibration of the absorbed water and surface hydroxyls, respectively. Moreover, the presence of the strong band was due to Fe—O stretching vibration. Surface absorbed moisture was common during sample preparation for FTIR analysis. Therefore, the FTIR spectrum confirmed that the synthesized product was pure iron oxide NP (a). The bands at 1395 and 1458 cm−1were ascribed to the symmetric and asymmetric stretches of COO—, indicating that the oleic acid molecule was attached to the iron oxide nanoparticles in a bidentate mode, with two oxygen atoms symmetrically coordinated to iron (b). The characteristic vibrational bands at 2852 and 2920 cm−1were attributed to the symmetric and antisymmetric —CH2 stretching from the structure of oleic acid. In addition, the band at 1639 cm−1was due to C═C from oleic acid. The SU8-mixed iron oxide sample showed several characteristic bands at 830, 1245, 1608, and 1738 cm−1, which, respectively, corresponded to an epoxide, aromatic ring, and carbonyl group from the SU8 molecules.FIG.11Bshows the X-ray diffraction (XRD) patterns that were implemented to examine the crystal structure of iron oxide nanoparticles (a) before and (b) after functionalization, and (c) SU8-mixed samples. All characteristic peaks are matched with the cubic spinal-structured magnetite (JCPDS card no. 65-3107). The optical properties of the as-synthesized and functionalized samples were also investigated by UV-vis absorption (FIG.12). The UV-vis absorption spectrum showed that, as the wavelength decreased, absorbance increased monotonically. The UV-vis spectrum indicated that the wide absorption range from 300 to 900 nm occurred with a broad peak center at 400 nm, corresponded to iron oxide absorption. The wide absorption may be caused by cluster formation of iron oxide NPs in an ethanol solution, which scattered almost UV radiation and provided long-tail-type features in the UV-vis absorption spectrum. Magnetic Properties of Iron Oxide NPs FIGS.13A-13Bdemonstrate the magnetization versus magnetic field plots (M-H loops) measured at 300 K, in addition to the full range of hysteresis between ±10 kOe for the as-synthesized and oleic acid functionalized iron oxide NPs. The samples showed no hysteresis at RT, signifying the superparamagnetic nature of the resultant NPs (a). A well-developed hysteresis loop was observed at 5 K, signifying the ferromagnetic nature of the resultant NPs (b). While not wishing to be bound to a theory, it was believed that, due to the air-gap condition and loosely bound nanoparticles at RT measurement, the samples were superparamagnetic nature. In contrast to RT measurement, the freezing state (at 5 K) condition satisfied the gap and loosely bound state, demonstrating the ferromagnetic nature, as shown with the pictorial presentation inFIGS.13A-13B. Furthermore, the saturation magnetization (Ms), remanent magnetization (MR), and coercivity (Hc) were calculated as 51-53 emu g−1, 20.31 emu g−1, and 400 Oe for as-synthesized and oleic acid functionalized iron oxide NPs, respectively (FIG.3B). Compared to the bulk iron oxide, the decrease in Mswas attributed to the decreased particle size and an increase in surface area. The energy of a magnetic particle in an external field is proportional to its size or volume via the number of magnetic molecules in a single magnetic domain. When this energy becomes comparable to the thermal energy, thermal fluctuations will significantly reduce the total magnetic moment at a given field. Such a phenomenon is more prominent with small nanocrystals. The temperature-dependent magnetization was also characterized (FIG.14), which was typical to magnetic nanoparticles. Zero-field cooled (ZFC) and field-cooled (FC) curves were measured in a magnetic field of 100 Oe in the temperature range of 5-300 K. The graph shows the two FC and ZFC curves, which have a divergence point close to room temperature. Moreover, FC magnetization remains nearly constant as the temperature decreased, whereas ZFC magnetization decreased as the temperature decreased. There was no distinctive blocking temperature (TB), which must be investigated further by varying the magnetic field. Inkjet Printing of Magnetic Ink and Fabrication of Fully Printed Tunable Inductor As-synthesized iron oxide NPs were used for ink formulation with about 10 wt % loading in water solvent. To confirm the particle size aggregate in the ink, the ink was diluted ten times with deionized (DI) water and characterized using Zetasizer (as shown inFIG.15). The graph clearly shows the size distribution with number of particles. The ≈51.7% particle aggregates corresponded to 121.5 nm, 48% for 242 nm, and 0.2% for 2582 nm. The ink was inkjet printed under constant printing conditions and vertically dropped from the nozzle, which formed dots (FIGS.16A-16B) and lines (FIGS.17A-17E) on the glass substrate. The 3D image of the dots showed the uniform dot pattern with a high density of NPs covering the entire dot area (FIG.16A). The 3D surface profiler measured the dot width as ≈55 μm and the thickness was ≈160 nm (FIG.16B). To further study the effect of overprinting on the substrate-surface-ink interaction and line uniformity, the line patterns with a drop spacing of 40 μm were printed on glass substrates while varying the number of overlayers (nol). The as-printed iron oxide lines were analyzed by the 3D surface profiler with varying nol(FIGS.17A-17E). The printed lines showed a width of 70±10 μm with number of overlayers.FIG.17Acorresponds to the single printing, which revealed that the density of NPs was not uniform along the width (i.e., there was a higher density at the edge of line than in the middle area; a-2). The first layer of printing was directly related to the substrate-ink interaction and its compatible properties, such as the surface tension of ink and surface energy of the substrate, directed the quality of printed lines. With successive overprinting, the edge area may be covered with more NPs and eventually printed with a more uniform pattern line. To confirm this, an overprinted layer was printed over the first-printed layer. As shown inFIGS.17B-17C, line uniformity and density was substantially improved by increasing the number of overlayers from 1 to 5. In addition, all the printed lines with the ink did not show any coffee-ring effects or line bulging. The thickness of the as-printed lines with nolwas summarized inFIG.18. The thicknesses of printed lines was controlled by the number of overprinted layers and by varying the drop spacing. In order to evaluate the functional properties of the magnetic ink, a tunable inductor was fabricated on top of an inkjet-printed magnetic film, as shown inFIGS.19A-19C. First, iron oxide nanoparticles ink were inkjet printed on a plastic substrate with five overprinted layers, followed by drying at about 80° C. for about 30 min (FIG.19A). The printed film resulted in a saturation magnetization of ≈12.4 memu under an applied field of about 1 kOe, while the coercivity was found to be 46 Oe, as shown inFIGS.20A-20B. After printing the magnetic film, a total of eight layers of silver-organo-complex (SOC) based silver ink was printed and cured using infrared (IR) heating for about 5 min (FIG.19B). Finally, the fully printed tunable inductor was attached on an FR4 board (support substrate) for testing purpose, as shown in (FIG.19C). For RF characterization of the inductor, two port S-parameter measurements were performed using Agilent E8361C PNA series network analyzer. The inductor was fed by a 50Ω microstrip transmission line. The measured inductance of the printed inductor is shown inFIGS.21A-21B. At 100 MHz, it had an inductance of about 19.6 nH and self-resonant frequency (SRF) of about 870 MHz (a). To measure the tunability of the printed inductor, an external magnetic field of up to 12 kOe was applied using MicroMag 3900 vibrating sample magnetometer (VSM). The inductance versus the frequency under the influence of external magnetic field for printed inductor is shown inFIGS.21A-21B. A tuning of about 24% was observed when about 12 kOe magnetic field was applied. A smaller tuning of about 18% was observed when lower magnetic field of about 2 kOe was applied. The fully printed inductor realized with the formulated ink described herein showed much higher tuning than the case when commercial iron oxide nanoparticles ink were used (only 0.8% tuning with 5 kOe magnetic field,FIGS.22A-22B). The results summarized in Table 1 clearly indicated superior performance and suitability to tunable RF components as compared to the commercially available ink. Fabrication of Freestanding Magnetic Substrate and its Characterization Functionalized iron oxide nanoparticles were successfully embedded in the SU8 matrix to develop freestanding magnetic substrate. The functionalized iron oxide nanoparticles were mixed using stone mortar and pestle with the SU8 2000 (Microchem) epoxy resist at a 50:50 wt % ratio to formulate ink paste. When the ink paste was ready, it was printed using a manual screen-printing technique (i.e., squeegee). The steps for the fabrication process are displayed inFIGS.23A-23F. An FR-4 board with a sacrificial paper on the backside was used as a support material in this work, though any other material can be used instead of FR-4. The sacrificial paper was used because the ink was initially in a paste form and a support substrate was required until it solidified after UV exposure. A slot was created in the support material using LPKF4 Protomat S103 (a) to facilitate the printing of magnetic ink for a precise substrate thickness of about 1.5 mm. The empty slot was filled with the ink paste in three cycles. For each cycle, the filled materials were heated to about 80° C. for about 15 min followed by UV curing (λ=365 nm) for about 15 min (b). Once the ink was solidified with three cycles of the heating and the curing process, it was separated from the support material by cutting it from the edges (c). The sacrificial paper on the back of the magnetic substrate was removed by immersing it in warm water for about 10 min. An about 10 μm smoothening layer of “3D vero black plus” material was then inkjet printed and photocured on the top (d) and bottom (e) of the magnetic substrate. A total of eight layers of SOC ink each for ground plane and patch antenna were printed and cured using IR heating for about 5 min (f). The final prototype of patch antenna is shown in the inset ofFIG.23F. The preparation of freestanding substrate was performed through manual printing. However, through integrating advanced printing technology, such as a 3D printer equipped with a UV curing system, in-demand magnetic objects may be easily be created. Magnetostatic and Microwave Characterization Once the magnetic substrate was prepared, it was important to characterize its magnetostatic and microwave properties. A VSM was used for the B(H) curve measurements of the magnetic substrate, where B was the magnetic flux density and H was the magnetic field strength. The substrate, without any metallic layers on top, was placed in the VSM; the measured B(H) curve results are displayed inFIG.24A. The substrate demonstrated a saturation magnetization (4πMS), coercive field (HC), and remanent magnetization (BM) of about 1560 Gauss (G), about 46 Oe, and about 350 Gauss, respectively. For microwave tunable designs, stronger the saturation magnetization, larger is the tunability of the component. Here, the value of 1560 G was acceptable and provided decent tuning. This value may be increased by modifying the composition of the ink. After obtaining saturation magnetization, the next important parameter was the magnetization frequency of the substrate. The magnetization frequency was an important characteristic of ferrites because the ferrites do not show any low field losses after this frequency. From the saturation magnetization, the magnetization frequency of the material was calculated using the following formula: fm=γ4πMS=4.37 GHz. It was recommended that the center frequency of a microwave device be higher than the magnetization frequency of the substrate to avoid any low field losses. Once the magnetostatic properties of the material were known, it can be studied for its high-frequency and microwave properties. To extract the microwave properties of the printed substrate, a coplanar waveguide (CPW) based ring resonator was designed and fabricated on top of the substrate. The resonator was characterized for its S parameters from 1 to 10 GHz, and the fundamental resonance of the design was measured at 2.4 GHz. These results were used to extract the dielectric constant of the material. Since this was a magnetic material, the result obtained from the equation provided a product of the initial permeability and permittivity. This product was displayed inFIG.24B. The value of this product varied with respect to the frequency, which was expected due to the varying initial permeability of the ferrite material. Using this equation, the permittivity and permeability of the medium at different frequencies were calculated and are listed in Table 2. Since the material was lossy below fm, frequencies above fmwere considered in the table since these were the frequencies that may be used for the antenna design. In the initial design of any microwave device, this product can directly be used in the equation of the resonant frequency. In addition to the dielectric constant, the loss tangent (tan δ) of the material was calculated from the measured results. The conductor losses were calculated using the transmission line calculator of the Keysight in the Advanced Design System (ADS). The measured conductivity of the metal was about 5×106 S m−1, which was used to evaluate the conductor loss for different frequencies. Once the conductor loss was known, the dielectric loss of the material was evaluated. The loss tangent of the substrate at frequencies below fmwas relatively high. For example, at about 2.4 and about 4 GHz, the loss tangent values were 0.13 and 0.015, respectively, due to the low field losses of the magnetic material in the absence of the magnetic bias. However, the loss tangent values at frequencies above fmare in the acceptable range. Printed Linear Patch Antenna The magnetostatic and microwave characteristics of the printed magnetic ink were then used for the design of a patch antenna. The patch antenna design was used as proof of concept to show the viability of this ink in the implementation of tunable and reconfigurable passive microwave components. A rectangular patch antenna operating at about 8 GHz was designed and fabricated using inkjet printing, as shown inFIG.25A. The frequency of operation was almost twice the value of fm, thus avoiding the lossy spectrum of the substrate. The antenna had dimensions of about 6.4×7 mm. The antenna was initially measured for its impedance properties without any magnetic bias, as shown inFIG.25B. Subsequently, the antenna was characterized for its 3D radiation pattern, as shown inFIG.25C. The maximum gain of the antenna was ≈−0.7 dBi at about 8.2 GHz. The radiation pattern of the antenna showed directional properties with maximum gain in the bore-sight direction as expected with a patch antenna. To test the tuning capability, the impedance of the antenna was measured in the presence of a magnetostatic field which was generated by an electromagnet. The strength of the applied magnetic field varied from about 0 Oe to about 5 kOe. No change in the resonant frequency of the antenna was observed up to a bias strength of about 2 kOe because the magnetic fields were lost in the air due to the demagnetization effect. Above about 2 kOe, the frequency of the antenna began to tune down as shown inFIG.25D. Increasing the fields beyond this value reduced the center frequency to about 3.7 kOe. A total tuning range of 1.25 GHz was obtained, which was about 12.5% of the center frequency. Further increasing the bias resulted in a slight increase in the resonant frequency of the antenna, which could be because the substrate was saturated for a bias field strength of about 3.7 kOe. After this value, strong fields were required to tune the antenna using the Polder's equations. The measured reflection coefficient of the antenna at a bias value of 3.7 kOe was shown inFIG.25B. The antenna maintained its matching condition during the entire tuning range, which was required from such a design. No significant effect was expected on the antenna radiation pattern due to the applied bias, as it was reported that the radiation pattern of a ferrite-based patch antenna did not change significantly in the biased state. In conclusion, this Example successfully performed the preparation of the iron oxide nanoparticles and their ink formulation to demonstrate the fully printed highly tunable inductor. Further, oleic acid functionalization and integration of nanoparticles with SU8 was performed to fabricate the first printed freestanding magnetic substrate. The materials were characterized in detail to obtain the morphological, structural, chemical, optical, and magnetic properties. Furthermore, the printed substrate was characterized for its magnetostatic and microwave properties. The magnetic substrate demonstrated a saturation magnetization of 1560 G and a calculated magnetization frequency of 4.37 GHz. To prove the functionality of the ink, a patch antenna design was implemented. The antenna successfully demonstrated the frequency tuning due to the application of magnetostatic fields across it. For a center frequency of 8 GHz, a tuning range of 12.5% was achieved at a magnetic field strength of 3.7 kOe. Such a functional ink was not only highly suitable for tunable and reconfigurable microwave devices, but could also be explored in sensing, biotechnology, and biomedical areas. Other embodiments of the present disclosure are possible. Although the description above contains much specificity, these should not be construed as limiting the scope of the disclosure, but as merely providing illustrations of some of the presently preferred embodiments of this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of this disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form various embodiments. Thus, it is intended that the scope of at least some of the present disclosure should not be limited by the particular disclosed embodiments described above. Thus the scope of this disclosure should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present disclosure fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present disclosure, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. The foregoing description of various preferred embodiments of the disclosure have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise embodiments, and obviously many modifications and variations are possible in light of the above teaching. The example embodiments, as described above, were chosen and described in order to best explain the principles of the disclosure and its practical application to thereby enable others skilled in the art to best utilize the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the disclosure be defined by the claims appended hereto Various examples have been described. These and other examples are within the scope of the following claims. | 73,575 |
11858197 | DESCRIPTION OF PREFERRED EMBODIMENTS It is an object of the present invention to provide an additive manufacturing process for the manufacture of an object in an additive manufacturing apparatus according to the subject-matter of the claims. Additive manufacturing, also referred to as 3D printing, involves manufacturing an object by depositing the constituent material of the object to be manufactured in layer-by-layer fashion. Technologies that can be used to deposit the constituent material of the object to be manufactured in a layer-by-layer fashion include material extrusion, binder jetting, material jetting and directed energy deposition. In the context of the present invention, extrusion technology is of particular interest. Additive manufacturing technologies that employ extrusion to deposit the constituent material of the object to be manufactured of particular note for the purpose of the present invention are fused filament fabrication (FFF) or fused deposition modelling (FDM), since the material for the manufacturing is conveniently available as filament reels or solid subunits of the polymer that are fed to the printer head where the material, in general a polymer composition, is molten before being discharged through the nozzle of the print head according to a predefined path to form the layers making up the entire object, depending on the object being manufactured. It is understood that in the context of the present invention, the number of print heads and/or number of nozzles per print head is not particularly limited. While manufacturing objects according to the present invention on a lab scale is generally done with an additive manufacturing apparatus having a print head with a single nozzle, it is clear that on a larger scale a single additive manufacturing apparatus may be equipped with multiple print heads each having one or more nozzles operating in concert to either speed up the manufacture of a single object or to produce multiple objects in parallel. In the additive manufacturing process for the manufacture of an object in an additive manufacturing apparatus according to the present invention, the object is formed by one or several individual solid filamentous units, or lines, which are deposited in the additive manufacturing apparatus through the nozzle of the print head in a layer by layer fashion. For example, a first layer is printed, and the nozzle is then elevated and starts to print the next layer and so on until the object is formed. Alternatively, the support platform upon which the first layer is printed is lowered and the nozzle starts to print the next layer. The print head discharges a polymer composition in a molten state through the nozzle, which nozzle is equipped with a heating means capable of heating the polymer composition to a flowable state, i.e. a state in which the polymer component of the polymer composition, in particular the thermotropic liquid crystalline polymer is in a molten state or a molten liquid crystalline state. The polymer composition in a molten state is discharged and deposited along at least one predefined path such as to form one or several solid filamentous units of the object to be manufactured. The one or several solid filamentous units may have different cross-sectional shapes such as for example essentially circular, elliptic, rectangular or square. The object to be manufactured can, in some cases, be manufactured without interrupting the discharging of the polymer composition in a molten state. In other cases, discharging of the polymer composition in a molten state can be interrupted between layers or within layers. However, the mechanical properties are not significantly affected when comparing the case where the object is formed by a single continuous solid filamentous unit and the case where the object is formed by several separated solid filamentous units. The polymer composition comprises a thermotropic liquid crystal polymer as a polymer component of the polymer composition. It is understood that the polymer composition may thus comprise essentially a single thermotropic liquid crystal polymer as the polymer component of the polymer composition or may comprise a combination of two or more thermotropic liquid crystal polymer as the polymer component of the polymer composition. The polymer composition may comprise other non-polymer components such as for example additives or reinforcing fibres, electrically or thermally conductive fillers, fillers and additives. Suitable reinforcing fibres are for example aramids or inorganic reinforcing fibres such as glass or carbon fibres. The reinforcing fibers, fillers and additives may be dispersed in the polymer composition and may further be aligned in the direction of flow of the polymer composition in the solid filamentous units. Suitable electrically conductive fillers are for example graphene particles or carbon black. Suitable non-conductive fillers are for example titanium dioxide or PTFE. In the context of the present invention, the thermotropic liquid crystal polymer is not particularly limited. In a preferred embodiment of the additive manufacturing process, a thermotropic liquid crystal polymer is the sole polymer component of the polymer composition that is brought into a melt state or the liquid crystalline molten state and more preferably a thermotropic liquid crystal polymer is the sole polymer component of the polymer composition. Thermotropic liquid crystal polymer particularly suitable for the present invention are aromatic polyester thermotropic liquid crystal polymers, such as thermotropic liquid crystal polymers obtained by polycondensation of 4-hydroxybenzoic acid and 6-hydroxynaphthalene-2-carboxylic acid. The thermotropic liquid crystal polymer is deposited along a predefined path such that the smallest thickness of the one or several filamentous units is equal or less than 0.2 mm, preferably to 0.15 mm and more preferably to 0.10 mm and most preferably is between 0.1 and 0.01 mm. It is understood that the smallest thickness of the filamentous units of equal or less than 0.2 mm can be achieved by different strategies. On one hand, it is possible to increase the flow of polymer composition flow across a nozzle having a diameter of less than 0.2 mm or on the other hand, it is possible to reduce the flow across a nozzle having a diameter of more than 0.2 mm. Alternatively, the nozzle can be positioned such that the distance between the nozzle orifice and the surface on which the polymer composition melt substrate is deposited is adjusted to the desired smallest diameter, e.g. 0.2 mm, in which case any filamentous unit formed has at least a smallest diameter in z-direction, i.e. the smallest diameter of the deposited filamentous unit corresponds to the vertical height of the deposited filamentous unit or height of the deposited filamentous unit in z-direction. Generally speaking, the z-direction is normal to the plane in which the filamentous units of a layer are deposited. The polymer composition in a molten state is further actively cooled to form a solid filamentous subunit and is preferably actively cooled to form a solid filamentous subunit by forced convection. Active cooling can be achieved by, for example, providing an additive manufacturing apparatus having a temperature-controlled print enclosure. Forced convection can be achieved by means that are capable of directing a flow of coolant fluid towards the filamentous unit being deposited such as for example fans. The formed object can be subsequently annealed at less than 100° C., more preferably less than 50° C., most preferred less than 25° C. below the melting temperature of the thermotropic liquid crystal polymer for up to 6 hours, preferably up to 9 hours, more preferably up to 12 hours, most preferably up to 48 hours. In the case where the thermotropic liquid crystal polymer is a polyester obtained by polycondensation of 4-hydroxybenzoic acid and 6-hydroxynaphthalene-2-carboxylic acid, the formed object is preferably annealed at 260 to 280° C. under constant nitrogen flow for up to 96 h. The polymer composition being discharged in a molten state from a nozzle of a print head can preferably be in a molten liquid crystalline state. In the case where the thermotropic liquid crystal polymer is a polyester obtained by polycondensation of 4-hydroxybenzoic acid and 6-hydroxynaphthalene-2-carboxylic acid, the temperature at which a molten liquid crystalline state exists is between 280 and 320° C. The polymer composition being discharged in a molten state from a nozzle of a print head can have a temperature not exceeding the melting temperature of thermotropic liquid crystal polymer by more than 100° C., preferably by more than 50° C., preferably by more than 25° C., preferably by more than 15° C., and more preferably by more than 5° C. In the case where the thermotropic liquid crystal polymer is a polyester such as for example the ones obtained by polycondensation of 4-hydroxybenzoic acid and 6-hydroxynaphthalene-2-carboxylic acid, the temperature of the thermotropic liquid crystal polymer being discharged in a molten state corresponds most preferably to 285° C. The orifice of the nozzle has an essentially circular orifice and a diameter of less than 0.64 mm or of 0.05 to 0.635 mm and preferably a diameter of less than 0.4 mm or of 0.05 to 0.4 mm, and more preferably of a diameter of less than 0.31 mm or of 0.05 to 0.305 mm or has an essentially rectangular orifice and a diameter of less than 0.64 mm or of 0.050 to 0.635 mm and preferably a diameter of less than 0.4 mm or of 0.05 to 0.4 mm, and more preferably of a diameter of less than 0.31 mm or of 0.05 to 0.305 mm. In the case where the smallest diameter of the filamentous subunit is less than the diameter of the orifice of the nozzle, the distance between the underlying material and the orifice of the nozzle is adjusted to correspond to the smallest diameter of the filamentous unit. EXAMPLES FDM Filament Fabrication Liquid crystal polymer VECTRA® A950 (LCP), commercially obtainable from Ticona GmbH, Germany, was dried at 150° C. for 12 hours prior to extrusion. LCP filaments were prepared using a single-screw extruder (Teach-Line® E20 T, Collin, Germany) that was heated to 280, 290, 290 and 260° C. at the 4 zones along its longitudinal axis. The filament was extruded at 60 rpm and collected on a modified flat film line (Teach-Line® CR72 T, Collin, Germany) after cooling it in a water bath (Teach-Line® WB850, Collin, Germany). The speed of the collector rolls was adjusted to achieve a filament diameter of 1.75 mm. The filament was wound on FDM spools and dried at 70° C. for at least 24 hours before use. FDM Printing Setup A commercially available Fused Deposition Modelling (FDM) printer (Ultimaker 2+, Ultimaker, Netherlands) was modified with a geared direct drive extruder and an all-metal V6 hotend (E3D, UK) to achieve temperatures up to 400° C. The borosilicate glass build-plate was heated to 90° C. and coated with a thin layer of PVA-based adhesive spray (3DLac, Spain) before printing with LCP to improve bed adhesion and reduce warping. Generally, parts were printed at 295° C. at a speed of 35 mm/s with part cooling fans running at 20%. For printing lines, the speed was reduced to 20 mm/s to improve the quality of lines in contact with the glass surface. PLA and PEEK reference samples were printed using commercial filaments (Dutch Filaments B.V., Netherlands and 3D4MAKERS, Netherlands) at a temperature of 210° C. and 380° C., respectively. The build-plate was heated to 60° C. for PLA and 120° C. for PEEK. All other parameters were kept the same as for printing LCP. PEEK samples were further heat treated after printing at 150° C. for one hour followed by one hour at 200° C. to reach optimum crystallization. Print-paths (Gcode) with reduced control over the print directions were generated with Cura, an open source FDM slicer from Ultimaker. A custom slicer using Grasshopper for Rhinoceros (McNeel, Spain) was developed for objects with spatially tuned directional print paths or those where the orientation of the print-path was important. Thermal Annealing The solid-state thermal annealing was performed by heating the samples to 270° C. under constant nitrogen flow for 0 to 96 h. It is believed that solid-state cross-linking occurs via post-condensation reactions between carboxylic acid groups of the printed samples. The samples were fixed on a steel plate with polyimide tape to prevent deformation during the annealing process. Tensile Testing of Printed Filaments (FIG.1) Tensile tests were performed on filaments printed vertically starting on the surface (build-plate) and moving upwards (z-direction) and horizontally on the glass surface. To produce vertical filaments that do not curl during free-form extrusion, the feedstock material was first printed horizontally to ensure good attachment to the substrate. Vertical and horizontal filaments were printed with varying nozzle diameter and distance to the surface, respectively. Furthermore, the effects of the nozzle temperature and annealing time were examined for both printing configurations. The filament samples were glued onto individual paper frames according to ASTM C1557 to assure a constant gauge length of 20 mm. The tensile tests were carried out at a rate of 2 mm/min on an AGS-X (Shimadzu, Japan) universal testing machine with a 1 kN capacity load cell. The samples were imaged with an optical stereo microscope (WILD M10, Leica, Germany) during testing and their width and thickness measured using Fiji image analysis. Data analysis was performed using a custom MATLAB script. As can be seen fromFIG.1(a)-(c), the filament exhibits a core-shell structure. In particular, in (a) this is evidenced by the fact that the core of the fibre is still intact whereas the stiffer outer shell of the liquid crystal polymer filament is ruptured. Furthermore, the polarised light microscopy images in (b) and (c) confirm the core-shell structure in both vertical (b) and horizontal (c) filaments, as indicated by the higher illumination of the skin of the printed lines compared to the core. XRD analysis further corroborates a higher fraction of oriented domains in thinner samples in (d). As can be seen fromFIG.1(e), the Young's modulus and strength of vertically extruded filaments increase with decreasing nozzle diameter. The same effect also translates to horizontally printed filaments, where the Young's modulus and strength increase with decreasing filament thickness, i.e. height, reaching a maximum modulus of 34 GPa and a strength of 800 MPa at 0.05 mm filament height. As can be seen fromFIG.1(g), increased printing temperatures lead to decreasing Young's modulus. Furthermore, solid-state annealing (h) enhances the mechanical properties by increasing the molecular weight of the polymer, and the strength increases up to 400 MPa for vertically extruded filaments and up to 1 GPa for horizontally printed filaments. Tensile Testing of Printed Parts (FIG.2) Tensile tests were carried out using a Z020 (Zwick, Germany) universal testing machine with a 20 kN capacity load cell. Unidirectional tensile test specimens (ISO 527-5) with a nominal width of 5 mm, length of 110 mm and thickness of 2 mm were printed with print filament orientation varying from 0° to 90° with respect to the testing direction. The samples were supported in the clamping region with bonded glass fibre-reinforced polymer end tabs, resulting in a gauge length of 65 mm. Specimens were tested at a displacement-controlled rate of 2 mm/min. Data analysis was performed using a custom MATLAB script. In addition to the print direction, the effects of different layer heights, temperatures, and annealing time were investigated. As can be seen fromFIG.2(a) and (b)the Young's modulus and bending modulus of unidirectional printed parts are dependent on printing orientation and highest when the sample is tested in print direction, i.e. in the direction of main orientation of the filaments constituting the sample. As can be seen in (c), the lesser tensile strength in 90° orientation with respect to the printing direction can be ameliorated, in particular by annealing in excess of 24 hours, due to the improved adhesion between filaments. As can be seen fromFIG.2(d), for samples with print lines oriented in the loading direction, the fracture mode changes from a broom-like to a tough layer-like fracture due to the improved filament adhesion achieved by thermal annealing (96 h). This change also results in a saw-tooth break pattern in the stress-strain curve, which increases by a factor of 2 the amount of energy required to fracture the part (modulus of toughness). Tensile testing can also be performed on FDM printed objects, by cutting out a tensile specimen from a region of said object with dimensions according to ISO 527 and ASTM D638 for polymers, ISO 527 and ASTM D3039 for composites and ASTM C1273 and ISO 15490 for ceramics and testing said tensile specimen in a tensile test machine to measure the Young's modulus and tensile strength according to the standards listed above. Bending Tests of Printed Parts Bending tests were carried out on a AGS-X (Shimadzu, Japan) universal testing machine with a three-point bending setup using a span of 24 mm. Samples with different thicknesses (layer heights) were measured before and after annealing at a displacement controlled rate of 2 mm/min. The specimen geometry and the bending testing setup were chosen in accordance with ISO 14125. A span-to-thickness ratio of 16 was used to assure a flexural stress state with a limited influence of the constant shear stress within the specimen. LIST OF REFERENCE SIGNS none | 17,853 |
11858198 | DETAILED DESCRIPTION OF THE INVENTION Various non-limiting examples of the present disclosure will now be described to provide an overall understanding of the principles of the deflection members, and methods of manufacturing such deflection members, disclosed herein. One or more non-limiting examples are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the deflection members, and methods of manufacturing such deflection members, described herein and illustrated in the accompanying drawings are non-limiting examples. The features illustrated or described in connection with one non-limiting example can be combined with the features of other non-limiting examples. Such modifications and variations are intended to be included within the scope of the present disclosure. The present disclosure is directed to processes of using three dimensional printing technology to produce deflection members with a non-unitary reinforcing member that are intended for use in fibrous structure production (e.g., paper products and nonwovens). The process involves using computer control to print a framework of polymers of specific material properties onto, into and/or around a separately manufactured reinforcing member in an additive manner to create durable deflection members with a long lifespan and unique structural and topographical profiles. The terms “three dimensional printing technology”, “three dimensional printing system,” “three dimensional printer,” “3-D printing”, “printing,” “additive manufacturing”, “additive manufacturing apparatus”, “AM” and the like all generally describe various solid freeform fabrication techniques for using a build material or a print material to make three dimensional (3-D) objects by stereolithography (SLA), continuous liquid interface production (CLIP), selective deposition, jetting, fused deposition modeling (FDM, as marketed by Stratasys Corp., Eden Prairie, Minn.), also known as fused filament fabrication (FFF), bonded deposition modeling, selective laser melting (SLM), direct metal laser sintering (DMLS), selective laser sintering (SLS), laminated object manufacturing (LOM), and other techniques now known in the art, or that may be known in the future. Stereolithography may include the use of lasers, DLP projectors, DMD digital micro-mirror devices and/or combinations thereof. Digital masks may be used to control the distribution and localized control of radiation exposure either as from a source such as a display (e.g., LCD, LED) or displays that regulate the passage of curing radiation from a source. Additive manufacturing is widely used in both research and industry, such as, for example, the automotive and aviation industries, for creating components that require a high level of precision. Traditional additive manufacturing processes involve the use of CAD (Computer Aided Design) software to generate a virtual 3-D model, which is then transferred to process preparation software where the model is virtually disassembled into individual slices or layers. The model is then sent to an additive manufacturing apparatus, where the actual object in printed layer by layer. As previously detailed in the Background, current methods for additively manufacturing deflection members are unitary in nature (i.e., the deflection member does not constitute a unit comprised of previously separate components joined together) and/or don't include methods of manufacture that provide for a strong bond (i.e., “lock-on”) between the resinous framework and the reinforcing member. Accordingly, currently available additively manufactured deflection members do not have the strength or longevity to be economically utilized in current papermaking or nonwoven production processes. An example of a traditional deflection member of the general type useful in the present disclosure, but made according to the disclosure of U.S. Pat. No. 4,514,345, is shown inFIGS.1-3. As illustrated, a deflection member2includes a resinous framework4attached to a permeable reinforcing member6. Resinous framework4may comprise cross-linkable polymers or alternatively composite materials that include cross-linkable polymers and filler materials. For example, in some forms detailed herein, the resinous framework4includes cross-linkable polymers selected from light activated polymers (e.g., UV light activated, e-beam activated, etc.), heat activated polymers, multipart polymers, moisture activated polymers, chemically activated polymers, and combinations thereof. In some deflection members, the utilized resinous framework may include any of the cross-linkable polymers as described in U.S. Pat. No. 4,514,345 issued Apr. 30, 1985 in the name of Johnson et al., and/or as described in U.S. Pat. No. 6,010,598 issued Jan. 4, 2000 in the name of Boutilier et al. In other deflection members, the utilized resinous framework may include any of the cross-linkable polymers as described in U.S. Pat. No. 7,445,831 issued Nov. 4, 2008 in the name of Ashraf et al. Other suitable cross-linkable and filler materials known in the art may also be used as resinous framework. The pattern of resinous framework4can be structed in any decorative pattern known in the art of papermaking belts (micro patterns, i.e., the structure of an individual protuberance within the resinous framework and/or macro patterns, i.e., a pattern including multiple protuberances, or the overall deflection member belt pattern including many protuberances). In particular, patterns that are not able to be manufactured in traditional deflection member production processes, such as taught by Johnson et al., are of the most interest. For example, the resinous framework patterns taught by Manifold et al. in U.S. patent application Ser. No. 15/132,291 are of high interest. Reinforcing member6can be made of woven filaments8as are known and are common in the art of papermaking belts. In such non-limiting forms, woven filaments can be made of natural fibers, cotton fibers, coated fibers, genetically engineered fibers, synthetic fibers, metallic fibers, carbon fibers, silicon carbide fibers, fiberglass, mineral fibers, and/or polymer fibers including polyethylene terephthalate (“PET”) or PBT polyester, phenol-formaldehyde (PF); polyvinyl chloride fiber (PVC); polyolefins (PP and PE); acrylic polyesters; aromatic polyamides (aramids) such as Twaron®, Kevlar® and Nomex®; polytetrafluoroethylene such as Teflon® commercially available from DuPont®; polyethylene (PE), including with extremely long chains/HMPE (e.g. Dyneema or Spectra); polyphenylene sulfide (“PPS”); and/or elastomers. In one non-limiting form, the woven filaments of the reinforcing member are filaments as disclosed in U.S. Pat. No. 9,453,303 issued Sep. 27, 2016 in the name of Aberg et al. The woven filaments may be translucent, partially translucent, or opaque to assist and/or deter curing of the resinous framework. The reinforcing member may include woven filaments that exhibit a diameter of about 0.20 mm to about 1.2 mm, or about 0.20 mm to about 0.55 mm, or about 0.35 mm to about 0.45 mm. The reinforcing member may be manufactured by traditional weaving processes, or may be manufactured through other processes such as additive manufacturing, e.g., 3-D printing—but in such embodiments, the reinforcing member is not made in a unitary manner with the resinous framework. The reinforcing member may also be made of any other permeable material known in the art. The term “permeable” may be used to refer generally to a material or structure that allows a liquid state cross-linkable polymer being utilized to build the resinous framework of the deflection member to pass at least partially through or be at least partially absorbed. Such permeable materials can be a porous material such as textiles, fabrics, knits, woven materials, mesh, polymers, rubbers, foams, etc. The porous materials can be in the form of a flexible cloth, a sheet, a layer and other structures. Whether formed or woven filaments, reinforcing members may be of an endless or seamless design. Optionally, the reinforcing member may be cut or from stock of finite or infinite length. Once made, the deflection member may need to be seamed, sewn, fastened or fixed as is common in the art of papermaking or non-woven manufacture. Whether formed of woven filaments and/or other permeable materials, reinforcing member6may include voids (i.e., spaces naturally occurring in a woven product between filaments) and/or foramina (i.e., perforations formed in a previously non-perforated reinforcing member). Reinforcing member6may also be formed from impermeable or semi-impermeable materials known in the art, such as various plastics, metals, metal impregnated plastics, etc., that include voids and/or foramina. Whether permeable, impermeable, or semi-impermeable, the reinforcing member may be translucent, partially translucent, or opaque to assist and/or deter curing of the resinous framework. The particular deflection member structure shown inFIG.1includes discrete cured resin elements10and a continuous deflection conduit12(i.e., the space between the cured resin elements that allows a pressure differential to flow through voids18in woven reinforcing member6). The particular deflection member structure shown inFIG.2includes a resinous framework4that is structured in a continuous pattern with discrete deflection conduits12(i.e., the space surrounded by the continuous cured resin element that allows a pressure differential to flow through voids18in woven reinforcing member6). In non-illustrated embodiments, the resinous framework can also be structured to be a semi-continuous pattern on reinforcing member6. The illustrated patterns include a resinous framework that includes either discrete cured resin elements or deflection conduits in a hexagon shape when viewed from above or below. The deflection members created by the additive manufacturing processes detailed herein may have an identical or similar resinous framework structure. However, the deflection members created by the additive manufacturing processes detailed herein may have a resinous framework that may have any shape or structure known in the art of papermaking and nonwoven making belts. FIG.4illustrates a close up of a nonlimiting embodiment of a woven reinforcing member6. Filaments8are woven together to form voids18between the filaments. As can be observed, each void18is framed by four surrounding filaments8. Accordingly, in the non-limiting illustrated embodiment, each void has four side surfaces30, with each side surface being formed by the portion of the filament that faces inward towards the void. In other non-illustrated embodiments, the woven filaments may be woven in a different pattern, and thus, voids18may have more than four side surfaces, or as few as three or substantially two side surfaces. In other non-illustrated embodiments, the reinforcing member can be a material that is not a woven reinforcing member (e.g., a permeable or non-permeable material as detailed above). Such material may be a sheet or film and may be translucent, partially translucent, or opaque to assist and/or deter curing of the resinous framework. Such reinforcing member may include foramina. The foramina will function like the voids in a woven reinforcing member by also allowing a pressure differential to flow through the deflection conduits during the papermaking and/or nonwoven making processes. The voids/foramina provide an open area in the reinforcing member sufficient to allow water and/or air to pass through during papermaking and nonwoven making processes, but nevertheless preventing fibers from being drawn through. As fibers are molded into the deflection member during production of fibrous substrates, the reinforcing member serves as a “backstop” to prevent or minimize fiber loss through the deflection member. FIG.5illustrates a close up of a nonlimiting embodiment of a reinforcing member6that is not a woven reinforcing member and includes foramina40. Foramina40may be included in reinforcing member6in any number and/or size and/or regular or irregular shape (e.g., circles, ovals, triangles, squares, hexagons, octagons, etc.) and/or pattern. Foramina40each include at least one sidewall surface42. The side wall surface(s)42is/are the surface(s) that extend between the substantially planar upper surface20and the substantially planar lower surface22of reinforcing member6. For example, in foramina40that are of a circular or oval shape when viewed from above, there is a single continuous sidewall surface42. In foramina that are square in shape when viewed from above, there are four sidewall surfaces42. FIG.3is a cross-sectional view ofFIG.2taken along line3-3. As illustrated, overall deflection member2, as well as resinous framework4, have a substantially planar upper surface14and a substantially planar lower surface16. In non-illustrated embodiments, the deflection member and the resinous framework may have an upper surface and a lower surface that are not substantially planar. In such embodiments, the upper surface is considered to be an X-Y plane, wherein X and Y can correspond generally to the cross-direction (CD) and the machine direction (MD) respectively, that intersects the portion of the resinous framework that is the furthest distance above the reinforcing member in the Z direction. In the same embodiment, the lower surface is considered to be an X-Y plane that intersects the portion of the resinous framework that is the furthest distance below the reinforcing member in the Z direction. One skilled in the art will appreciate that the symbols “X,” “Y,” and “Z” designate a system of Cartesian coordinates, wherein mutually perpendicular “X” and “Y” define a reference plane formed by a flat, level surface upon which lower surface16of deflection member2sits, and “Z” defines a direction orthogonal to the X-Y plane. Accordingly, the term “X-Y plane” used herein refers to a plane that is parallel to the reference plane formed by the flat, level surface upon which lower surface16of deflection member2sits. The person skilled in the art will also appreciate that the use of the term “plane” does not require absolute flatness or smoothness of any portion or feature described as planar. In fact, the lower surface16of deflection member2can have texture, including so-called “backside texture” which is helpful when the deflection member is used as a papermaking belt on vacuum rolls in a papermaking process as described in Trokhan or Cabell et al. As used herein, the term “Z direction” designates any direction perpendicular to the X-Y plane. Analogously, the term “Z dimension” means a dimension, distance, or parameter measured parallel to the Z-direction and can be used to refer to dimensions such as the height of protuberances or the thickness, or caliper, of the unitary deflection member. It should be carefully noted, however, that an element that “extends” in the Z-direction does not need itself to be oriented strictly parallel to the Z-direction; the term “extends in the Z direction” in this context merely indicates that the element extends in a direction which is not parallel to the X-Y plane. Analogously, an element that “extends in a direction parallel to the X-Y plane” does not need, as a whole, to be parallel to the X-Y plane; such an element can be oriented in the direction that is not parallel to the Z direction. When viewed in cross-section, the illustrated deflection members include a resinous framework that includes either discrete cured resin elements or discrete deflection conduits with substantially planar upper and lower surfaces in common with the substantially planar upper and lower surfaces of the deflection member. Further, the wall surfaces that span the distance between the upper and lower surfaces of the resinous framework are substantially flat and perpendicular to both the upper and lower surfaces. The deflection members created by the additive manufacturing processes detailed herein may have an identical or similar resinous framework structure. However, the deflection members created by the additive manufacturing processes detailed herein may have a resinous framework that can have any shape or structure known in the art of papermaking and nonwoven making belts. For example, the wall surfaces can be straight or curved, perpendicular or angled to the upper and lower surfaces, and the upper and lower surfaces can be flat, textured, patterned, consistent, irregular, stepped, cantilevered, overhanging, porous and/or angled. Further, as illustrated inFIG.3, reinforcing member6may have a substantially planar upper surface20and a substantially planar lower surface22. In embodiments that have a woven reinforcing member, such reinforcing member may have macroscopically substantially planar upper and lower surfaces, while also having a microscopically non-substantially planar upper and lower surfaces. As used herein, the terms containing “macroscopical” or “macroscopically” refer to an overall geometry of a structure under consideration when it is placed in a two-dimensional configuration. In contrast, “microscopical” or “microscopically” refer to relatively small details of the structure under consideration, without regard to its overall geometry. For example, in the context of the reinforcing member, the term “macroscopically substantially planar” means that the reinforcing member, when it is placed in a two-dimensional configuration, has—as a whole—only minor deviations from absolute planarity, and the deviations do not adversely affect the reinforcing member's performance At the same time, the reinforcing member can have a microscopical non-substantially planar upper and lower surfaces due to the three-dimensional pattern of woven filaments, as illustrated herein inFIGS.1-3. In embodiments of deflection member that include a woven reinforcing member, upper surface20of reinforcing member6is considered to be an X-Y plane (i.e., a plane that is parallel to a reference plane formed by the flat, level surface upon which lower surface16of deflection member2sits) that intersects with the portion of the reinforcing member that is the furthest distance in the Z direction above lower surface16of deflection member2. Lower surface22of reinforcing member6is considered to be an X-Y plane that intersects the portion of the reinforcing member that is the furthest distance in the Z direction below upper surface14of deflection member2. Process for Making Deflection Members The additive manufacturing processes detailed below may be used to produce deflection members of the general type (including specific deflection members disclosed in the incorporated references) detailed above that include a resinous framework and a non-unitary reinforcing member. The types of additive manufacturing apparatuses that are employable in the methods detailed here are any type now known in the art, or that may be known in the future. Two interesting, but non-limiting, examples of applicable additive manufacturing apparatuses include SLA and CLIP, as are currently known in the art of additive manufacturing. Regardless of the particular type of additive manufacturing apparatus employed, the apparatus may include at least one radiation source and a vat containing a photopolymer resin. The at least one radiation source may include one, two, three, four, five, six, seven, eight, nine, ten, or more individual radiation sources. The at least one radiation source may include between 1 and about 50 individual radiation sources, between 1 and about 20 individual radiation sources, or between 1 and about 15 individual radiation sources, or between 1 and about 10 individual radiation sources, or between 1 and about 5 individual radiation sources, or between 1 and about 3 individual radiation sources. In some embodiments detailed below, such as methods for continually printing deflection members, the at least one radiation source may include 50 or more individual radiation sources, or between about 50 and about 50,000 individual radiation sources, or between about 50 and about 900 individual radiation sources, or between about 50 and about 220 individual radiation sources, or between about 50 and about 100 individual radiation sources, or between about 50 and about 75 individual radiation sources. These radiation sources may be oriented in the cross-direction (CD) and/or machine direction (MD) at one or more locations along the length of a deflection member. The at least one radiation source may include one or more individual radiation sources located at an upper location on the additive manufacturing apparatus (i.e., upper radiation source(s)) and/or include one or more individual radiation sources located at a lower location on the additive manufacturing apparatus (i.e., lower radiation source(s)). The radiation may be directed orthogonally towards the surface of the deflection member and/or reinforcing member, or may be angled towards, or may be reflected towards the surface of the deflection member and/or reinforcing member (i.e., directed in a non-orthogonal manner). The at least one radiation source emits radiation that is utilized in the curing of the photopolymer resin. The at least one radiation source can generate actinic radiation from an ultraviolet (UV) laser, a visible (VIS) laser, an infrared (IR) laser, a DLP projector, an LED array or display, an LCD panel or display, fiber optic bundles or assemblies thereof, or any other radiation type now known in the art, or that may be known in the future. In additive manufacturing apparatuses that include multiple radiation sources, the radiation sources may be all be of the same type, wavelength, and/or output strength, or the radiation sources may be any combination of types, wavelength, and/or output strengths. A non-limiting example of a UV laser can be constructed starting with a laser diode, such as a 375 nm (70 mW maximum power) available from ThorLabs (part number L375P70MLD) or less expensive VIS lasers operating at 405 nm (available in 20 mW to 1 W maximum power, L405P20 and L405G1 respectively from ThorLabs). Other non-limiting examples may include argon-ion lasers which can, depending on the type, emit at a variety of wavelengths in UV, VIS and IR: 351.1 nm, 363.8 nm, 454.6 nm, 457.9 nm, 465.8 nm, 476.5 nm, 488.0 nm, 496.5 nm, 501.7 nm, 514.5 nm, 528.7 nm, 1092.3 nm. Commercial examples of applicable 405 nm lasers include the Form series of SLA printers available from FormLabs such as the Form 1+ and Form 2 (250 mW maximum power with a 140 micron spot size). Still another example of a laser applicable to the methods detailed herein is a VIS laser (532 nm, maximum 6 W), as detailed by M. Shusteff et al. in U.S. Patent Publication No. 2018/001567, taught to be effective at volumetric curing of resin via multiple orthogonal beams when interested in shapes from intersecting extruded profiles. Energy is provided and/or controlled in sufficient quantity to promote curing and thereby exceeding thresholds provided by dissolved oxygen or other inhibitors such as those consistent with the publications: Continuous AM by Volumetric Polymerization Inhibition Patterning, Jan. 11, 2019 by M. P. de Beer;Science Adv.5:eaau8723+Supplementary Materials;and U.S. Patent Publication Nos. 2019/0134888 and 2019/0126534 to DeSimone et al. and WO2014/126837 to DeSimone et al. and U.S. Patent Publication No. 2017/0120515 to J. P. Rolland et al. The vat containing photopolymer resin may be of any size to accommodate the printing of deflection members. The vat may be clear, translucent, or opaque, and constructed of plastic, stainless steel or any other material known in the art that is deep enough to hold the required amount of photopolymer resin. The vat may be lined with a minimally or non-reflective surface such black Formica. The volume of resin in the vat is controlled to incrementally or wholly deliver the final thickness in the finished deflection member. Multiple vats may be used or the resin in the vat may be replaced to deliver different material properties or control depth of cure due to resin absorption properties at the radiation wavelength. As detailed above, the photopolymer resin(s) applicable for the additive manufacturing methods detailed herein may include cross-linkable polymers selected from light activated polymers (e.g., UV light activated, e-beam activated, etc.) now known in the art, or that may be known in the future. The photopolymer resin may include any of the cross-linkable polymers as described in U.S. Pat. No. 4,514,345 issued Apr. 30, 1985 in the name of Johnson et al., and/or as described in U.S. Pat. No. 6,010,598 issued Jan. 4, 2000 in the name of Boutilier et al. In addition, the photopolymer resin may include any of the cross-linkable polymers as described in U.S. Pat. No. 7,445,831 issued Nov. 4, 2008 in the name of Ashraf et al. Other suitable cross-linkable and filler materials known in the art may also be employed as the photopolymer resin. The reinforcing members applicable for the additive manufacturing methods detailed herein may be any of the reinforcing members detailed herein. First Method: In one method for manufacturing a deflection member, an additive manufacturing apparatus100is provided that includes at least one radiation source130and a vat140containing photopolymer resin150. A reinforcing member106is provided that has a first surface120and a second surface122opposite the first surface. Second surface122of reinforcing member106is contacted with photopolymer resin150contained in vat140. In some embodiments, such contact may be only slight contact between second surface122of reinforcing member106and photopolymer resin150contained within vat140. In other embodiments, the contact may be a result of the entire reinforcing member being submerged within photopolymer resin150contained in vat140. In other embodiments, the contact between second surface122of reinforcing member106and photopolymer resin150may be of an amount in between these two extremes, for example, reinforcing member106may be a quarter, or half, or three-quarters submerged within photopolymer resin150. Once contact is made between reinforcing member106and the photopolymer resin150, a setup as illustrated in the exemplary embodiments ofFIG.6or7is achieved.FIG.6illustrates an embodiment where at least one radiation source130is located above vat140containing photopolymer resin150and the contact between second surface122of reinforcing member106and the photopolymer resin contained in the vat is only between the second surface and the photopolymer resin.FIG.7illustrates an embodiment where at least one radiation source130is located below vat140containing photopolymer resin150and the contact between second surface122of reinforcing member106and the photopolymer resin contained in the vat is the result of the entire reinforcing member being submerged in the photopolymer resin. In either exemplary embodiment, the utilized reinforcing member may be translucent so that radiation may pass through the reinforcing member. Radiation135may then be created by at least one radiation source130and directed from the at least one radiation source towards first surface120of reinforcing member106such that the radiation passes through the first surface of the reinforcing member to at least partially cure photopolymer resin in contact with second surface122of the reinforcing member to create at least a portion of a lock-on layer (not shown). In some embodiments, radiation135is enough to create the entire lock-on layer. The term “lock-on layer” is used to describe the layer of at least partially cured photopolymer resin that surrounds the reinforcing member. Lock-on layer may include the at least partially cured resin that surrounds first surface120, second surface122, the sidewall surfaces42of any foramina40(as detailed inFIG.5), the side surfaces30of any voids18of reinforcing member106(as detailed inFIGS.1-4), and or any other surface of the reinforcing member, such as the outers edges of the overall member. The radiation may be assisted to cure the photopolymer resin in contact with the second surface through any means known in the art, including, but not limited to, radiation strength or intensity, opaque photopolymer resin, and/or a build plate adjacent to or in contact with the second surface of the reinforcing member that stops/reflects the radiation once it travels through the reinforcing member. Once the first portion of the lock-on layer is cured, in the embodiment illustrated inFIG.6, reinforcing member106can be submerged into photopolymer resin150. Reinforcing member106movement can be carried out through utilization of a build plate (not shown) or a tensioned reinforcing member (i.e., between rollers not shown) moving by manual or computer control, or any other way known in the art of additive manufacturing. In the embodiment ofFIG.7, reinforcing layer106is already submerged in photopolymer resin150, so the reinforcing layer may be backed away from the bottom of vat140, allowing photopolymer resin to flow between the reinforcing layer and the bottom of the vat. In alternate embodiments, the upper surface of the photopolymer resin can be moved relative to the upper surface of the reinforcing member by adding an additional volume of resin, and optionally may accelerate leveling and bubble removal by mechanical (e.g., wiping, not shown) or thermal (e.g., pre-heating or heating the resin) means or combinations thereof. This reinforcing layer movement can be carried out through utilization of a build plate (not shown) or a tensioned reinforcing member (i.e., between rollers not shown), moving by manual or computer control, or any other way known in the art of additive manufacturing. Build plate may be made of any material known in the art that can assist in reflecting/stopping the utilized radiation, for example, an opaque film, stainless steel, brushed aluminum or other metals known in the art. In either embodiment, photopolymer resin150is now in contact with first surface120. In alternate embodiments, a build plate could be a clear film or solid material such as glass, quartz or polymer to enable transmission of radiation or polymer to allow diffusion of gas such as oxygen. Radiation135may then be created by at least one radiation source130and directed from the at least one radiation source towards first surface120of reinforcing member106such that the radiation at least partially cures photopolymer resin in contact with the first surface of the reinforcing member to create at least a portion of a lock-on layer (not shown). In some embodiments, this portion of the lock-on layer in addition to the previously described portion of the lock-on layer (cured photopolymer resin in contact with second surface122of reinforcing member106) will make up the entire lock-on layer. In embodiments where reinforcing member106includes voids18, radiation135may also be created by at least one radiation source130and directed from the at least one radiation source towards first surface120of the reinforcing member such that the radiation at least partially cures photopolymer resin in contact with at least one side surface30of at least some of the voids to create at least a portion of the lock-on layer (not shown). In some embodiments, this portion of the lock-on layer in addition to at least one of the previously described portions of the lock-on layer (cured photopolymer resin in contact with the first and/or second surfaces of the reinforcing member) will make up the entire lock-on layer. In some embodiments, radiation135may be repeated to create at least a portion of the lock-on layer or make-up the entire lock-on layer. In embodiments where reinforcing member106includes foramina40, radiation135may also be created by at least one radiation source130and directed from the at least one radiation source towards first surface120of the reinforcing member such that the radiation at least partially cures photopolymer resin in contact with at least one sidewall42of at least some of the foramina to create at least a portion of the lock-on layer (not shown). In some embodiments, this portion of the lock-on layer in addition to at least one of the previously described portions of the lock-on layer (cured photopolymer resin in contact with the first and/or second surfaces of the reinforcing member) will make up the entire lock-on layer. In some embodiments where reinforcing member106includes foramina40, radiation135may be repeated to create at least a portion of the lock-on layer or make-up the entire lock-on layer. After the lock-on layer is created through one or more of the steps described above, radiation135may be created by at least one radiation source130and directed towards first surface120of reinforcing member106to at least partially cure photopolymer in contact with the lock-on layer to create a build layer (not shown). In some embodiments, radiation135may be repeated with at least one radiation source130to create at least a portion of the build-up layer or make-up the entire build-up layer. An exemplary embodiment is that a portion of the lock-on layer and build layer can be created almost simultaneously or the entire lock-on layer and build layer can be created almost simultaneously. The term “build layer” is used to describe the layer(s) of at least partially cured photopolymer resin that is/are created upon the lock-on layer. The lock-on layer can be backed away from the bottom of vat140, allowing photopolymer resin to flow between the lock-on layer and the bottom of the vat. In alternate embodiments ofFIG.6andFIG.7, the upper surface of the photopolymer resin can be moved relative to the upper surface of the reinforcing member by adding an additional volume of resin and optionally may accelerate leveling and bubble removal by mechanical (e.g. wiping, not shown) or thermal (e.g. pre-heating or heating the resin) means or combinations thereof. The build layers stack on top of each other and create a structure that will resemble the resinous framework of traditional deflection members. As described above, the build layers created by additive manufacturing in the methods detailed herein that form the resinous framework equivalent of traditional deflection members may be in any shape, style or structure now known, or known in the future. The number of build layers that build on top of one another (with the bottom build layer contacting the lock-on layer) may be between 1 and about 500, or may be between 1 and about 300, or may be between 1 and about 200, or may be between 1 and about 150, or may be between 1 and about 100, or may be between 1 and about 75, or may be between 1 and about 50, or may be between 1 and about 25, or may be between 1 and about 50,000. When creating the build layer(s), the reinforcing member/lock-on layer is moved further from radiation source130with creation of each successive build layer. Alternatively, the radiation source may be moved further away from the reinforcing member/lock-on layer may with creation of each successive build layer. This reinforcing layer/lock-on layer movement can be carried out through utilization of a build plate (not shown) moving by manual or computer control, or any other way known in the art of additive manufacturing. Further, in embodiments where the radiation source moves or is reflected, the radiation source movement or reflection, or combination thereof, may be carried out through utilization of any means known in the art. Individual build layer thickness may represent incremental distance on the order of microns—examples include, but are not limited to, 1000, 100, 10, 1 and/or 0.1 microns. While creating the lock-on layer and/or build layer(s), reinforcing member106may be tensioned to control warp while curing. Tension may occur in both planar and non-planar configurations. The build layers may be registered with the previous layer. Other shapes may be created by practicing one or more layers in an unregistered fashion relative to the previous layer. Registration is defined as positioning an X-Y region along a Z axis that is common to all layers within a shape—an example would be stacking layers to create a symmetrical shape. Other methods of stacking may require positioning that is off-center for a given X-Y region but registered with the previous layer to preserve continuity in one or more side walls. Lastly, it is possible that registered stacking is substantially symmetrical rather than perfectly symmetrical. After the at least a portion of the lock-on layer is created, or after the entire lock-on layer is created, or after the entire lock-on layer and a portion of the build layer(s) are created, or after the entire lock-on layer and the entire build layer(s) are created, supplemental radiation may be created and directed towards the deflection member to further cure at least one of at least a portion of the lock-on layer and/or at least a portion of the build layer(s). The supplemental radiation may be created by at least one radiation source130described above, or may be created by at least one supplemental radiation source (not shown). The at least one supplemental radiation source may be located on the same side of the reinforcing member as the at least one radiation source, or may be located on the opposite side of the reinforcing member of the at least one radiation source, or in some embodiments on both sides. Second Method: In another method for manufacturing a deflection member depicted inFIG.8, an additive manufacturing apparatus200is provided that includes at least one upper radiation source230and at least one lower radiation source232and a vat240containing photopolymer resin250. A reinforcing member206is provided that has an upper surface220and a lower surface222opposite the upper surface. Reinforcing member206is submerged in photopolymer resin250contained in vat240, such that lower surface222is in contact with the bottom of the vat. In this exemplary embodiment, the utilized reinforcing member may be translucent so that radiation may pass through the reinforcing member, but it may also be opaque. Radiation237may then be created by at least one lower radiation source232and directed from the at least one lower radiation source towards lower surface222of reinforcing member206such that the radiation at least partially cures photopolymer resin in contact with lower surface222of the reinforcing member to create at least a portion of a lock-on layer (not shown). In some embodiments, radiation237is enough to create the entire lock-on layer. In some embodiments, radiation237from at least one lower radiation source232can be repeated to create the entire lock-on layer. The term “lock-on layer” is used to describe the layer of at least partially cured photopolymer resin that surrounds the reinforcing member. Lock-on layer may include the at least partially cured resin that surrounds upper surface220, lower surface222, the sidewall surfaces42of any foramina40(as detailed inFIG.5), the side surfaces30of any voids18of reinforcing member206(as detailed inFIGS.1-4), and or any other surface of the reinforcing member, such as the outers sides of the overall member. In some methods, radiation237from at least one lower radiation source232may create a lock-on layer that includes at least partially cured resin that contacts at least one of the upper surface220, lower surface222, the sidewall surfaces42of any foramina40(as detailed inFIG.5), the side surfaces30of any voids18of reinforcing member206(as detailed inFIGS.1-4), and or any other surface of the reinforcing member, such as the outers sides of the overall member. Accordingly, radiation237from at least one lower radiation source232may create the entire lock-on layer. In other methods, the portion of the lock-on layer described above may be combined with one or more of the portions of the lock-on layer described below to form the complete lock-on layer. After (or during) the first portion of the lock-on layer is at least partially cured, in the embodiment illustrated inFIG.8, reinforcing member206can be raised to the top of the vat containing photopolymer resin250so that the upper surface220is just below the upper surface of the photopolymer resin. Reinforcing member206movement can be carried out through utilization of a build plate (not shown) or a tensioned reinforcing member (i.e., between rollers not shown) moving by manual or computer control, or any other way known in the art of additive manufacturing. In alternate embodiments ofFIG.8, the upper surface of the photopolymer resin can be moved relative to the upper surface of the reinforcing member by adding an additional volume of resin and optionally may accelerate leveling and bubble removal by mechanical (e.g. wiping, not shown) or thermal (e.g. pre-heating or heating the resin) means or combinations thereof. Radiation235may be optionally created by at least one upper radiation source230and directed from the at least one upper radiation source towards upper surface220of reinforcing member206such that the radiation at least partially cures photopolymer resin in contact with the upper surface of the reinforcing member to create at least a portion of a lock-on layer (not shown). In some embodiments, this portion of the lock-on layer in addition to the previously described portion of the lock-on layer (cured photopolymer resin in contact with lower surface222of reinforcing member206) will make up the entire lock-on layer. In some embodiments, radiation235from at least one upper radiation source230can be repeated to create the entire lock-on layer. In embodiments wherein reinforcing member206includes voids18, radiation235and/or237may also be created by at least one radiation source230,232and directed from the at least one radiation source towards upper surface220and/or lower surface222of the reinforcing member such that the radiation at least partially cures photopolymer resin in contact with at least one side surface30of at least some of the voids to create at least a portion of the lock-on layer (not shown). In some embodiments, this portion of the lock-on layer in addition to at least one of the previously described portion(s) of the lock-on layer (cured photopolymer resin in contact with the upper and/or lower surfaces of the reinforcing member) will make up the entire lock-on layer. In some embodiments where reinforcing member206includes voids18, radiation235and/or237may be repeated simultaneously or alternating to create at least a portion of the lock-on layer or make-up the entire lock-on layer. In embodiments wherein reinforcing member306includes foramina40, radiation335and/or337may also be created by at least one radiation source330,332and directed from the at least one radiation source towards upper surface320and/or lower surface322of the reinforcing member such that the radiation at least partially cures photopolymer resin in contact with at least one sidewall42of at least some of the foramina to create at least a portion of the lock-on layer (not shown). In some embodiments, this portion of the lock-on layer in addition to at least one of the previously described portion(s) of the lock-on layer (cured photopolymer resin in contact with the upper and/or lower surfaces of the reinforcing member) will make up the entire lock-on layer. In some embodiments where reinforcing member206includes foramina40, radiation235and/or237may be repeated simultaneously or alternating to create at least a portion of the lock-on layer or make-up the entire lock-on layer. After the lock-on layer is created through one or more of the steps described above, radiation235may be created by at least one upper radiation source230and directed towards upper surface220of reinforcing member206to at least partially cure photopolymer in contact with the lock-on layer to create one or more build layer(s) (not shown). The term “build layer” is used to describe the layer(s) of at least partially cured photopolymer resin that is/are created upon of the lock-on layer. In some embodiments, radiation235may be repeated with at least one upper radiation source230to create at least a portion of the build-up layer or make-up the entire build-up layer. An exemplary embodiment is that a portion of the lock-on layer and build layer can be created about simultaneously or the entire lock-on layer and build layer can be created about simultaneously. The term “build layer” is used to describe the layer(s) of at least partially cured photopolymer resin that is/are created upon the lock-on layer. The lock-on layer can be backed away from the top of the vat222, allowing photopolymer resin to flow between the lock-on layer and the top of the vat. In alternate embodiments ofFIG.8, the upper surface of the photopolymer resin can be moved relative to the upper surface of the reinforcing member by adding an additional volume of resin and optionally may accelerate leveling and bubble removal by mechanical (e.g. wiping, not shown) or thermal (e.g. pre-heating or heating the resin) means or combinations thereof. The build layers stack on top of each other and create a structure that will resemble the resinous framework of traditional deflection members. As described above, the build layers created by additive manufacturing in the methods detailed herein that form the resinous framework equivalent of traditional deflection members may be in any shape, style or structure now known, or known in the future. The number of build layers that build on top of one another (with the bottom build layer contacting the lock-on layer) may be between 1 and about 500, or may be between 1 and about 300, or may be between 1 and about 200, or may be between 1 and about 150, or may be between 1 and about 100, or may be between 1 and about 75, or may be between 1 and about 50, or may be between 1 and about 25, or between 1 and about 50,000. When creating the build layer(s), the reinforcing member/lock-on layer is moved further from radiation source230with creation of each successive build layer. Alternatively, the radiation source may be moved further away from the reinforcing member/lock-on layer may with creation of each successive build layer. This reinforcing layer/lock-on layer movement can be carried out through utilization of a build plate (not shown) moving by manual or computer control, or any other way known in the art of additive manufacturing. Further, in embodiments where the radiation source moves or is reflected, the radiation source movement or reflection, or combinations thereof, may be carried out through utilization of any means known in the art. Individual build layer thickness may represent incremental distance on the order of microns—examples include, but are not limited to, 1000, 100, 10, 1 and/or 0.1 microns. While creating the lock-on layer and/or build layer(s), reinforcing member106may be tensioned to control warp while curing. Tension may occur in both planar and non-planar configurations. The build layers may be registered with the previous layer. Other shapes may be created by practicing one or more layers in an unregistered fashion relative to the previous layer. Registration is defined as positioning an X-Y region along a Z axis that is common to all layers within a shape—an example would be stacking layers to create a symmetrical shape. Other methods of stacking may require positioning that is off-center for a given X-Y region but registered with the previous layer to preserve continuity in one or more side walls. Lastly, it is possible that registered stacking is substantially symmetrical rather than perfectly symmetrical. After the at least a portion of the lock-on layer is created, or after the entire lock-on layer is created, or after the entire lock-on layer and a portion of the build layer(s) are created, or after the entire lock-on layer and the entire build layer(s) are created, supplemental radiation may be created and directed towards the deflection member to further cure at least one of at least a portion of the lock-on layer and/or at least a portion of the build layer(s). The supplemental radiation may be created by at least one radiation source130described above, or may be created by at least one supplemental radiation source (not shown). The at least one supplemental radiation source may be located on the same side of the reinforcing member as the at least one radiation source, or may be located on the opposite side of the reinforcing member of the at least one radiation source, or in some embodiments on both sides. Third Method: In another method for manufacturing a deflection member depicted inFIG.9, an additive manufacturing apparatus300is provided that includes at least one upper radiation source330and at least one lower radiation source332and a vat340containing photopolymer resin350. A reinforcing member306is provided that has an upper surface320and a lower surface322opposite the upper surface. Reinforcing member306is submerged in photopolymer resin350contained in vat340, such that the upper surface320is just below the upper surface of the photopolymer resin. In this exemplary embodiment, the utilized reinforcing member may be wholly or partially translucent so that radiation may pass through the reinforcing member, but it may also be opaque. Radiation335may then be created by at least one upper radiation source330and directed from the at least one upper radiation source towards upper surface320of reinforcing member306such that the radiation at least partially cures photopolymer resin in contact with upper surface320of the reinforcing member to create at least a portion of a lock-on layer (not shown). In some embodiments, radiation335is enough to create the entire lock-on layer. In some embodiments, radiation335from at least one upper radiation source330can be repeated to create the entire lock-on layer. The term “lock-on layer” is used to describe the layer of at least partially cured photopolymer resin that surrounds the reinforcing member. Lock-on layer may include the at least partially cured resin that surrounds upper surface320, lower surface322, the sidewall surfaces42of any foramina40(as detailed inFIG.5), the side surfaces30of any voids18of reinforcing member206(as detailed inFIGS.1-4), and or any other surface of the reinforcing member, such as the outers sides of the overall member. In some methods, radiation335from at least one upper radiation source330may create a lock-on layer that includes at least partially cured resin that contacts at least one of the upper surface320, lower surface322, the sidewall surfaces42of any foramina40(as detailed inFIG.5), the side surfaces30of any voids18of reinforcing member306(as detailed inFIGS.1-4), and or any other surface of the reinforcing member, such as the outers sides of the overall member. Accordingly, radiation335from at least one upper radiation source330may create the entire lock-on layer. In other methods, the portion of the lock-on layer described above may be combined with one or more of the portions of the lock-on layer described below to form the complete lock-on layer. After (or during) the first portion of the lock-on layer is at least partially cured, in the embodiment illustrated inFIG.9, reinforcing member306can be lowered to the bottom of vat340containing photopolymer resin350so that the lower surface322is in contact with the bottom of the vat. Reinforcing member306movement can be carried out through utilization of a build plate (not shown) or a tensioned reinforcing member (i.e., between rollers not shown), moving by manual or computer control, or any other way known in the art of additive manufacturing. Radiation337may be optionally created by at least one lower radiation source332and directed from the at least one lower radiation source towards lower surface322of reinforcing member306such that the radiation at least partially cures photopolymer resin in contact with the lower surface of the reinforcing member to create at least a portion of a lock-on layer (not shown). In some embodiments, this portion of the lock-on layer in addition to the previously described portion of the lock-on layer (cured photopolymer resin in contact with upper surface320of reinforcing member306) will make up the entire lock-on layer. In some embodiments, radiation337from at least one lower radiation source332can be repeated to create the entire lock-on layer. In embodiments wherein reinforcing member306includes voids18, radiation335and/or337may also be created by at least one radiation source330,332and directed from the at least one radiation source towards upper surface320and/or lower surface322of the reinforcing member such that the radiation at least partially cures photopolymer resin in contact with at least one side surface30of at least some of the voids to create at least a portion of the lock-on layer (not shown). In some embodiments, this portion of the lock-on layer in addition to at least one of the previously described portion(s) of the lock-on layer (cured photopolymer resin in contact with the upper and/or lower surfaces of the reinforcing member) will make up the entire lock-on layer. In some embodiments where reinforcing member306includes voids18, radiation335and/or337may be repeated simultaneously or alternating to create at least a portion of the lock-on layer or make-up the entire lock-on layer. In embodiments wherein reinforcing member306includes foramina40, radiation335and/or337may also be created by at least one radiation source330,332and directed from the at least one radiation source towards upper surface320and/or lower surface322of the reinforcing member such that the radiation at least partially cures photopolymer resin in contact with at least one sidewall42of at least some of the foramina to create at least a portion of the lock-on layer (not shown). In some embodiments, this portion of the lock-on layer in addition to at least one of the previously described portion(s) of the lock-on layer (cured photopolymer resin in contact with the upper and/or lower surfaces of the reinforcing member) will make up the entire lock-on layer. In some embodiments where reinforcing member306includes foramina40, radiation335and/or337may be repeated simultaneously or alternating to create at least a portion of the lock-on layer or make-up the entire lock-on layer. After the lock-on layer is created through one or more of the steps described above, radiation337may be created by at least one lower radiation source332and directed towards lower surface322of reinforcing member306to at least partially cure photopolymer in contact with the lock-on layer to create a build layer (not shown). The term “build layer” is used to describe the layer(s) of at least partially cured photopolymer resin that is/are created upon of the lock-on layer. In some embodiments, radiation337may be repeated with at least one lower radiation source332to create at least a portion of the build-up layer or make-up the entire build-up layer. An exemplary embodiment is that a portion of the lock-on layer and build layer can be created about simultaneously or the entire lock-on layer and build layer can be created about simultaneously. The term “build layer” is used to describe the layer(s) of at least partially cured photopolymer resin that is/are created upon the lock-on layer. The lock-on layer can be backed away from the bottom of the vat, allowing photopolymer resin to flow between the lock-on layer and the bottom of the vat. In alternate embodiments ofFIG.9, the lower surface of the photopolymer resin can be moved relative to the upper surface of the reinforcing member by moving of the entire vat, or the bottom portion of the vat. The build layers stack on top of each other and create a structure that will resemble the resinous framework of traditional deflection members. As described above, the build layers created by additive manufacturing in the methods detailed herein that form the resinous framework equivalent of traditional deflection members may be in any shape, style or structure now known, or known in the future. The number of build layers that build on top of one another (with the bottom build layer contacting the lock-on layer) may be between 1 and about 500, or may be between 1 and about 300, or may be between 1 and about 200, or may be between 1 and about 150, or may be between 1 and about 100, or may be between 1 and about 75, or may be between 1 and about 50, or may be between 1 and about 25, or may be between 1 and about 50,000. When creating the build layer(s), the reinforcing member/lock-on layer is moved further from radiation source332with creation of each successive build layer. Alternatively, the radiation source may be moved further away from the reinforcing member/lock-on layer may with creation of each successive build layer. This reinforcing layer/lock-on layer movement can be carried out through utilization of a build plate (not shown) moving by manual or computer control, or any other way known in the art of additive manufacturing. Further, in embodiments where the radiation source moves or is reflected, the radiation source movement or reflection, or combination thereof, may be carried out through utilization of any means known in the art. Individual build layer thickness may represent incremental distance on the order of microns—examples include, but are not limited to, 1000, 100, 10, 1 and/or 0.1 microns. While creating the lock-on layer and/or build layer(s), reinforcing member106may be tensioned to control warp while curing. Tension may occur in both planar and non-planar configurations. The build layers may be registered with the previous layer. Other shapes may be created by practicing one or more layers in an unregistered fashion relative to the previous layer. Registration is defined as positioning an X-Y region along a Z axis that is common to all layers within a shape—an example would be stacking layers to create a symmetrical shape. Other methods of stacking may require positioning that is off-center for a given X-Y region but registered with the previous layer to preserve continuity in one or more side walls. Lastly, it is possible that registered stacking is substantially symmetrical rather than perfectly symmetrical. After the at least a portion of the lock-on layer is created, or after the entire lock-on layer is created, or after the entire lock-on layer and a portion of the build layer(s) are created, or after the entire lock-on layer and the entire build layer(s) are created, supplemental radiation may be created and directed towards the deflection member to further cure at least one of at least a portion of the lock-on layer and/or at least a portion of the build layer(s). The supplemental radiation may be created by at least one radiation source130described above, or may be created by at least one supplemental radiation source (not shown). The at least one supplemental radiation source may be located on the same side of the reinforcing member as the at least one radiation source, or may be located on the opposite side of the reinforcing member of the at least one radiation source, or in some embodiments on both sides. EXAMPLES OF PROCESSES FOR A MAKING DEFLECTION MEMBER Most 3D printing equipment (e.g., an SLA apparatus) have options for slicing a three dimensional object in to slices or layers. The slices or layers can typically be any desired thickness up to about 200 microns, or up to about 300 microns, with some non-limiting thicknesses being 10 microns, 25 microns, 50 microns and 100 microns. Recently released from Formlabs, the new Form 3/3L increases the maximum thickness per layer to 300 microns. All slices or layers do not need to be the same thickness, as layer thickness can vary in the printing of a single object. However, the max layer thickness that 3D printing equipment can typically build is less than a normal reinforcing member thickness. Accordingly, the operation of the equipment expects a Z distance equivalent to the layer thickness, and thus methods have been developed to work with a physically constraining reinforcing member present within the object being printed. EXAMPLE 1 A Form 2 SLA (laser) printer from Formlabs, Inc.® was modified to enable inclusion of a reinforcing member in the build process. A reinforcing member was constructed using 100% combed cotton needle point canvas (12 mesh and about 540 micron thick). The X-Y strands of the reinforcing member were white and opaque in appearance. The resin vat was loaded with Formlabs Flexible V2 resin which is gray in color. A hoop was additively manufactured using an Objet 30 Prime PolyJet 3D printer—where the hoop enabled tension to be applied in both the MD and CD direction holding the reinforcing member against an upper build platform made of brushed aluminum. A continuous cross-hatch pattern was constructed in Solidworks (3D CAD) and exported as an STL file. The STL file was sliced into layers using PreForm; and PreForm launched the build. The reinforcing member-modified platform was submerged to the bottom of the resin vat and a single laser was driven by galvo mirrors to cure resin for the lock-on layer and subsequent build layers. Between such layers, the reinforcing member-modified build platform was separated from the bottom of the vat, raised, and incrementally repositioned above the previous layer position. During this repositioning, a mechanical wiper removed debris and redistributed resin across the build area. The laser was positioned beneath the vat and transmitted the radiation through the transparent vat. EXAMPLE 2 In another example similar to Example 1, the build platform was modified to include the reinforcing member at the 7thlayer in the build sequence of 14×50 micron thick layers. Operation was paused to insert the reinforcing member and hoop on to and around the build platform. A portion of the result is shown inFIGS.11,12and13, such that the pattern is locked on to the reinforcing member by partially surrounding the strands. EXAMPLE 3 In another example similar to Example 2, the build platform was modified to include a reinforcing member at the 14thlayer in the build sequence of 28×50 micron thick layers. Operation was paused to insert the reinforcing member and hoop on to and around the build platform. This resulted in a 3D pattern wholly locked onto the reinforcing member. EXAMPLE 4 Using a Form 1+ SLA from Formlabs in a bottom up configuration (laser also beneath the vat), a reinforcing member was affixed to the build platform via black Gorilla tape. The tape was pressed against a PPS-reinforcing member and wrapped around the edges of the build platform. A second layer of tape was added to increase the depth of resin between the first surface of the reinforcing member and the inner bottom surface of the vat. The distance was about 0.81 mm. Improved resolution was achieved by covering the reflective aluminum build platform with red 3M tape or flat black Formica prior to printing. Black Formica is preferred due to slight solubility of the red component of the 3M tape into the resin. An improved build platform is achieved when the radiation is absorbed on the build platform surface. Repetitive passes of energy were exposed to essentially the same thick pool of resin while the SLA printer executed a build. Build layers were not created by successive layers of uncured resin but rather successive exposures of energy according to the 3D CAD model. A pumping action of resin into the fixed space and movement of the reinforcing member can cause the reinforcing member to shift and reduce the number of exposures locally within the resin. EXAMPLE 5 To account for undesired resin and reinforcing member displacement, a Form 1+ SLA was inverted to enable the laser to radiate a stationary vat of resin beneath the laser (similar to the upper laser inFIG.8), and the build plate was removed. Since the vat was stationary, the reinforcing member in the vat was also stationary. The vat was constructed from a square petri dish and was transparent to the radiation. Successive pattern exposures of the laser cured the fixed resin volume in the desired pattern with both regions equivalent to lock-on and build layers. The thickness of each build layer was determined by the height of the photopolymer resin in the vat. EXAMPLE 6 In another example similar to Example 5, to facilitate removal from the vat (petri dish), a transparent barrier film was used on the bottom of the vat. This kept the vat clean from uncured resin. EXAMPLE 7 In another example similar to Example 6, to increase the thickness of the overall build layer region or to alter the shape of the cured resin pattern, additional resin is added to increase the fixed resin volume after the first set of exposures. The steps can be repeated to achieve the final thickness or shape. EXAMPLE 8 In another example similar to Example 7, to improve the final layer, a barrier film can be added which limits further diffusion of atmospheric oxygen into the resin and enables depletion of the dissolved oxygen in free radial photopolymerization. The barrier film can be smooth creating a planar surface on the top of protuberances or resinous framework. Optionally, the film can be textured to impart a textured surface to the resinous framework consistent with U.S. Pat. No. 9,909,258 issued Mar. 6, 2018 in the name of Seger et al. EXAMPLE 9 A MakeBlock LaserBot Engraving Kit (part RB-Mab-240 from RobotShop Inc, Swanton, Vermont) was modified to point up rather than down and include a 405 nm (450-500 mW) laser, to orient a Form 1+ vat above the laser plane and operate similar toFIG.7. The laser was controlled in the XY coordinate direction to create the letters TEST as a pattern using a transparent photopolymer. Besides galvo and mirror controlled lasers (as in Example 5), this demonstrated the potential to use a laser mounted on an XY gantry motion controlled table. EXAMPLE 10 Using configurations as shown inFIGS.6and7, and combining techniques from Examples 5-8, Peopoly Moai SLA (models Moai 130 and Moai 200) were modified to operate without the moving build plate inFIG.6and the laser was inverted similar toFIG.7. These used a fixed volume of resin with repeated radiation exposures up to 26 times at about 59% to 69% laser power to demonstrate simultaneous lock-on layer creation and build layer creation. This demonstrated capability for XY galvo mirror control only rather than Formlabs Form 1+ which has galvo mirror control and a 45 degree reflecting mirror. Fibrous Structure: One purpose of the 3-D printed deflection member (produced as detailed herein) is to provide a forming surface on which to mold fibrous structures such as paper products including paper towels, toilet tissue, and facial tissue, as well as mold nonwovens including diaper, adult incontinence and feminine care topsheet materials, and the like. When used in a papermaking process, the deflection member can be utilized in the “wet end” of a papermaking process, as described in more detail below, in which fibers from a fibrous slurry are deposited on the web side surface of the deflection member. Similarly, the deflection member can be used to catch and mold fibers in a nonwoven making process. Thus, as can be understood from the description herein, a fibrous structure can be shaped to the general shape of the deflection member such that the shape and size of the 3-D features of the fibrous structure are a close approximation of the size and shape of the 3-D objects printed on the resinous framework of the deflection member. Processes for Making Fibrous Structure: In one form, deflection members as disclosed herein may be used in a papermaking process. With reference toFIG.10, one exemplary form of a process for producing a paper web500comprises the following steps. First, a plurality of fibers501are provided and deposited on a forming wire123of a papermaking machine, as is known in the art. The present disclosure contemplates the use of a variety of fibers, such as, for example, cellulosic fibers, synthetic fibers, or any other suitable fibers, and any combination thereof. Papermaking fibers useful in the present disclosure include cellulosic fibers commonly known as wood pulp fibers. Fibers derived from soft woods (gymnosperms or coniferous trees) and hard woods (angiosperms or deciduous trees) are contemplated for use in this disclosure. The particular species of tree from which the fibers are derived is immaterial. The hardwood and softwood fibers can be blended, or alternatively, can be deposited in layers to provide a stratified web. U.S. Pat. No. 4,300,981 issued Nov. 17, 1981 in the name of Carstens; and U.S. Pat. No. 3,994,771 issued Nov. 30, 1976 in the name of Morgan et al. are incorporated herein by reference for the purpose of disclosing layering of hardwood and softwood fibers. The wood pulp fibers can be produced from the native wood by any convenient pulping process. Chemical processes such as sulfite, sulfate (including the Kraft) and soda processes are suitable. Mechanical processes such as thermomechanical (or Asplund) processes are also suitable. In addition, various semi-chemical and chemi-mechanical processes can be used. Bleached as well as unbleached fibers are contemplated for use. When the fibrous web of this invention is intended for use in absorbent products such as paper towels, bleached northern softwood Kraft pulp fibers may be used. Wood pulps useful herein include chemical pulps such as Kraft, sulfite and sulfate pulps as well as mechanical pulps including for example, ground wood, thermomechanical pulps and Chemi-ThermoMechanical Pulp (CTMP). Pulps derived from both deciduous and coniferous trees can be used. In addition to the various wood pulp fibers, other cellulosic fibers such as cotton linters, rayon, and bagasse can be used in this invention. Synthetic fibers, such as polymeric fibers, can also be used. Elastomeric polymers, polypropylene, polyethylene, polyester, polyolefin and nylon can be used. The polymeric fibers can be produced by spunbond processes, meltblown processes and/or other suitable methods known in the art. The paper furnish can comprise a variety of additives, including but not limited to fiber binder materials, such as wet strength binder materials, dry strength binder materials, chemical softening compositions, latexes, bicomponent fibers with a soften-able or melt-able outer shell, and thermoplastic fibers. Suitable wet strength binders include, but are not limited to, materials such as polyamide-epichlorohydrin resins sold under the trade name of KYMENE™ 557H by Hercules Inc., Wilmington, Del. Suitable temporary wet strength binders include but are not limited to synthetic polyacrylates. A suitable temporary wet strength binder is PAREZ™ 750 marketed by American Cyanamid of Stanford, Conn. Suitable dry strength binders include materials such as carboxymethyl cellulose and cationic polymers such as ACCO™ 711. The CYPRO/ACCO family of dry strength materials are available from CYTEC of Kalamazoo, Mich. Forms of fiber bonding may also be utilized, including, but not limited to, carding and hydroentangling. The paper furnish can comprise a debonding agent to inhibit formation of some fiber to fiber bonds as the web is dried. The debonding agent, in combination with the energy provided to the web by the dry creping process, results in a portion of the web being debulked. In one form, the debonding agent can be applied to fibers forming an intermediate fiber layer positioned between two or more layers. The intermediate layer acts as a debonding layer between outer layers of fibers. The creping energy can therefore debulk a portion of the web along the debonding layer. Suitable debonding agents include chemical softening compositions such as those disclosed in U.S. Pat. No. 5,279,767 issued Jan. 18, 1994 in the name of Phan et al., the disclosure of which is incorporated herein by reference. Suitable biodegradable chemical softening compositions are disclosed in U.S. Pat. No. 5,312,522 issued May 17, 1994 in the name of Phan et al.; U.S. Pat. Nos. 5,279,767 and 5,312,522, the disclosures of which are incorporated herein by reference. Such chemical softening compositions can be used as debonding agents for inhibiting fiber to fiber bonding in one or more layers of the fibers making up the web. One suitable softener for providing debonding of fibers in one or more layers of fibers forming the web is a papermaking additive comprising DiEster Di (Touch Hardened) Tallow Dimethyl Ammonium Chloride. A suitable softener is ADOGEN® brand papermaking additive available from Witco Company of Greenwich, Conn. The embryonic web can be typically prepared from an aqueous dispersion of papermaking fibers, though dispersions in liquids other than water can be used. The fibers are dispersed in the carrier liquid to have a consistency of from about 0.1 to about 0.3 percent. Alternatively, and without being limited by theory, it is believed that the present disclosure is applicable to moist forming operations where the fibers are dispersed in a carrier liquid to have a consistency less than about 50 percent. Conventional papermaking fibers can be employed, and the aqueous dispersion can be formed in conventional ways. Conventional papermaking equipment and processes can be used to form the embryonic web on the Fourdrinier wire. The association of the embryonic web with the deflection member can be accomplished by simple transfer of the web between two moving endless belts as assisted by differential fluid pressure. The fibers may be deflected into the deflection member by the application of differential fluid pressure induced by an applied vacuum. Any technique, such as the use of a Yankee drum dryer or through air dryers, can be used to dry the intermediate web. Foreshortening can be accomplished by any conventional technique such as creping or rush transfer. The plurality of fibers can also be supplied in the form of a moistened fibrous web (not shown), which should preferably be in a condition in which portions of the web could be effectively deflected into the deflection conduits of the deflection member and the void spaces formed between the suspended portions and the X-Y plane. As depicted inFIG.10, embryonic web comprising fibers501is transferred from forming wire123to belt121on which the deflection member, produced as detailed herein, can be disposed. Alternatively, or additionally, a plurality of fibers or fibrous slurry, can be deposited onto the deflection member directly from a headbox or otherwise, including in a batch process (not shown). Papermaking belt100comprising the deflection member held between the embryonic web and belt121can travel past optional dryers/vacuum devices and about rolls119a,119b,119k,119c,119d,119e,and119fin the direction schematically indicated by the directional arrow “B”. A portion of fibers501can be deflected onto the deflection member such as to cause some of the deflected fibers to be disposed within any voids printed in the 3-D printed resinous member of the deflection member. Depending on the process, mechanical and fluid pressure differential, alone or in combination, can be utilized to deflect a portion of fibers501into any voids of the deflection member. For example, in a through-air drying process, vacuum apparatus148ccan apply a fluid pressure differential to the embryonic web disposed on the deflection member, thereby deflecting fibers into the deflection conduits of the deflection member. The process of deflection may be continued with additional vacuum pressure, if necessary, to even further deflect the fibers into any voids present on the deflection member. Finally, a partly-formed fibrous structure associated with the deflection member can be separated from the deflection member at roll119kat the transfer to Yankee dryer128. By doing so, the deflection member having the fibers thereon, is pressed against a pressing surface, such as, for example, a surface of Yankee drying drum128. After being creped off the Yankee dryer, fibrous structure500results and can be further processed or converted as desired. In another form, the deflection members as disclosed herein may be used in a nonwoven making process to capture/mold fibers in the creation of a nonwoven web, the type of which is commonly used as a top sheet and/or outercover nonwoven in diapers, adult incontinence products and feminine care products. Such processes use forced air and/or vacuum to draw fibers down into the deflection member, and are further detailed in commonly assigned U.S. patent application Ser. No. 15/879,480, filed Jan. 25, 2018 in the name of Ashraf et al. In the interests of brevity and conciseness, any ranges of values set forth in this specification are to be construed as written description support for claims reciting any sub-ranges having endpoints which are whole number values within the specified range in question. By way of a hypothetical illustrative example, a disclosure in this specification of a range of 1-5 shall be considered to support claims to any of the following sub-ranges: 1-4; 1-3; 1-2; 2-5; 2-4; 2-3; 3-5; 3-4; and 4-5. The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.” Every document cited herein, including any cross referenced or related patent or application is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any example disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such example. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. While particular examples of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the present disclosure. It is therefore intended to cover in the appended Claims all such changes and modifications that are within the scope of this disclosure. | 79,282 |
11858199 | DETAILED DESCRIPTION In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. Descriptions associated with any one of the figures may be applied to different figures containing like or similar components/steps. While the sequence diagrams each present a series of steps in a certain order, the order of some of the steps may be changed. FIG.1depicts a cross-section of three-dimensional (3D) printing system100(also called a vat polymerization printer), in which electromagnetic radiation (e.g., ultra-violet light) is used to cure photo-curable liquid resin18in order to fabricate object22(e.g., a 3D object). Object22may be fabricated layer by layer; that is, a new layer of object22may be formed by photo-curing a layer31of liquid resin18adjacent to the bottom surface of object22(also called the build area), the object may be raised by extractor plate20, allowing a new layer of liquid resin18to be drawn under the newly formed layer; and the process repeated to form additional layers. The 3D printing system100includes tank10for containing the liquid resin18. The bottom of tank10includes bottom opening12to allow electromagnetic radiation28from digital light processing (DLP) light source26to enter into tank10. DLP light source26may comprise a DLP light projector, or a digital micromirror device (DMD) that is irradiated by a light source. While one DLP light source is depicted inFIG.1, it is possible that in other embodiments (not depicted), multiple DLP light sources may be employed to project electromagnetic radiation into tank10at the same time, allowing a higher intensity of electromagnetic radiation to be achieved. An optional radiation-transparent backing member16(e.g., borosilicate glass or a toughened glass such as an alkali-aluminosilicate glass of approximately 100 μm thickness) may be used to seal the tank opening12(i.e., to prevent the photo-curing liquid polymer 18 from leaking out of tank10), while at the same time, allowing electromagnetic radiation to enter into tank10in order to cure the liquid resin18. One challenge faced by 3D printing systems of the present kind is that in addition to adhering to the object22, newly formed layers tend to adhere to the bottom of tank10. Consequently, when the extraction plate20to which the object is attached is raised by height adjustor30, the newly formed layer could tear and/or become dissociated from the object22. To address this issue, a flexible membrane14may be disposed adjacent to backing member16(if present) or may form the bottom of the tank10(if no backing member is used). Flexible membrane14may be formed of silicone or another material, and optionally, coated with a non-stick material such as polytetrafluoroethylene (PTFE) to reduce the likelihood for the newly formed layer to adhere to the bottom of tank10. The flexible membrane14is transparent (or nearly so) to the wavelength of radiation emitted by the DLP light source26so as to allow that radiation to enter into tank10in order to cure the liquid resin18. A mask25may be disposed adjacent to tank opening12to spatially filter the radiation that is incident on layer31, so that specific regions of the liquid resin18, that correspond to the cross section of the object22being printed, are cured. Mask25may be a transmissive spatial light modulator, such as a liquid crystal display (LCD) with a two-dimensional array of addressable pixels. As will be more clearly described in the figures below, certain ones of the pixels may be controlled to be transparent, while others may be controlled to be opaque. Transparent pixels allow radiation to pass through the mask25at certain spatial locations of mask25and into tank10, consequently curing portions of the liquid resin18, while opaque pixels prevent radiation from passing through certain spatial locations of mask25. Advantageously, DLP light source26may be configured to impart radiation with low intensity (e.g., less than 25% of the peak radiation, less than 10% of the peak radiation, less than 1% of the peak radiation, etc.) on opaque pixels so as to minimize the heating of mask25and in turn minimize the heating of resin18. The radiation on transparent pixels is maintained with a high intensity (e.g., greater than 75% of the peak radiation, greater than 90% of the peak radiation, etc.) as such radiation is needed to cure the resin18in build area31. However, since the resolution of a DLP light source26typically is lower than the resolution of mask25(e.g., an LCD mask), the above relationship of light intensity to opaque or transparent pixels may not hold for the opaque pixels at the perimeter of transparent pixel regions. For the opaque pixels at the perimeter of transparent pixel regions, the radiation from the DLP light source26may still be high and thus the function of those opaque pixels to block light is still carried out. Conceptually, the mask25enhances the resolution of DLP light source26, as described in more detail below inFIG.2. If not already apparent, such selective radiation of mask25(and hence the minimizing of the heating of resin18) is not possible with conventional light sources that emit a uniform collimated beam of light which radiates all pixels of mask25with the same intensity of radiation irrespective of whether the respective pixels are transparent or opaque. Controller50may be communicatively coupled to DLP light source26, mask25, and height adjustor30via control signal paths38a,38band38c, respectively (e.g., electrical signal paths). Controller50may control the addressable pixels of mask25such that the transparent pixels of mask25correspond to a cross section of an object to be printed. Similarly, controller50may control DLP light source26such that portions of the light from DLP light source26with high intensity correspond to a cross section of an object to be printed. Importantly, the operation of DLP light source26may be synchronized with the operation of mask25, such that light from DLP light source26with high intensity is transmitted through the transparent pixels of mask25and light from DLP light source26with low intensity is blocked by the opaque pixels of mask25. Such synchronized control by controller50is described in more detail below inFIG.4. Controller50may also control height adjustor30to control the vertical position of height extractor20, and consequently of object (or partially formed object)22that is affixed to height extractor20. Using height extractor20, the position of object22may be translated in a direction perpendicular to an extent of the flexible membrane14. FIG.2depicts a schematic to visually represent light28from DLP light source26(e.g., with varying intensity in the spatial dimension) being filtered by mask25(more specifically, a column or row of pixels25′ from mask25), before the filtered light28′ reaches build area31(more specifically, strip31′ from build area31) of tank10of the 3D printing system100. For simplicity of illustration, a two-dimensional slice through the 3D printing system100is being illustrated inFIG.3, as shown by the inset which provides some context to the orientation of the two-dimensional slice. As shown inFIG.3, light28is transmitted from DLP light source26, the light28having varying intensity in the spatial dimension. Light28is filtered by mask25, producing filtered light28′. Light with high intensity (for the most part) passes through the transparent pixels of mask25, whereas light with low intensity (for the most part) is blocked by the opaque pixels of mask25. Notice how the transitions of the light intensity are sharper in filtered light28′, as compared to light28, illustrating the increased resolution provided by mask25. The filtered light28′ then cures resin18at the build area31. FIG.3depicts a schematic to visually explain the synchronized control of DLP light source26and mask25. At time instance t1, light pattern302a(with a high intensity portion302band a low intensity portion302c) is transmitted to DLP light source26, and mask pattern304a(with transparent portion304band opaque portion304c) is transmitted to mask25. The shape of high intensity portion302bsubstantially resembles the shape of transparent portion304bat time instance t1, demonstrating the synchronized control of DLP light source26and mask25by controller50. At time instance t2, light pattern306a(with a high intensity portion306band a low intensity portion306c) is transmitted to DLP light source26, and mask pattern308a(with transparent portion308band opaque portion308c) is transmitted to mask25. The shape of high intensity portion306bsubstantially resembles the shape of transparent portion308bat time instance t2, further demonstrating the synchronized control of DLP light source26and mask25by controller50. At time instance t3, light pattern310a(with a high intensity portion310band a low intensity portion310c) is transmitted to DLP light source26, and mask pattern312a(with transparent portion312band opaque portion312c) is transmitted to mask25. The shape of high intensity portion310bsubstantially resembles the shape of transparent portion312bat time instance t3, further demonstrating the synchronized control of DLP light source26and mask25by controller50. For simplicity of illustration, only one high intensity portion was depicted and only one transparent portion was depicted, but it is understood that in practice, one or more high intensity portions and one or more transparent portions may be present. FIG.4depicts flow diagram400of a process for printing a layer of a partially formed object22using 3D printing system100in which light from DLP light source26is filtered by mask25before curing resin18at build area31of the tank10. At step402, light28from DLP light source26may be projected toward bottom opening12of tank10containing liquid resin18. At step404, mask25may be used to filter light28from DLP light source26. As described above, in most instances light with high intensity from DLP light source26may be transmitted through the transparent pixels of mask25, and light with low intensity from DLP light source26may be blocked by the opaque pixels of mask25. However, at the “boundary regions” (i.e., the opaque pixels surrounding regions with transparent pixels), light with high intensity from the DLP light source26may also be blocked by the opaque pixels of mask25, thereby enhancing the resolution of DLP light source26. At step406, liquid resin18in build area31of the tank10may be cured by the filtered light28′ from the DLP light source26so as to form a layer of a partially formed object22. As is apparent from the foregoing discussion, aspects of the present invention involve the use of various computer systems and computer readable storage media having computer-readable instructions stored thereon.FIG.5provides an example of system500that may be representative of any of the computing systems (e.g., controller50) discussed herein. Note, not all of the various computer systems have all of the features of system500. For example, certain ones of the computer systems discussed above may not include a display inasmuch as the display function may be provided by a client computer communicatively coupled to the computer system or a display function may be unnecessary. Such details are not critical to the present invention. System500includes a bus502or other communication mechanism for communicating information, and a processor504coupled with the bus502for processing information. Computer system500also includes a main memory506, such as a random access memory (RAM) or other dynamic storage device, coupled to the bus502for storing information and instructions to be executed by processor504. Main memory506also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by processor504. Computer system500further includes a read only memory (ROM)508or other static storage device coupled to the bus502for storing static information and instructions for the processor504. A storage device510, for example a hard disk, flash memory-based storage medium, or other storage medium from which processor504can read, is provided and coupled to the bus502for storing information and instructions (e.g., operating systems, applications programs and the like). Computer system500may be coupled via the bus502to a display512, such as a flat panel display, for displaying information to a computer user. An input device514, such as a keyboard including alphanumeric and other keys, may be coupled to the bus502for communicating information and command selections to the processor504. Another type of user input device is cursor control device516, such as a mouse, a trackpad, or similar input device for communicating direction information and command selections to processor504and for controlling cursor movement on the display512. Other user interface devices, such as microphones, speakers, etc. are not shown in detail but may be involved with the receipt of user input and/or presentation of output. The processes referred to herein may be implemented by processor504executing appropriate sequences of computer-readable instructions contained in main memory506. Such instructions may be read into main memory506from another computer-readable medium, such as storage device510, and execution of the sequences of instructions contained in the main memory506causes the processor504to perform the associated actions. In alternative embodiments, hard-wired circuitry or firmware-controlled processing units may be used in place of or in combination with processor504and its associated computer software instructions to implement the invention. The computer-readable instructions may be rendered in any computer language. In general, all of the above process descriptions are meant to encompass any series of logical steps performed in a sequence to accomplish a given purpose, which is the hallmark of any computer-executable application. Unless specifically stated otherwise, it should be appreciated that throughout the description of the present invention, use of terms such as “processing”, “computing”, “calculating”, “determining”, “displaying”, “receiving”, “transmitting” or the like, refer to the action and processes of an appropriately programmed computer system, such as computer system500or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within its registers and memories into other data similarly represented as physical quantities within its memories or registers or other such information storage, transmission or display devices. Computer system500also includes a communication interface518coupled to the bus502. Communication interface518may provide a two-way data communication channel with a computer network, which provides connectivity to and among the various computer systems discussed above. For example, communication interface518may be a local area network (LAN) card to provide a data communication connection to a compatible LAN, which itself is communicatively coupled to the Internet through one or more Internet service provider networks. The precise details of such communication paths are not critical to the present invention. What is important is that computer system500can send and receive messages and data through the communication interface518and in that way communicate with hosts accessible via the Internet. Thus, methods and systems for photocuring liquid resin with reduced heat generation using a DLP light source have been described. It is to be understood that the above-description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. | 16,348 |
11858200 | DETAILED DESCRIPTION Hybrid Manufacturing of Precursors The present invention relates to heterogeneous engineering of precursors through surface treatment of printed precursor material to create a film made of a different material, or through multi-material printing with different precursor materials, whereby heterogeneous precursors are formed; heating of heterogeneous precursors with the shape transformation due to the differences in thermal expansion coefficient or thermal shrinkage ratio of heterogeneous precursors accompanying the material transformation to high-temperature materials, whereby in situ 4D printed high-temperature materials are formed. To improve the precision of manufacturing, laser machining was integrated with 3D printing, resulting in a high-resolution hybrid additive-subtractive manufacturing system. 3D printed precursors are laser engraved with a laser scanning strategy that was tuned by laser scanning power and speed, and then high-resolution high-temperature structural materials were obtained with a heat treatment processes.FIG.1adepicts two processes for formation of shaped ceramic materials. In the first process, an ink formed of a polymeric ceramic precursor and optional ceramic particle filler is printed in a desired shape by 3D printing. Following 3D printing, shaping of the printed ink is performed by a shaping technique such as laser engraving. Following shaping, material treatment in a selected atmosphere, such as oxygen or ozone, optionally coupled with UV, is performed. This yields a coated, shaped printed material. Finally, heating is performed to decompose the polymeric ceramic precursor and sinter the coated, shaped, and printed material to yield the final ceramic article. In general, the printing ink containing a polymeric precursor and optional particles. Particles may include ceramic, glass, metal, diamond or other suitable fillers. A variety of ceramic particles may be used including, but not limited to, alumina (Al2O3), zirconia (ZrO2), titania (TiO2), silicon nitride (Si3N4), calcium oxide (CaO), silicon carbide (SiC), yttria (Y2O3), or aluminum nitride (AlN). Metal particles include, but are not limited to, iron, titanium, and nickel. In one aspect, the particles may have a particle size ranging from approximately 1 nm to 100 microns. The polymeric ceramic precursor may be selected from a polysiloxane, including polyborosiloxanes and polycarbosiloxanes. Polymers that include Si—N bonds may be used such as polysilazane and poly(organosilylcarbodiimide). Other polymeric ceramic precursors include silica hydrogels and other silicon-containing polymers. An exemplary polymeric ceramic precursor used in the examples below is polydimethylsiloxane (PDMS) or cellulose. In general, the combination of polymeric ceramic precursor and ceramic particles may be selected based on a desired level of shrinkage during sintering, depending upon the desired final product shape. In the second process (method 2) shown inFIG.1a, a selected polymeric ceramic precursor ink (with or without particle filler) is deposited as a first layer by 3D printing. A second layer is deposited by printing having different materials or different amounts of materials such that the drying and shrinkage behavior of the first and second layers is different from one another. In this method the first and second layers may be different precursor materials, or the same precursor material filled with different filler particles, or the same precursor material filled with different amounts of the same filler particles. The layered approach permits an article designer to create different properties, layer by layer. The different shrinkage properties of the different material layers create a controlled deformation during the heat treatment to decompose the polymeric ceramic precursor/sinter ceramic or metal particles. Composite materials may be formed (for example, metal-ceramic composites) through the layered approach. With the selection of novel precursor material systems and the precursor laser engraving (PLE) method, the laser machining process can be cost-efficient, high-resolution, and environmentally friendly, which enables the building of complex and precise high-temperature structural materials. A mapping model for varying laser scanning power and laser scanning speed is established. It shows that relatively deep features are generated by increasing laser scanning power and decreasing the laser scanning speed, and the depth of the features may be precisely adjusted with a step of around 50 μm (35 μm after ceramization; four times better than the direct ink writing process) (FIG.2b). The precursors are transformed into either amorphous-crystalline dual-phase ceramics (FIGS.2c-2e) or amorphous glasses (FIG.2f) with proper heat treatments. The resultant ceramics and glasses had average compositions of SiO0.74C0.43Zr0.18and SiO0.59C0.25, respectively, as measured by energy-dispersive spectroscopy (EDS). Resolution-Scalability Synergy The hybrid additive-subtractive manufacturing system of the present invention achieved resolution-scalability synergy. A typical microelectromechanical systems (MEMS) resonant strain sensor based on a double-ended tuning fork (DETF) was built (FIG.2jandFIG.5). The printed ceramic MEMS resonant strain sensors based on DETF offer potential for high-sensitivity strain sensing applications in harsh engineering environments. The PLE method can also be applied in the post-processing of 3D printed structures. The surface roughness Ra of a pristine 3D printed ceramic precursor structure was 16.5 μm, and it was reduced by 44% (to 9.2 μm) after laser engraving (FIG.2k). Moreover, the surface roughness of the resultant ceramic structure was further improved by uniform linear shrinkage during polymer-to-ceramic transformation. After polymer-to-ceramic transformation, the large-scale (as large as 12 cm) ceramic plates remained flat with a uniform shrinkage of 30%, resulting in good retention of the global shape and local features (FIG.2g-2i). The method offers great potential for applications of engineering ceramics in fields like astronautics, aeronautics, bioimplants, and electronics. The negative engraving of Chinese traditional calligraphy characters on a Fe alloy (FIG.2landFIG.6a) and diamond (FIG.2mandFIG.6b) plates illustrates the universality of this hybrid additive-subtractive manufacturing method. The resultant Fe alloys had an average composition of Fe45O39C16, as measured by EDS. In Situ 4D Printing The rapid polymer-to-ceramic transformation of heterogeneous structural precursors was conducted in an induction heating furnace (FIG.7). An induction heating technique was applied, and a video recording was taken of the resulting rapid 4D shape transformation to enable the mechanism analysis of in situ high-temperature 4D printing. The heating rate was as fast as 100-1,000° C. min−1, which was 10 to 100 times faster than conventional resistance heating approaches (typically slower than 20° C. min−1) Thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) results showed that the polymer-to-ceramic transformations were typically achieved within 300-900° C. (FIG.8a, b), and the material transformation to ceramics was generated in seconds with a heating rate of 1,000° C. min−1(FIG.7b). With method 1, the difference between the thermal expansion behaviors of the UV/ozone film and elastomers led to bending deformation, and the bending stiffness of the ceramic precursors and curvatures of resultant ceramics could be precisely tuned with the depth and width of laser engraving (FIG.3a). With method 2, since the thermal expansions of different precursors were close (FIG.8c), the shape transformation resulting from the thermal expansion effect was very limited compared with that from thermal shrinkage during polymer-to-ceramic transformation (FIG.3b). The influence of the PLE depth of the precursor in method 1 on the curvature of resultant ceramic structures was determined (FIG.3c), and the finite element analysis (FEA) simulations of thermal expansion effects on bending curvature were consistent with the experimental results (FIG.3d). The influence of filler concentrations in the precursor in the method 2 on the curvature of the resultant ceramic/glass composite structure was studied, and the FEA simulations of thermal shrinkage effects on bending curvature were consistent with the experimental results (FIG.3e). Thermal Expansion-Shrinkage Balance The present invention demonstrates that there exists a balance between thermal expansion and thermal shrinkage accompanying the shape transformation and material transformation process (FIG.3f). Due to the different thermal expansion and shrinkage behaviors of heterogeneous structural precursors, the ceramic precursor will transform in both shape configuration and material components under thermal treatment. Before the ceramization, the difference in thermal expansion coefficients of different materials in the precursor resulted in a first-state shape transformation. After the ceramization, the differences in the thermal shrinkage ratio for the different materials in the precursor resulted in a second-state shape transformation along with the material transformation. The balance between thermal expansion and shrinkage serves as the mechanism for 4D printing of high-temperature structural materials. With method 1, the thermal expansion effect dominates the shape transformation, whereas with method 2 the thermal shrinkage effect dominates. Potential Aerospace Applications In situ 4D printing can achieve great geometrical flexibility for high-temperature materials, including structures with zero, positive, and negative Gaussian curvature. Demonstrations of 4D printed ceramic/glass composites with a sinusoidal surface (K=0) (FIG.10a), cap surface (K>0) (FIG.10b), and saddle surface (K<0) (FIG.3gandFIG.12) were carried out. The repeatability of this heterogeneous engineering system was also demonstrated (FIG.10c). This paradigm offers promising opportunities for high-temperature applications, especially in the field of aerospace. Twelve blades with flat surfaces were simultaneously programmed to achieve twisting deformations, resulting in a flower-like symmetrical structure. The all-ceramic turbine disc and 12 blades were 4D printed in situ as a single piece without an assembly process (FIG.3h). The paradigm of in situ 4D printing and integrated shaping for the all-ceramic turbine blisk opens a route to developing advanced and intelligent aerospace propulsion components with high system efficiency, low life-cycle cost, and reduced environmental pollution. Firstly, in situ 4D printing of high-temperature materials of the present invention overcomes severe limitations in building geometrically complex propulsion components with conventional wrought, casting, welding, and subtractive manufacturing. Furthermore, the relatively simple structure of precursors may be utilized for precision machining of complex-shaped high-temperature materials. For example, it would be much easier to polish the flat surface of the blade inFIG.3hthan a curved surface using the PLE method. Secondly, ceramic materials have low density, high hardness, excellent thermal stability, and can work with increased turbine inlet temperature (higher than 1,300° C.), reduced cooling air requirements, and increased combustion efficiency, compared with conventional high-temperature alloys. Thus, the all-ceramic turbine blisk offers the potential for increasing the engine thrust-to-weight ratio and the overall efficiency, accompanied by fuel savings and environmental friendliness. Thirdly, the integrated shaping of the engine turbine disc and blades can reduce assembly time and lifecycle costs, and improve the control of clearances between parts of the propulsion system, which would reduce the vibration, wear, and noise resulting from assembly deviations. Furthermore, the inventive situ 4D printing can apply to the space exploration industry, in areas such as morphing thermal protection systems, on-orbit manufacturing and repair, and space colonization. The integration of shape and material transformations would offer flexible solutions to the thermal protection system of a reentry vehicle/capsule. With real-time measured information, an optimized thermal protection system with satisfying shape-morphing capability and reliability could be 4D printed in situ in response to the uncertain shape and ever-changing thermal environments of the reentry vehicle/capsule resulting from various factors such as ablation and complex flow effects. In the meantime, compared to the traditional design of heavy thermal shields, the lightweight design would be attractive in consideration of the payload and cost. Moreover, the concept could be used in space for on-orbit manufacturing of ultra-high-performance turbine blades or on-orbit repair (such as additive remanufacturing) of heat shields and other essential parts that could fail during a long-term mission, which would be much faster and cheaper compared to the traditional way since sending anything into orbit or beyond is very expansive, or even impossible for ultra-large-scale components. Methodology and Advantages The methodology and advantages of the present invention are illustrated inFIG.4. High-resolution and scalable hybrid additive-subtractive manufacturing is achieved by the integration of 3D printing with subtractive manufacturing, multi-material printing, and 2D additive manufacturing, resulting in heterogeneous structural precursors. During rapid heating by an induction heating technique or conventional heating by a resistance heating technique, shaping and material transformation can be observed in situ, leading to the in situ 4D printing of high-temperature materials, including ceramics, glasses, metals, diamonds, and composites (FIG.4a). Compared with prior methods, the present invention enables breakthroughs in material universality, geometrical flexibility, scalability, resolution, and speed of transformation into high-temperature materials (FIG.4b). The technique of the present invention can be applied to ceramic/glass/metal/diamond/composites, whereas most previous works on the additive manufacturing of high-temperature structural materials were applicable to only one type or two types of ceramic/glass/metal/diamond materials. Meanwhile, the present invention demonstrates 4D printing with non-contact stimuli, in contrast to other works of 4D printing with contact stimuli, 4D shaping with cast molding, printed origami with direct manual folding, and 3D printing only. Furthermore, the present invention can achieve large scalability (above 12 cm), high resolution (as high as 35 μm), and fast speed of transformation into high-temperature materials (in seconds). EXAMPLE Preparation of Materials For ceramic materials, the polymeric ceramic precursor with ceramic particles ink included poly(dimethylsiloxane) (PDMS, SE1700, Dow Corning) and ZrO2nanoparticles (20-50 nm, TONG LI TECH CO LTD). Either 10 wt % or 20 wt % ZrO2nanoparticles were added in liquid PDMS, and mixed by triple roller mills (EXAKT). Afterwards, the ink was poured into a syringe and centrifuged. For SiOC glass materials, an ink of liquid PDMS was poured into a syringe and centrifuged. For Fe alloy materials, an ink included iron powder (5-9 μm, Strem Chemicals, Inc.) and a cellulose binder (Shanghai Macklin Biochemical Co., Ltd.). The amount of iron powder was 70 wt %. Fe alloys were obtained by heating dried precursors to 800° C. for 2 hours, followed by cooling to ambient temperature in a resistance heating furnace with an argon flow of 200 mL min−1. The heating and cooling rates were 5° C. min−1and 10° C. min−1, respectively. For diamond materials, diamond particles (80 μm) were purchased from Tianjian Carbon Material Co., Ltd., China. Acrylic acid ammonium salt polymer (≥99%) was purchased from Kaima Biochemical Co., Ltd., China. Acrylamide (≥99%) was purchased from Sigma-Aldrich. 2-Hydroxy-2-methylpropiophenone (Irgacure 1173, ≥99%), and N,N′-Methylenebisacrylamide (Bis-acrylamide, ≥99%) were purchased from J&K Scientific. All materials were used as supplied. First, a 30 wt % acrylamide solution was prepared. Irgacure-1173, bis-acrylamide and acrylic acid ammonium salt polymer were then added, with their respective weights determined based on the desired diamond weight. The mixed slurry was stirred with a magnetic mixer (MS-H340-S4, DLAB, China) at 500 rpm for 10 minutes. After that, the slurry was poured into a printing syringe or a prefabricated silicone mold and irradiated by UV radiation with a wavelength of 365 nm for 30 minutes. The prepared diamond based composite samples (green bodies) were placed into an oven at 80° C. for 3 hours. Then the dry green bodies were heated to a predetermined temperature, based on the carbonization degree required, at a ramp rate of 5° C. min−1and left to dwell for 5 hours. Finally, they were cooled to room temperature still at a ramp rate of 5° C. min−1The entire sintering process was carried out in argon with a flow rate of 100 mL min−1. In Situ 4D Printing For the bending of heterogeneous ceramic precursors in the induction heating process with method 1, as shown inFIG.1a,FIG.3a, andFIG.3c,3D printing of solid precursors (22 mm×2 mm×0.8 mm) with the ink of PDMS/10 wt % ZrO2was conducted using a direct ink writing machine (Regenovo Biotechnology Co., Ltd.). The printed precursors were cured at 150° C. for 30 minutes in an oven. The cured precursors were laser-engraved to generate 11 evenly distributed grooves on their top surfaces with a CO2laser machining equipment (Epilog). The width of each groove was 1 mm, and their depths were 100, 200, 300, 400, and 500 μm. Then the samples were flipped and exposed with UV/ozone treatment for 8 hours. The heterogeneous ceramic precursors were heated to 1,300° C. within 12 minutes in an induction heating furnace with an argon flow of 200 mL min−1, followed by holding at 1,300° C. for 10 minutes. For the bending of heterogeneous ceramic/glass precursors in the induction heating process with method 2, as shown inFIG.1a,FIG.3b, andFIG.3d, solid precursors (30 mm×2 mm×0.4 mm) with the inks of glass precursor (pristine PDMS) and ceramic precursor (PDMS/10 wt % ZrO2or PDMS/20 wt % ZrO2) were 3D printed. The samples included two layers, and each layer with a height of 0.2 mm was printed with the glass or ceramic precursor. For the top sample inFIG.3e, the top and bottom layers of the corresponding heterogeneous precursor were pristine PDMS and PDMS/20 wt % ZrO2, respectively. For the bottom sample inFIG.3e, the top and bottom layers of the corresponding heterogeneous precursor were pristine PDMS and PDMS/10 wt % ZrO2, respectively. The printed precursors were cured at 150° C. for 30 minutes in an oven. The heterogeneous ceramic/glass precursors were heated to 1,300° C. within 12 minutes in an induction heating furnace with an argon flow of 200 mL min−1, followed by holding at 1,300° C. for 10 minutes. For the 4D printing of ceramic/glass composite saddle surfaces in the resistance heating process, as shown inFIG.3g, solid precursors (23 mm×23 mm×0.8 mm) with the ink of pristine PDMS were 3D printed and then cured as the middle layers of the heterogeneous precursors. Patterns with a height of 0.2 mm were printed and then cured on both the top and bottom surfaces of the prepared solid precursors with the ink of PDMS/20 wt % ZrO2, as shown inFIG.11a. The well-prepared heterogeneous ceramic/glass precursors were heated to 1,000° C. for 2 hours followed by cooling to ambient temperature under vacuum in a resistance heating furnace, at heating and cooling rates of 5° C. min−1and 10° C. min−1, respectively. For 4D printing and integrated shaping for the all-ceramic turbine blisk, as shown inFIG.3h, a sample of an engine turbine disc (6.4 mm in height; 40 mm and 16 mm in diameter for the outer and inner circles, respectively) with 12 blades (24 mm×9 mm×0.4 mm) was 3D printed. The surface of each blade was flat and intersected the ground at 45°. Then each blade was selectively exposed to UV/ozone treatment for 16 hours by masking the surface with a laser cut paper, as shown inFIG.11b. The heterogeneous ceramic precursors were heated to 1,000° C. for 2 hours, followed by cooling to ambient temperature under vacuum in a resistance heating furnace. The heating and cooling rates were 5° C. min−1and 10° C. min−1, respectively. Characterization Scanning electron microscopy (SEM, Nova-Nono430, FEI) was used to characterize the structures of Fe alloys, diamonds, and the UV/ozone film on the surface of ceramic precursors. The average composition of high-temperature materials was measured by EDS. Transmission electron microscopy (TEM, Titan Themis 200/Strata 400S, FEI) was used to characterize the amorphous-crystalline dual-phase structure of ceramics and amorphous structure of SiOC glass. Focused ion beam (FIB, 4505/talos F200, FEI) was used to prepare samples for TEM. The crystal structures of Fe alloys and diamonds were analyzed by X-ray diffraction (XRD, SmartLab, Rigaku). Optical profiler measurements (NPFLEX, Bruker) were applied on the laser-engraved samples to obtain the corresponding 3D morphology information. Tension tests (Testpilot-10, Wance) of precursors were performed with 3D printed solid samples (75 mm×10 mm×1 mm), and the displacement rate was 5 mm min−1Nanoindentation tests (Hysitron TI980, Bruker) were performed on the surface of UV/ozone film to obtain its modulus for the FEA simulation. To analyze the thermal decomposition process of the precursors, thermogravimetric analysis (TGA, Pyris 1 TGA, Perkin Elmer) and differential scanning calorimetry (DSC, Diamond DSC, Perkin Elmer) tests were performed at a heating rate of 106° C. min−1under a nitrogen flow of 50 mL min−1Thermal expansion tests (DIL402C, NETZSCH) of precursors were performed with 3D printed solid samples (20 mm×20 mm×4 mm), and the samples were heated to 300° C. at a heating rate of 5° C. min−1. Simulation Finite element analysis (FEA) was performed to explore the deformation behavior during thermal expansion or thermal shrinkage using the commercial software ABAQUS (2016). The UV/ozone film was modeled as elastic shells. The precursor and UV/ozone film were assumed to be an incompressible neo-Hookean material and elastic material, respectively. The mechanical properties and dimensions of the structures were consistent with the experimental measurements. The linear thermal expansion coefficients of pristine PDMS, PDMS/10 wt % ZrO2, and PDMS/20 wt % ZrO2before transforming into glass/ceramics were set as 303×10−6, 283×10−6, and 291×10−6° C.−1, respectively, according to thermal expansion tests inFIG.8c. The moduli of pristine PDMS, PDMS/10 wt % ZrO2, and PDMS/20 wt % ZrO2were set as 1.61 MPa, 1.14 MPa, and 1.56 MPa, respectively, according to tension tests inFIG.8d. The region of 0-10% strain in the loading process was applied to obtain the corresponding Young's modulus. The thickness of UV/ozone film with the exposure of 8 hours was set as 33 μm according to SEM results inFIG.9a, and its modulus was set as 13 MPa according to nanoindentation results inFIG.9b. The modulus of the equivalent film was calculated by assuming that the cross sections had the same tensile stiffness. The linear shrinkage values of pristine PDMS, PDMS/10 wt % ZrO2, and PDMS/20 wt % ZrO2during polymer-to-glass/ceramic transformations with induction heat treatment were set as 14%, 12%, and 11%, respectively, according to testing the results under the same conditions with heterogeneous samples inFIGS.3aand3b. The linear shrinkage values of pristine PDMS and PDMS/20 wt % ZrO2during polymer-to-glass/ceramic transformations with resistance heat treatment were set as 20% and 16%, respectively, according to the testing results under the same conditions with heterogeneous samples inFIG.3g. For method 1, the thermal expansion of precursors dominated the shape transformation. Thus, thermal expansion was only considered during simulations based on method 1. For method 2, since the thermal expansions of different precursors were very close, the thermal shrinkage dominated the shape transformation, and we neglected the effect of thermal expansion in FEA simulations. INDUSTRIAL APPLICABILITY The above-mentioned hybrid additive-subtractive manufacturing system may be utilized to develop rapid, precise, and scalable manufacturing of high-temperature materials, by increasing the 3D printing efficiency from line-by-line printing to sheet-by-sheet printing. With the further integration of hybrid manufacturing and origami/kirigami folding, an origami/kirigami-inspired 4D printing strategy would provide a new pathway towards complicated shaping of high-temperature materials. The possibility of developing precursors with shape memory behaviors and implementing control with different external stimuli (such as magnetic fields, pneumatic deformations, chemical reactions, or their combinations) for in situ 4D printing of high-temperature materials offers versatility in tackling the challenges of applying structural materials in various sophisticated and demanding working environments. Furthermore, attempts at improving the toughness of ceramic materials by heterogeneous engineering of the soft/rigid hybrid ceramic precursor/ceramic material systems could be anticipated in the future. While the present disclosure has been described and illustrated with reference to specific embodiments thereof, these descriptions and illustrations are not limiting. It should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the present disclosure as defined by the appended claims. The illustrations may not necessarily be drawn to scale. There may be distinctions between the artistic renditions in the present disclosure and the actual apparatus due to manufacturing processes and tolerances. There may be other embodiments of the present disclosure which are not specifically illustrated. The specification and the drawings are to be regarded as illustrative rather than restrictive. Modifications may be made to adapt a particular situation, material, composition of matter, method, or process to the objective, spirit and scope of the present disclosure. All such modifications are intended to be within the scope of the claims appended hereto. While the methods disclosed herein have been described with reference to particular operations performed in a particular order, it will be understood that these operations may be combined, sub-divided, or re-ordered to form an equivalent method without departing from the teachings of the present disclosure. Accordingly, unless specifically indicated herein, the order and grouping of the operations are not limitations. | 27,134 |
11858201 | DETAILED DESCRIPTION OF THE INVENTION FIG.1shows a step of a usual method for manufacturing a part made of composite material. Thus, the method consists in making a skein E by winding pre-impregnated fibers F on two axes A and B. Though theoretically the fibers are stretched between the two axes, in reality we observe an increase in thickness at the level of the axes A and B, and especially a transverse swelling in the median portion C and a filling of the space D between the axes A and B, associated with a folding of the fibers F in this area. Therefore, such a method does not permit to achieve the desired goal, namely that the fibers F are rectilinear, in order to be capable of being stressed not only in traction, but also in compression. As already mentioned, the term “fibers” is understood to mean all the forms in which the reinforcing fibers can be present, and namely, but non-restrictively, strands or cords of reinforcing fibers. When referring now toFIG.2, we can see a cross-section of a portion of a part P made by means of the method according to the invention. This part P includes a matrix M into which reinforcing fibers F are embedded. The method according to the invention consists in arranging the fibers F so that they are kept aligned, parallel to each other and especially perfectly rectilinear. To achieve this goal, the fibers are aligned and juxtaposed to form a layer, which is in turn covered with another layer. It should be noted that the terms “layer” and “superposition” are not restrictive, they do not involve a mandatory orientation, they are used for ease of understanding. InFIG.2, the portion of the composite part being shown includes three superimposed layers, C1, C2and C3of four fibers F (first layer fibers F1, second layer fibers F2, etc.) each. The layer C1is obtained by stretching four fibers F (first layer fibers F1) between return means, not shown, while keeping them spaced apart from each other. The layer C2is made on top of the layer C1, at a distance from the latter, and in the same way, namely by tensioning the fibers F between return means, and the same applies for layer C3. According to this embodiment, the distance between two successive layers is obtained by means of return means specific to each layer. After the construction of such a structure F3of fibers F, it is embedded into the matrix M, through various known means, such as, non-restrictively, dipping, molding, casting, infusion, spraying. When referring now toFIG.3, it can be seen that according to a variant of the method according to the invention, maintaining the distance between two successive layers can be achieved not through return means specific to each layer, but through depositing spacer elements E between each of them. The spacer means E can be of different types, they can consist, non-restrictively, of fibers arranged in a direction different from those of the layers C1, C2and C3, or of the resin, identical to the one the matrix M is comprised of. It should be noted that, for the purpose of automating the manufacturing method according to the invention, the spacer elements E can advantageously be deposited between each layer by means of an additive manufacturing method. When referring toFIG.4, we can see another variant of implementation of the method according to the invention, in which the particular positioning of the spacer elements E supporting the same layer C1, C2or C3of fibers F permits a shaping of each of these layers C1, C2or C3, so as to provide them for example with a curved shape. In the embodiment being shown, it should be noted that the spacer elements E can consist of fibers, while other spacer elements E′ are arranged both between the layers C1, C2or C3, and between the spacers E. FIG.5shows another variant of implementation of the method according to the invention. In this variant, F fibers, or more particularly strands, coated with a thermoplastic or thermosetting material are used so as to form around each of them a sheath G with a chosen thickness. When making the layers C1, C2and C3, the sheaths G permit to maintain the distance between the fibers F of the same layer, but also between the fibers of two successive layers. According to this variant, since maintaining the distance between the fibers is obtained by means of the sheaths G, then only remains to ensure the tension of the fibers. It is also possible to provide several fibers arranged in parallel and regularly spaced from each other two by two, the whole being surrounded by a single sheath forming spacer means. FIG.6shows the fiber structure F of a part V made of composite material, before the operation of associating the matrix M. The manufacture of this part V is similar to the method shown inFIG.4. Part V is made of the intersection of parallel walls L and N, where the walls L are flat, while the walls N are curved around a longitudinal axis perpendicular to the walls L. The walls L consist of the superposition of layers C1, C2. . . Cn, each formed of juxtaposed fibers F, kept apart from each other through their tension on return means R, in this case pins, while between each layer C1, C2. . . Cn is interposed a layer C′1, C′2. . . C′n of fibers F, spaced apart from each other, stretched over return means, not shown, permitting to perform, through a progressive offset, the curved shaping of the walls N. Irrespective of the mode of implementation of the method according to the invention, the desired goal is achieved, namely the straightness of the fibers, which allows optimum tensile as well as compressive strength. On the other hand, the method according to the invention is perfectly automatable, which constitutes another aim of the invention. | 5,763 |
11858202 | Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION Example embodiments will now be described more fully with reference to the accompanying drawings. The present disclosure, in the various embodiments discussed below, relates to systems and methods to control the thermal history of AM material by supplemental surface heating of the powdered material being built into a finished part. More particularly, the various embodiments and methodologies discussed below involve using a supplemental, wide area heating subsystem with a tailored intensity profile to heat the part either prior to, during or even after, fusing of the powder material takes place. In one embodiment a tailored intensity profile may be used with the supplemental heating subsystem. The supplemental heating reduces the thermal gradients present in the material as the powder being used to form the part is being fused by a primary heating system (e.g., fusing laser). The thermal history can be further controlled by ramping down the tailored (e.g., selected) heat/illumination provided by the supplemental heating subsystem over time to reduce the cooling rate of the material. The thermal control gained leads to better control over the formation of microstructure and residual stress in the finished part, rather than what may be achieved by just using a localized laser alone during the fusing of select portions of the powdered material to form the part. Controlling the thermal history of a metal during additive manufacturing in the localized fashion highlighted by this invention allows very close control over both the microstructural formation and the residual stresses in the completed part. Referring toFIG.1, a system10in accordance with one embodiment of the present disclosure is shown. The system10in this example may include a primary heat generating subsystem12, a supplemental heat generating subsystem14and a computer or electronic controller16(hereinafter simply “computer16”) for controlling the on/off operation and power levels applied by each of the primary and supplemental heat generating subsystems12and14, respectively. The primary heat generating subsystem12may be formed by a laser, for example a diode laser or any other form of laser suitable for melting powdered material in a laser powder bed fusion (LPBF) process. For convenience, the primary heat generating subsystem12will be referred to simply as the “primary laser subsystem12” throughout the following discussion. The supplemental heat generating subsystem14, in one example, is formed using a diode laser subsystem made up of four independent diode lasers14a-14demitting beams at a selected wavelength (e.g., in one example at λ=1007 nm). The supplemental heat generating subsystem14, which will be referred to simply as “supplemental heating subsystem14”, generates a wide area beam15′. The wide area beam15′ may be selected to illuminate the entire build area or just a selected portion of the build area. By the term “build area” it is meant the area on a build plate22where powder layer24, for example metal powder, may be deposited. In contrast, a fusing beam12aproduced by the primary laser subsystem12, which is used to perform the fusing of the powder layer24, may be a significantly smaller diameter beam than the wide area beam15′, and in some instances only 10% or less of the diameter of the wide area beam. In one example the wide area beam15′ may be a circle having a diameter of about 1.0″ while the fusing beam12amay have a diameter of only about 1 mm, or even less. These are only provided as examples, and the precise shape and/or diameter of the fusing beam12aand the shape and/or dimension of the wide area beam15′ will be selected to meet the needs of a specific application. The power level used for the wide area beam15′ may be any desired power level. More specifically, the power level and intensity profile of a build may be selected to best fit the specific needs of the application. This allows for full control of the thermal history of the build process. The computer16may include a memory18(which may also be an independent or external memory), which is preferably a non-volatile memory such as RAM, ROM, etc. The memory18may be used to store one or more algorithms20for controlling power levels applied by the primary laser subsystem12and/or controlling movement of the build plate22, or possibly even movement of primary laser subsystem12and/or movement of the supplemental heating subsystem14. The algorithms20may also include power control algorithms for controlling both the power (i.e., intensity) of the primary laser subsystem12and/or the supplemental heating subsystem14. If movement of the primary laser subsystem12and/or the supplemental heating subsystem14is needed, then suitable mechanisms will need to be incorporated to enable the highly controlled movement of the primary laser subsystem12and/or the supplemental heating subsystem14. It is expected that in most implementations, it will be preferable to control movement of the build plate22when forming the part, in which case a suitable mechanism (not shown) responsive to control signals from the computer16(or a different computer or controller/processor) may be used to move the build plate22. The system10may further incorporate a primary beam steering subsystem26, responsive to steering control signals from the computer16, for steering the fusing beam12aas needed to fuse selected portions (or even an entire area) of the powder layer24. The primary beam steering subsystem26may include mirrors or any suitable means for steering the fusing beam12a. For example, the system disclosed in U.S. Pat. No. 9,308,583 to El-Dasher et al., issued Apr. 12, 2016, and assigned to the assignee of the present disclosure, which is hereby incorporated by reference, may potentially be used in whole or in part to form the primary beam steering subsystem26. Primary laser subsystem12is also responsive to On/Off control signals from the computer16, as well as power control signals for controlling its power output. An electronically controllable mask28, responsive to control signals from the computer16(or a separate computer/processor), may be used to control the size (e.g., diameter) and/or shape of the wide area beam15′ as the wide area beam is used during formation of the part. The mask28may be as simple as a metal plate with a hole cut out or as sophisticated as an optically addressable light valve, akin to those manufactured by Meadowlark Optics of Frederick, Colorado. In either case, these masks act as a filter for the wide area laser, selectively allowing only a desired pattern to pass though and emit onto the build plate22at any given time. The system10may further incorporate a first focusing optic30for focusing the four independent beams from the diodes lasers14a-14dto a smaller beam15a. A mirror32may be used to turn the beam15aand direct it into a second focusing optic34, which further focuses the beam15ato produce smaller diameter beam15b. The beam15bis directed into a third focusing element36to focus the portions of the beam15bso the beam portions substantially fully overlap, and create an even small diameter beam15c. The beam15cis directed into a conventional beam homogenizer38that evens out the intensity of the15cfrom an uneven intensity (representative illustration40a) to a substantially uniform intensity (representative illustration40b) beam15d. A fourth focusing optic42may be used to enlarge the beam15dto a predetermined size or diameter to create beam15e. A fifth focusing optic44, if needed, may be used to further resize the beam15ebefore the beam is received by the mask subsystem28. The mask subsystem28may be responsive to mask sizing and/or shaping control signals from the computer16and may be used to control the size and/or shape of the beam15eto produce the wide area beam15′, which is used to provide the supplemental heating to all or just a select subportion(s) of the powder layer24. Optical components46a,46b,46cand46dmay be used to redirect the wide area beam15′ onto the build plate22. Enlarged window1ainFIG.1further illustrates that the wide area beam15′ may be redirected using a dichroic optic48through a window50onto the build plate22. The dichroic optic48allows the fusing beam12ato pass through without any interference onto the powder layer24disposed on the build plate22. The power level of the wide area beam15′ may be controlled by suitable control signals from the computer16, but the intensity of the wide area beam15′ is not sufficient to fuse the powder of the powder layer24. It will be appreciated that while in the embodiment illustrated inFIG.1, the supplemental heating subsystem14has the diode lasers14a-14doperating at a wavelength of λ=1007 nm and the primary laser subsystem12using a diode laser operating at λ=1078 nm, that the operating wavelengths need not be different, but could be the same. Furthermore, while the system10is shown with the fusing beam12aand the wide area beam15′ being coaxial, the two beams need not necessarily be coaxial. Additionally, using properly selected optics, the projection of the wide area beam15′ can be scaled to cover large areas, only requiring an adjustment in diode laser beam intensity to maintain an adequate flux at the site being illuminated. With total control of the intensity, location, and timing of the wide area beam15′, a user is given unprecedented control of the thermal history of the LPBF process. The localized nature of this heating method is more efficient than merely heating an entire build chamber or heating the build plate22. Enlarged window1bofFIG.1illustrates the mask subsystem28being used in two different ways: to project the wide area beam15′ onto a subportion of the powder layer24to provide supplemental heating, while the fusing beam12asimultaneously illuminates and fuses a much smaller portion of the powder layer24within the region being illuminated by the wide area beam15′. The enlarged window1bofFIG.1also shows the wide area beam15′ being used to pre-heat (or even post-heat) an area outside of the portion of the powder layer24that is being heated using the fusing beam12a. Accordingly, it will be appreciated that the supplemental heating of the powder layer24provided by the wide area beam15′ may be performed 1) prior to applying the fusing beam12ato the same portion of the powder layer24, or 2) simultaneously with application of the fusing beam12a, or 3) even after the fusing beam12ahas finished fusing a portion of the powder layer and has been moved to a different location of the powder layer. Optionally, it is also possible that the wide area beam15′ may be used in different ways on different portions of a given powder layer24. For example, one or more portions of the powder layer24may be illuminated simultaneously using both the fusing beam12aand the wide area beam15′, while one or more other areas of the same powder layer are either pre-heated or post-heated using the wide area beam15′. Or alternatively, application of the fusing beam12amay only partially overlap, in time, the application of the wide area beam15′ to a given section/portion of the powder layer24. Still further, the size of the wide area beam12′ and or its intensity (i.e., its power level) may be varied at different locations on a given powder layer24, and these factors may be controlled in connection with the pre-heating, the simultaneous heating, or the post-heating operations described above. In various embodiments, both pre-heating and a degree of post-heating may be performed, with the power level of the wide area beam15′ being ramped down over a predetermined time after the fusing beam12ahas finished a fusing operation, to thus reduce the cooling rate of the part. The desired structural characteristics of the part will dictate, at least in part, exactly how the wide area beam15′ is to be used. Referring toFIG.2, a flowchart100is shown illustrating high level operations that may be performed by the system10in creating a part from a quantity of powdered material (e.g., metal or plastic powdered material). At operation102the system10identifies an initial (or next) area of the powder layer24on the build plate22to be melted. At operation104the computer16may select at least one area of the powder layer24for pre-heating, simultaneous heating or post-heating, using the wide area beam15′. At operation106the wide area beam15′ may then be generated by turning on the supplemental heating subsystem14. Either before, simultaneously with, or subsequent to generating the wide area beam15′, the fusing beam12amay be generated using the primary laser subsystem12, as indicated at operation108. The fusing beam12amay be generated using a fixed or variable power level selected by the computer16, or it may simply use a predetermined, fixed power level. At operation110the mask subsystem28may be controlled to dimension the wide area beam15′ as needed and to heat one or more desired subportions (or even an entirety) of the powder layer24, at the selected power level. If a variable power level is incorporated into the system10, then the power level may be changed as needed by appropriate control signals from the computer16to the primary laser subsystem12. The fusing beam12amay be used at operation112, along with the primary beam steering subsystem26, to fuse one or more selected areas of the powder layer24(or even the entire powder layer), by using a designated power level. The fusing may be accomplished either shortly after the wide area beam15′ has been applied for a designated pre-heating time duration to a given area of the powder layer24, or simultaneously with the wide area beam15′ such that both the wide area beam15′ and the fusing beam12aare both acting on the same subportion of the powder layer24, or even prior to applying the wide area beam15′. At operation114, a check may be made by the computer16if all the layers of the part have been formed and, if not, at operation116a new powder layer24may be laid down over the just-formed layer, and then operations102-116repeated. Once the computer16detects that all layers of the part have been formed, the process ends. Referring toFIG.3, a graph200is shown to illustrate the reduction in residual stress of a stainless steel part made using the system10. Point202indicates the highest stress where no diode laser pre-heating was used. Point204indicates a significant reduction in the residual stress in the part when no pre-heating was applied, but an application of a five second ramp down of the wide area beam15′ was applied after the powder was fused. By “ramp down” it is meant the wide area beam15′ was applied at a selected intensity and then ramped down to zero over the designated time. Point206indicates a further reduction of the residual stress present in the part when two seconds of pre-heating and a five second ramp down heating signal were applied using the wide area beam15′. Point208indicates the residual stress level using no-preheating and a ten second ramp down application of the wide area beam15′. Lastly, point210indicates the stress level at a minimum when both two seconds of pre-heating and 10 seconds of ramped down post-heating was used. The various embodiments of the present disclosure thus disclose systems and methods for controlling the thermal history of AM material (e.g., powder, such as metal powder, plastic powder, etc.) by surface heating the material being built using a selected intensity profile from a supplemental heat source. The residual stresses and microstructure of the formed part can be altered by heating the underlying material with the selected intensity profile applied with the wide area beam15′ before, during or even after the fusing beam12amelts/heats the powdered material, thereby reducing the thermal gradients present in the material. The thermal history can be further controlled by ramping down the selected illumination intensity of the wide area beam15′ over a relatively short time (e.g., on the order of seconds or less) to reduce the cooling rate of the powdered material. This thermal control of the part as the part cools leads to significantly better control over the formation of microstructure and residual stress than what can be achieved using the fusing laser12aalone. The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. | 21,124 |
11858203 | DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS In accordance with the present invention, a device1for generative manufacturing of an object made up of a plurality of cross sections according to one exemplary embodiment is shown inFIG.1. The device includes an application unit2a, a curing unit30situated adjacent thereto and spatially separated, and a substrate20. Device1may optionally include a further application unit2bidentical to application unit2a. Application unit2bis situated spatially separated from both application unit2aand from curing unit30, preferably adjacent to curing unit30. Application unit2aincludes an application surface3aformed as a cylindrical drum. Application surface3ais electrostatically charged via an electrical charging unit4a. An exposure unit5amay expose application surface3aat points or at least in certain areas with the aid of a laser beam6a, which may be deflected in two dimensions, and thus eliminate an electrostatic charge on application surface3aat the exposed points. A two-dimensional structure, namely a reproduction of one of the cross sections of the object to be produced, may be reproduced on a charge distribution on application surface3ain this way. After the exposure by exposure unit5a, sinterable material9ais applied to application surface3aby a material supply7a. Sinterable material9amay be electrostatically chargeable in this case. Sinterable material9aonly adheres at the exposed points on application surface3a. An excess of sinterable material9amay be removed from application surface3aby a leveling unit designed as a doctor blade8a. The leveling unit may also, alternatively or additionally, be situated as a further doctor blade10a,10bspatially separated between application unit2aand curing unit30and/or between application unit2band curing unit30. Application surface3a, which is designed as a cylindrical drum, advantageously rotates away clockwise below the particular units in this case. The reproduction of a cross section of the object to be produced is transferred from application surface3ato substrate20. Substrate20is mounted by a substrate holder21, substrate holder21being movable by a drive22in all three spatial directions. To assist the transfer of the reproduction from application surface3ato substrate20, substrate20or substrate holder21may in turn be electrostatically charged by a further electrical charging unit4c. After the reproduction made of sinterable material9ahas been transferred to substrate20, substrate20is moved by drive22from a position below application unit2ato a position below curing unit30. Curing unit30includes a heating wire31, which heats up in such a way that the reproduction made of sinterable material9acures and solidifies on substrate20. In an alternative specific embodiment, it may be provided that the curing unit is designed as an optical curing unit. This may also be understood as an infrared light source, for example, which heats curable material91by irradiation using infrared light and thus cures it. The infrared light source may be designed as an infrared laser in this case. Furthermore, an optical curing unit may also be such that ultraviolet or visible laser light cross-links sinterable material9ain such a way that it cures and solidifies. After the curing of the reproduction made of sinterable material9aon substrate20, the next reproduction made of sinterable material9amay be transferred onto substrate20. This may again be carried out, for example, in application unit2a, in which application surface3awas charged, exposed, and provided with sinterable material9ain the meantime. Alternatively, this next step may also be carried out in further application unit2b. In this case, further application surface3bwas in the meantime charged via further charging unit4b, exposed by further exposure unit5band further laser beam6b, and provided with further sinterable material9bby further material supply7b. An excess of further sinterable material9bmay optionally have been removed by further doctor blade8bfrom further application surface3b. For this purpose, substrate20including substrate holder21was moved by drive22accordingly below application unit2aor below further application unit2b, for example, along an axis indicated by double arrow23in relation to application unit2a, further application unit2b, and curing unit30. After transfer of the further reproduction onto substrate20or onto the reproduction already provided on substrate20, substrate20is moved by drive unit22back to the position below curing unit30where further reproduction is cured and bonds to the underlying reproduction. As a function of a number of reproductions already transferred to the substrate, substrate holder21is moved together with substrate20by drive22perpendicularly in relation to axis23. This movement, indicated by double arrow24, is used to set a distance between substrate20or the reproductions already transferred to the substrate and application unit2a,2b. These steps of application and curing may be repeated in any order until the object or component to be produced is finished. The manufacturing speed of device1may be significantly increased by the presence of two application units2a,2band a curing unit30situated spatially separated therefrom. Depending on a rotational speed of application surface3a,3b, designed as a cylindrical drum, and a speed of drive22, for example, embodied as a high-agility axis system, very high application speeds may be achieved and thus the manufacturing speed of the method may be further increased. FIG.2shows a flow chart of a method100for generative manufacturing of an object made up of a plurality of cross sections. In an application step103, a sinterable material9a,9bis applied as a reproduction of one of the cross sections of the object to an application surface3a,3bby an application unit2aor a further application unit2b. Sinterable material9a,9bmay be provided in this case as a sinterable powder and/or as a sinterable liquid. Sinterable material9amay furthermore be electrostatically chargeable. In a following accommodation step, the reproduction is transferred from application surface2a,2bonto a substrate20. Substrate20may be electrostatically charged in this case. In a following movement step105, a relative movement takes place between substrate20and application unit2a,2band/or a curing unit30a, which is situated adjacent to application unit2aand further application unit2b. The relative movement takes place in such a way that substrate20having the reproduction made of sinterable material9a,9bis positioned at a position below curing unit30. In a following curing step106, curing of the reproduction made of sinterable material9a,9bon substrate20is carried out by curing unit30. It may optionally be provided that before the step of application103, a step of electrostatic charging101of application surface3aand/or further application surface3bis carried out by an electrical charging unit4a,4b. It may optionally be provided that after charging step101and before application step103, an exposure step102is carried out, during which an electrostatic charge on application surface3aand/or on further application surface3bis at least in certain areas eliminated by an exposure unit5a,5b, in order to electrostatically structure application surface3aand/or further application surface3b. Due to this electrostatic structuring, in the next step, namely application step103, sinterable material9a,9bis applied only at the points on application surface3aand/or further application surface3bat which the electrical charge was previously eliminated by exposure. After the step of curing106, a further movement step107may optionally be carried out, during which substrate20including substrate holder21is moved by drive22from the position below curing unit30to a position below application unit2aor further application unit2b, so that the method may be repeated until the reproduction of the last cross section of the object or component to be produced is applied and cured. FIG.3shows a schematic view of a control unit200, which is designed to carry out method100according to the exemplary embodiment fromFIG.2. Control unit200includes a processing unit201and a storage unit202. Furthermore, control unit200includes an input interface203, via which it has a signal connection to an external input unit205, designed as a computer, for example. The geometrical dimensions or data of the individual cross sections of an object to be produced may be transferred via external input unit205to processing unit201. These data may be buffered in storage unit202. Processing unit201computes therefrom, in consideration of pre-definable framework parameters, an instruction for how device1or application unit2a, further application unit2b, drive22, and/or curing unit30are to be activated. These data are provided or transferred from processing unit201via output interfaces204to the particular units. | 8,989 |
11858204 | In the Figures, like numbers refer to like objects throughout. Objects in the Figures are not necessarily drawn to scale. DETAILED DESCRIPTION OF EMBODIMENTS Various embodiments of the invention will now be described by means of the Figures. FIG.1shows a principal sketch of a first laser printing system100. The laser printing system100comprises two laser arrays110with semiconductor lasers115and an optical element170. The semiconductor lasers115are VCSELs which are provided on a semiconductor chip. In this case all VCSELs115of one array110are provided on one chip. The optical element170is an imaging lens with a focal distance f. The arrays110have a width D perpendicular to the plane of the drawings which is diffusely imaged to a working plane180by means of the imaging lens. The width d of the diffuse image of each array110with the width D in the working plane180defines the width of a pixel in the working plane180. The width of the pixels d is smaller than the width D of the respective array. The images of the arrays are thus demagnified. The distance b between the working plane180and the imaging lens or optical element170is bigger than the focal length f of the imaging lens. The optical element170or imaging lens defines together with the working plane180an object plane150in distance g bigger than the focal length of the imaging lens. The light emitting surfaces of the VCSELs115are not arranged in the object plane but behind the object plane in a distance such that no sharp projection of the light emitting surfaces of the VCSEL115is provided. The distance a between the light emitting layers of the VCSELs115and the object plane is chosen in a way that the laser light of at least two VCSEL115of one laser array110simultaneously illuminate an area element of a pixel.FIG.2shows the arrangement of a divergence angle of laser light emitted by one VCSEL115in relation to the object plane150in more detail. The divergence angle of the VCSELs115is given by an angle α as shown inFIG.2and defines the cone of laser light emitted by the single VCSEL115. The VCSELs115in the laser array110do have a distance p with respect to each other (pitch). The relation between pitch p and distance a has to fulfill the condition: a≥p*(tanα)−1 Laser light emitted by the VCSELs115of the laser array110overlap in the object plane150such that each area of the same size as the laser array110in the object plane150is illuminated by means of at least two VCSEL115. Each area element of the pixel defined by the pixel size d is consequently also illuminated via the imaging lens by means of at least two VCSELs115of the respective laser array110. The VCSELs of each laser array are driven in parallel and thus emit laser light at the same time. The size of the pixel is given by d=M*D, wherein the magnification M is given by M=b/g. The image of the laser array110in the working plane180is diffuse in order to increase the homogeneity of the energy input to the object in the working plane180and improve the reliability with respect to malfunctions of single VCSEL. The total distance between the laser arrays110of the laser module and the working plane180may be increased by means of a micro-lens array175which may be combined with the laser array110as shown inFIG.3. The micro-lens array175may be arranged between the laser array110and the object plane150in order to decrease the divergence angle α of each VCSEL115. The distance a and therefore the total distance to the working plane150has to be increased in order to fulfill the condition a≥p*(tanα)−1if the pitch of the VCSELs115remains the same. In an improvement of the condition discussed with respect toFIG.2may be achieved by taking into account an active diameter v of the VCSELs115in case of VCSELs115with circular aperture. The active diameter v corresponds to the diameter of the light emitting area of the active layer. The relation between active diameter v, pitch p and distance a has in this improved embodiment to fulfill the condition: a≥(p−v)*(2 tanα)−1. FIG.4shows a principal sketch of an arrangement of laser arrays110in a laser module of the laser printing system100. The laser or VCSEL arrays110are not quadratic but rectangular, with the long side of the rectangle being arranged in the direction of the movement of the object (seeFIG.5). This allows higher total powers per pixel, without reducing the resolution in the lateral direction. The VCSEL arrays110are further arranged in two columns which are slightly shifted with respect to each other (cascaded or staggered arrangement). This enables a defined overlap with respect to the illumination of area elements of the object if the object moves perpendicular to the direction of the columns of VCSELs. FIG.5shows a principal sketch of a first arrangement of laser modules of the laser printing system100. The laser modules comprise staggered or cascaded arrangements of laser arrays110as shown inFIG.4and an optical element170. The optical element170images all laser arrays110of the respective laser modules to the working plane180of the laser printing system100. The optical element170defines the total size Y of the laser module wherein the width of the arrangement of laser arrays110of the respective laser module defines the printing width y of one laser module. The laser modules are arranged in columns parallel to each other wherein each column is shifted such that a continuous area can be illuminated in the working plane180if the object moves in direction250relative to the laser modules. The printing area can thus be adapted to the size of the object in the working plane independent on the size Y and printing width y of the single laser module. The number of columns needed in order to continuously illuminate an object moving in the working plane180depends on the size Y and printing width y of the laser modules. The laser modules within one column are separated by at least by a distance Y such that at least N=Y/y columns are needed. The cascaded optical elements170may be fabricated as a single piece e.g. by glass molding. Alternatively, a lens array may be assembled from individual lenses by active or passive alignment. FIG.6shows a principal sketch of a second arrangement of laser modules of the laser printing system. The arrangement is quite similar to the arrangement discussed with respect toFIG.5. The laser arrays110of the laser modules are slanted (rotated around their center) with respect to a direction perpendicular to the direction of movement250of the object relative to the laser modules. This enables integrated intensity profiles with smooth slopes as shown inFIGS.7and8, which may also overlap with the adjacent pixels, to improve the homogeneity of the total intensity distribution, especially if the pixels are slightly misaligned with respect to each other. FIG.7shows an integrated intensity profile in a direction610perpendicular to the direction of movement250of the object relative to the laser modules with every second pixel off in the arrangement of laser modules shown inFIG.6. The pixel profile is almost triangular, with large slopes that overlap with the adjacent pixels.FIG.8shows an integrated intensity profile with an arbitrary pattern of on/off switched pixel in the arrangement of laser modules shown inFIG.6. The numbers “1” and “0” indicate which of the adjacent laser arrays110are switched on or off. The integrated intensity profile shows the overlap of two or more neighboring pixels in the working plane180. FIG.9shows a principal sketch of method steps of a method of laser printing. The shown sequence of steps does not necessarily imply the same sequence during execution of the method. Method steps may be executed in different order or in parallel. In step910the object like a sheet of paper is moved in the working plane of the laser printing system relative to the laser module. In step920laser light is emitted by means of the laser module comprising at least two laser arrays of semiconductor lasers and at least one optical element. In step930the laser light emitted by the laser arrays is imaged, such that laser light of semiconductor lasers of one laser array is imaged to one pixel in the working plane and an area element of the pixel is illuminated by means of at least two semiconductor lasers. The object may be moved and at the same time laser light of the laser arrays may be emitted and imaged to the working plane. When using individually addressable lasers or laser arrays, the maximum speed in the 3D printing process can be obtained when along a line all individual pixels can be written at the same time, i.e. by a separate laser or laser array per pixel. Typical line widths in a laser printing system or machine are in the order of 30 cm or more. On the other hand, the size or printing width of a laser module of individually addressable lasers or laser arrays is limited to a few cm. These laser modules correspond usually to one micro-channel cooler on which the laser modules are arranged. It is therefore necessary to use a number of laser modules and corresponding micro-channel coolers and to stack them together to a complete laser printing module or printing head. Alignment tolerances between neighboring micro-channel coolers with laser modules may result in a gap in the working plane180to which no or not sufficient laser light can be provided. In worst case such a gap leads to defects with respect to processing of the object as printed sheets of inferior quality or in the parts produced by means of a 3D printer/additive manufacturing machine. In view of the typical size of a laser light source116of 100 μm and the fact that several alignment tolerances add up together, the problem of a gap is a severe issue. Even with tight tolerances in each individual step of assembling the laser printing system, the overall tolerance chain can lead to significant deviations of 30 μm or more. It may be advantageous in this respect not only to provide overlapping intensity distributions but to use additional laser light sources116at the edge of each laser module. Said laser light sources116are so called overlap laser light sources117which are arranged such that the light of these overlap laser light sources117overlaps with light of laser light sources116of neighboring laser module. This means that the pitch between neighboring laser modules is smaller than the total printing width of the laser module by at least the width of one laser light source116(e.g. 100 μm). If the maximum tolerance from the mechanical/optical alignment of neighboring laser modules is smaller than the width of one laser light source116, it is sufficient to have—by design—an overlap of one laser light source116in order to avoid gaps in the working plane to which no laser light can be provided. Anyhow, it may alternatively be possible to provide more than one overlap laser light sources117if the maximum tolerance from the mechanical/optical alignment of neighboring laser modules is bigger than the width of one laser light source116. It may in this case be possible to use the overlap laser light sources117in accordance with the width of the gap between neighboring laser modules. The laser printing system may in this case be calibrated such that the overlap laser light sources117fill the unintended gap between the laser modules. Depending on the gaps and the width of one laser light source116it may be that one, two, three or even more of the overlap laser light sources117are used in order to enable a continuous, i.e. seamless illumination of the working plane. FIG.10shows an embodiment of such an arrangement with overlap laser light sources117which are arranged in an overlapping arrangement of neighboring laser modules which are laser sub-modules120in order to compensate potential misalignment of laser submodules120with respect to each other. The overlap laser light sources117are indicated by a line pattern. The printing width of neighboring laser sub-modules120overlap by a complete laser light source116or more explicit overlap laser light source117. A laser light source116may comprise different as the previous embodiments only a single laser or in accordance with the previous embodiments a laser array such as laser arrays110. The single lasers may comprise optical elements like micro-lenses. In case of laser arrays micro-lens arrays may be comprised. The arrangement of the laser sub-modules120is similar to the arrangement as shown inFIG.5. The laser modules shown inFIG.5are arranged such that each laser array110illuminates a dedicated pixel or area element in the working plane180. The laser sub-modules120as shown inFIG.10are arranged such that in case of no alignment errors during assembly the overlap laser light sources117are adapted such that they can illuminate the same area element in the working plane180as a laser light source116of a neighboring laser sub-module120. FIGS.11and12show schematically an embodiment of a 3D-laser printing system for additive manufacturing. Referring toFIG.11, the 3D-laser printing system includes a process chamber300with a support400for carrying building material and a three-dimensional article500to be built thereon. On the support400a building platform450may be provided which serves as a removable base for removing the three-dimensional article500after the building process is finished. It shall be noted that the building platform450may also be omitted. A boundary structure470, such as vertical walls, may be arranged around the support400to confine layers of the building material on the support400. The boundary structure may be arranged as a removable frame, which may include a vertically movable base which is removably attached to the support400, similarly to the building platform450. As illustrated inFIG.12, a building area480may be defined by the boundary structure470. The building area480may have a rectangular contour as shown inFIG.12or any other contour such as but not limited to a square-shaped or a circular contour. Above the support400, an illumination unit700is arranged. Preferably, the illumination unit700is movable across the building area480in a direction depicted by the arrow inFIG.12which is the direction of movement250in this embodiment. The illumination unit700may be configured to be moved back in an opposite direction. It may be switched on or switched off during the back movement. The support400is movable up and down relative to the illumination unit in a vertical direction, i.e. in a direction perpendicular to the direction of movement250of the illumination unit700. The support400is controlled in such a manner that an uppermost layer of the building material forms the working area180. The 3D-laser printing system further includes a control system800for controlling various functions of the 3D-printing system. A recoating device (not shown) may be provided to apply layers of building material onto the building platform450or the support400or the movable base of a removable frame (not shown). Furthermore, one or more separate heating device(s) (not shown) may be provided that may be used to heat an applied layer of building material to a process temperature and/or to control the temperature of the building material in the boundary structure470, if necessary. The building material preferably is a powder material that is configured to transform under the influence of the laser light emitted by the laser light sources into a coherent mass. The transformation may include, for example, melting or sintering and subsequent solidification and/or polymerization in the melt. Preferably, the building material is a plastic powder, for example a thermoplastic powder. Examples of such plastic powders are PA 12 (polyamide 12) or other polyamides, polyaryletheretherketone, such as PEEK or other polyetherketones. The powder may also be a powder from a metal or a metal alloy with or without a plastic or metal binder, or a ceramic or composite or other kind of powder. Generally, all powder materials that have the ability to transform into a coherent mass under the influence of the laser light emitted by the semiconductor lasers can be used. The building material may also be a paste-like material including a powder and an amount of liquid. Typical medium grain sizes of the powder lie between 10 μm or even less and 100 μm, measured using laser diffraction according to ISO 13320-1. Typical wave length of the laser light sources are preferably 980 or 808 nm in conjunction with absorbers (laser light absorbing additives to the powder material), e.g. but not limited to Carbon Black, suitable to enable a sufficient absorption of the chosen wave length. In principle any wavelength is possible as long as a suitable absorber material can be added to the powder material. Typical layer thicknesses of the powder layers may range between about 10 μm and about 300 μm, in particular for plastic powders, and about 1 μm up to about 100 μm, in particular for metal powders. The illumination unit700will be described more in detail with reference toFIG.11to13.FIG.13shows an arrangement of laser modules similar to that ofFIG.5with the difference that more than two columns and the demagnified image produced by the laser modules with the optical elements in the working plane180are shown.FIG.13shall not be considered as a perspective view but only as a schematic sketch depicting the arrangement of modules and the corresponding demagnified images. As schematically depicted inFIG.13, the illumination unit700includes a plurality of laser modules200arranged in columns perpendicular to the direction of movement250. Like inFIGS.5and6, the columns of the laser modules are staggered with respect to each other such that a first laser module2001of a first column c1of laser modules is adapted to illuminate a first area y1of the powder in the working plane180. The second module2002of a second column c2of laser modules is adapted to illuminate a second area y2of the powder in the working plane180, wherein the first area y1is adjacent to the second area y2such that continuous, i.e. seamless illumination of the object is enabled, By means of this, the illuminated areas y1, y2in the working plane180form a contiguous area in the direction perpendicular to the direction of movement. As further depicted inFIG.13, laser modules that are staggered in the direction of movement250form cascades. A first cascade k1is formed by the first laser modules2001,2002,200nof the columns A second cascade k2ist formed by the second laser modules2011,2012,201nof the columns and so on. The number of cascades is such that the sum of the individual printing widths y in a direction perpendicular to the direction of movement250covers the width of the building area480. For different 3D-laser printing systems having different building areas, the number of cascades can be easily adapted to cover the different widths of the respective building areas480. In a typical example of a 3D-laser printing system for additive manufacturing using VCSEL, as semiconductor lasers, one array may have several hundreds of semiconductor lasers, for example VCSELs, one module may include 2×16=32 arrays, one cascade may include 9 modules and the illumination unit may include several of those cascades, for example 3. This typically allows to illuminate a building area480of about 84 mm. Other building areas can be achieved by selecting appropriate numbers of modules per cascade and of cascades. As described above, one single optical element170is associated with one module and one module is preferably used to illuminate 16, 32 or 64 pixel in the working plane. Referring again toFIG.11, since the illumination unit700is arranged within the process chamber, it is exposed to the ambient conditions that exist in the process chamber300, such as the average temperature, temperature gradients, vapors, gas flows, such as inert gas flows, dust, splashes of molten material which could emerge from the building area, monomers emerging from the transformation process of the building material and moving around in the process chamber etc. A distance between the outermost optical element of the illumination unit700that is facing towards the building area and the working plane180may be in the range between about 5 mm to about 50 mm. This arrangement of the illumination unit700is different from the known laser-melting or laser-sintering machines. To protect the illumination unit700, a protective device750is arranged on a side of the illumination device700facing the support400. The protective device750may be realized by at least one plate that is transparent for the laser light. The transparent plate may be integrally formed with the illumination device700. In particular, the protective device750may be a glass plate. Moreover, the protective device750may be a single piece protecting all modules of the illumination unit700or may be composed of a plurality of pieces, one for each module. A distance between the outermost surface of the protective device and the working area may be only several millimeters, for example, about 5 mm. More generally, if a specific demagnification of n:1 is intended, a distance between the laser emitting portion of the semiconductor lasers and the outermost optical element (in the optical path) may be essentially about n times the distance between the outermost optical element and the working area180. Preferably, a temperature control device (not shown) is associated with the protective device750. The temperature control device may be realized in the form of a number of (i.e. one or more) heating elements. Preferably, the heating elements are arranged on the transparent plate, in particular only on such positions, where effectively no laser light is transmitted or where no laser light is intended to be transmitted. More preferably, the heating elements are provided on a side of the protective device750that faces away from the support400, i.e. that faces towards the laser light sources of the illumination unit700. This facilitates cleaning of the protective device and reduces abrasive wear of the heating elements. The heating elements may be in the form of heat conductive paths. In particular, the heating elements may be vapor-deposited or provided in the transparent plate during manufacturing of the protective device. In a further modification, the protective device750may include an assembly of two or more glass plates with vacuum or gas in-between the plates for thermal isolation. With such a design, a heat flow into the interior of the illumination unit700can be reduced or even prevented. In the case of an assembly of plates, the heating device may be provided at an inner side of one plate facing towards an adjacent plate, in particular of the outermost plate facing towards its adjacent plate. The temperature control device controls the temperature of the protective device750in such a manner that the temperature is adjusted to a specific temperature preferably in a range between around a few (preferably 10 at most, more preferred 5 at most and most preferred 3 at most) Kelvin below the process temperature to a few (preferably 10 at most, more preferred 5 at most and most preferred 3 at most) Kelvin above the process temperature. Due to the energy consumption and limited efficiency of the semiconductor lasers, the illumination unit700is cooled and preferably held at a temperature that can be considerably lower than the process temperature of the transformation process of the building material, depending on the building material used. Hence, heat loss by thermal radiation from the layers of building material to the illumination unit700is reduced or prevented. Moreover, the forming of condensates at the surface of the protection device750can be reduced or avoided. Those condensates would reduce the transparency of the glass plate/laser window/protective device and therefore would reduce the disturbance and/or the amount of absorbed laser light energy at the surface of the powder material. As a consequence, the quality of the three-dimensional articles to be built would be decreased. The temperature control device therefore ensures good quality of the three-dimensional articles to be built. The presence of the protective device750requires the image distance b, i.e. the distance between the optical element170and the working plane180(seeFIG.1), to be a certain minimum image distance. Due to the necessary demagnification, the object distance g, i.e. the distance between the object plane150and the optical element170, is relatively high. The divergence angle α of each VCSEL115results in the fact that the beam path of VCSEL-arrays of adjacent modules cross each other which renders a module-wise imaging onto the object plane150difficult. To avoid this, the illumination unit700includes micro lens arrays175as depicted inFIG.3for each module. Preferably, the laser arrays110of the modules200are arranged as depicted inFIG.14. In a further preferred embodiment, an optical element170associated with such an arrangement of the laser arrays110has a contour obtained from a circular or rotationally symmetrical contour, which is truncated on opposing sides and wherein the opposing sides1of the optical element170are aligned with respect to each other along an axis which is preferably orientated in a direction perpendicular to the direction of movement250. More precisely, in the case of the arrangement of the laser arrays as inFIG.14, the optical element170has the contour of a modified rectangle with two opposing circular segment-shaped short sides s that connect the parallel long sides1. This takes into account that a circular optical element would not be fully illuminated with the rectangular arrangement of the laser arrays as depicted inFIG.14. Hence, the portions of a circular optical element that are not fully illuminated can be omitted. By means of the shape of the optical element170, the size of a module in the direction of movement250can be reduced. As a result thereof, the size of the entire illumination unit700in the direction of movement250can be reduced. This has the advantage that a line oriented in the direction of movement can be illuminated within a reduced time which enhances the productivity of the whole 3D-printing system. Also, neighboring pixels at the border between one module2001and a neighboring module2002of one cascade k1and/or of one module200nof one cascade k1and a neighboring module2011of a neighboring cascade k2can be illuminated with reduced time offset. This also increases the quality of the three-dimensional article. The arrangement of the VCSELs in the laser array110defines the intensity profile. If the arrangement is substantially rectangular, i.e. the VCSELs are arranged in the array in rows and columns, the integrated intensity profile600of the array is substantially rectangular, i.e. the integrated intensity profile has a so-called “flat top” profile as depicted inFIG.16a. In a module according toFIG.4, where several arrays110are switched on and several arrays are switched off, the integrated intensity of the module in a direction610perpendicular to the direction of movement250is as shown inFIG.16b, i.e. has sharp edges (in the case that the object plane150is coincident with the active area of the semiconductor lasers). It may be desirable to have an integrated intensity profile without sharp edges. This can be achieved by an arrangement according toFIG.15, wherein the VCSELs in one array110arc positioned in rows and columns and wherein the outer contour of the array is substantially polygonal, in particular, substantially hexagonal. The individual VCSELs are positioned at grid points that are staggered from one column to the next column, wherein the columns are oriented perpendicular to the direction of movement250. Preferably, the outer contour of the array has a hexagonal shape with two opposing parallel sides p which extend perpendicular to the direction of movement250. As depicted inFIG.17a, the integrated intensity profile600of a laser array with a substantially hexagonal shape as shown inFIG.15, has rounded edges and is similar to a Gaussian intensity distribution. For a laser module with switched on/off arrays, the integrated intensity profile600along a direction610comprises rounded transitions as depicted inFIG.17b. Hence, deviations from an average value of intensity are smaller. With the illumination unit700, one pixel in the working area is illuminated by a multitude of semiconductor lasers of a laser array110at the same time. The total number of semiconductor lasers may be selected such that failure of less than a predetermined number of the semiconductor lasers reduces the output power of the laser array110only within a predetermined tolerance value. As a result thereof, the requirements with respect to the working life of the individual VCSELs may not be unusually high. The individual VCSELs of a laser array may be grouped in sub-groups with respect to their addressability by control signals. A sub-group may include at least two VCSELs. At least two sub-groups of VCSEL of one laser array may be individually addressable such that an output power, i.e. an intensity, of the laser array110is controllable by switching off one or more sub-groups of VCSEL. Also, an embodiment may be provided where the semiconductor lasers of one laser array are individually addressable so that an output power of the laser array may be controlled by switching on/off individual semiconductor lasers. In a further embodiment, the semiconductor lasers or the laser arrays of the illumination unit700can be further controlled such that a semiconductor laser or a laser array which is not used for illuminating can optionally be used for providing heat to the building material in the working plane180. To accomplish this, a control device is provided which controls the semiconductor lasers individually or the laser arrays in such a manner that the semiconductor lasers or a laser array which is not used for illuminating emits less intensity as required for transforming the building material so as to only heat the building material in the working plane. This heating can be used in addition to the separate heating device described above or as an exclusive heating system that pre-heats the building material to a working temperature. The illumination unit700may include overlap light sources117as explained with reference toFIG.10. The overlap light sources117are preferably provided at the border between one module of one column to a neighboring module of a neighboring column, for example module2001of column c1and module2002of column c2inFIG.13and/or from one module in one cascade to a neighboring module in a neighboring cascade, for example module200nin cascade k1and module2011in cascade k2inFIG.13. The overlap light source117balances the energy loss resulting from a time offset of adjacent pixels perpendicular to the direction of movement250due to the staggered arrangement of a module and/or due to the cascaded arrangement of the modules. The overlap light sources117can be controlled in such a manner that energy losses due to time offset and/or energy losses or energy excesses due to misalignment of VCSELs or arrays can be compensated. Hence, the sum of energy that is provided to the working area by overlap light sources117can be adjusted to be the energy necessary for illuminating in the case of time offset zero and/or perfectly aligned VCSELs or arrays. The energy provided by the overlapping VCSELs or arrays can be selected depending on the type of building material. Influencing factors may be the heat conductivity of the powder bed, the heat conductivity of the melt or the sintered mass, the particle size, etc. In a further modification, the semiconductor lasers of the illumination unit are realized by VECSELs (Vertical External Cavity Surface Emitting Laser). The 3D-printing system described above is operated as follows. Layers of the building material are successively deposited onto the support400or the building platform450or a previously illuminated layer such that the new layer of building material forms the working plane180. Then, the illumination unit700moves across the building area480in the direction of movement250and selectively illuminates the building material in the working area180at positions corresponding to the cross-section of the three-dimensional article in the respective layer. After one layer has been illuminated, the support is moved downward such that the new layer can form the working area180. While the invention has been illustrated and described in detail in the drawings and the foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. From reading the present disclosure, other modifications will be apparent to persons skilled in the art. Such modifications may involve other features which are already known in the art and which may be used instead of or in addition to features already described herein. Variations to the disclosed embodiments can be understood and effected by those skilled in the art, from a study of the drawings, the disclosure and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality of elements or steps. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope thereof. LIST OF REFERENCE NUMERALS 100laser printing system110laser array115semiconductor laser116laser light source117overlap laser light source120laser sub-module150object plane170optical element175micro-lens array180working plane200,2001,2002,200n2011,2012,201nlaser modules250direction of movement300process chamber400support450building platform470boundary structure480working area500three-dimensional article600integrated intensity610direction perpendicular to direction of movement700illumination unit750protective device800control unit910method step of the object920method step of emitting laser light930method step of imaging the laser light | 34,477 |
11858205 | DETAILED DESCRIPTION OF THE EMBODIMENTS The embodiments of this application provide composites with controllable superhydrophilic and superhydrophobic interface performances, comprising hydrophobic powder and/or hydrophilic powder and jointing phase powder, wherein the jointing phase powder is thermoplastic polymers. The composites with controllable superhydrophilic and superhydrophobic interface performances provided by this application are composed of the hydrophobic powder and the jointing phase powder, or composed of the hydrophilic powder and the jointing phase powder, or composed of the hydrophobic powder, the hydrophilic powder and the jointing phase powder. In these applications, the interface performances of the composites can be continuously changed from the superhydrophilicity to the superhydrophobicity by regulating the mass percentage of the hydrophobic powder, the hydrophilic powder and the jointing phase powder, achieving the controllable superhydrophilic and superhydrophobic performances. In some embodiments, the hydrophobic powders comprise at least one of polytetrafluoroethylene, polyvinylidene fluoride and hydrophobic fumed silica. In some embodiments, the hydrophilic powders comprise at least one of hydrophilic fumed silica, glass bead, copper oxide powder, aluminium oxide powder, calcium carbonate powder, titanium dioxide powder and magnesium oxide powder. In some embodiments, the thermoplastic polymer comprises at least one of polypropylene powder, polyethylene powder, polyinyl chloride powder, polystyrene powder, polycarbonate powder, epoxy resin powder, phenolic resin powder, polyamide powder and polysulfone powder. In some embodiments, the composites with controllable superhydrophilic and superhydrophobic interface performances comprise the following components in parts by weight: 0.001-5 parts of hydrophobic powder, 0.001-90 parts of hydrophilic powder and parts of jointing phase powder. In some embodiments, if the composites with controllable superhydrophilic and superhydrophobic interface performances comprise the hydrophilic powder and the jointing phase powder, the hydrophilic powder comprises at least one of hydrophilic fumed silica, hydrophilic glass bead and hydrophilic mica powder, wherein the particle size of hydrophilic fumed silica is 5-100 nm, the particle size of hydrophilic glass bead is 1-75 μm, and the particle size of hydrophilic mica powder is 0.5-90 μm. The jointing phase powder comprises at least one of hydrophilic phenolic resin and hydrophilic epoxy resin. The particle size of the jointing phase powder is 1-100 μm. The mass percentage of the hydrophilic powder in the composites with controllable superhydrophilic and superhydrophobic interface performances is 3-90%. Specifically, if the hydrophilic powder is just the hydrophilic fumed silica, the mass percentage of the hydrophilic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances is 3-6%; if the hydrophilic powder is just the hydrophilic glass bead, the mass percentage of the hydrophilic glass bead in the composites with controllable superhydrophilic and superhydrophobic interface performances is 60-90%; and if the hydrophilic powder is just the hydrophilic mica powder, the mass percentage of the hydrophilic mica powder in the composites with controllable superhydrophilic and superhydrophobic interface performances is 30-80%. In some embodiments, if the composites with controllable superhydrophilic and superhydrophobic interface performances comprise the hydrophobic powder and the jointing phase powder, the particle size of the jointing phase powder is 1-100 μm; the hydrophobic powder comprises at least one of hydrophobic fumed silica and polytetrafluoroethylene powder. The particle size of hydrophobic fumed silica is 5-100 nm, and the particle size of polytetrafluoroethylene powder is 1-80 μm. The mass percentage of hydrophobic powder in the composites with controllable superhydrophilic and superhydrophobic interface performances is 3-36%. Specifically, if the hydrophobic powder is just the hydrophobic fumed silica, the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances is 3-6%; and if the hydrophobic powder is just the polytetrafluoroethylene powder, the mass percentage of the polytetrafluoroethylene powder in the composites with controllable superhydrophilic and superhydrophobic interface performances is 15-30%. In some embodiments, if the composites with controllable superhydrophilic and superhydrophobic interface performances comprise the hydrophobic powder, the hydrophilic powder and the jointing phase powder, the particle sizes of the hydrophobic powder, the hydrophilic powder and the jointing phase powder are all 0.005-100 μm. Based on the same inventive concept, the embodiments of the present invention further provides a preparation method for the composites with controllable superhydrophilic and superhydrophobic interface performances, comprising the following steps: the hydrophobic powder and/or the hydrophilic powder and the jointing phase powder were uniformly mixed and stirred to obtain the composites with controllable superhydrophilic and superhydrophobic interface performances. Specifically, the hydrophobic powder and/or the hydrophilic powder and the jointing phase powder are put in a stirrer for stirring and mixing for 1-3 h at a speed of 200-500 r/min, and then mixed powder is sieved with a 50-70-mesh sieve net. The mixed powder can be used for 3D printing after being sieved with the 50-70-mesh sieve net, in order to avoid the particle aggregations. Based on the same inventive concept, the embodiment of the present invention further provides a 3D printing method, comprising the following steps: S1. The composites with controllable superhydrophilic and superhydrophobic interface performances are provided. S2. According to the 3D models of the to-be-manufactured printed parts, the selective laser sintering process is used to enable the composites with controllable superhydrophilic and superhydrophobic interface performances to be formed. Specifically, the 3D models of the to-be-manufactured printed parts are firstly constructed by using a drawing software and saved in a stl format. Then, the constructed 3D models are imported into the printing equipment. The prepared composites are filled into the powder supply cylinder of the printer. The printing parameters are adjusted to match with the filled composite powder. And finally, the to-be-manufactured printed part can be printed. In this application, the superhydrophobic or superhydrophilic components with stability and wear-resistance are prepared by configuring hydrophobic powder, hydrophilic powder and jointing phase powder of different weight fractions, which can meet the requirements of different wettability for different applications. Specifically, if the composites with controllable superhydrophilic and superhydrophobic interface performances comprise a mixture of the hydrophilic powder and the jointing phase powder, the hydrophilic powder is embedded into the gaps and surfaces of the jointing phase powder matrix material in the printing process, thereby endowing the formed parts with intrinsic and wear-resistant superhydrophilic performance. Even if the surfaces of the formed parts are strongly worn, the exposed parts still have the superhydrophilic performance. Specifically, if the composites with controllable superhydrophilic and superhydrophobic interface performances comprise the mixture of the hydrophobic powder and the jointing phase powder, and are printed layer by layer, the hydrophobic powder will be uniformly distributed in the gaps and on the surfaces of the jointing phase, thereby endowing the formed part with intrinsic superhydrophobic performance. Even if the surfaces of the formed parts are strongly worn, the exposed parts still have superhydrophobic performance. In some embodiments, if the composites with controllable superhydrophilic and superhydrophobic interface performances comprise the mixture of the hydrophobic powder, the hydrophilic powder and the jointing phase powder, the printing parameters are as follows: the laser power of 4-20 W, the scanning speed of 500-4000 mm/s, and the preheating temperature of 25-150° C. In some embodiments, a specific mode of selective laser sintering processing is as follows: slicing the established 3D model with a thickness of 0.1-0.2 mm layers and using laser to conduct selective regional processing layer-by-layer, in which the jointing phase is dissolved, and then rapidly cooled and cured. In some embodiments, when the composites with controllable superhydrophilic and superhydrophobic interface performances comprise the mixture of the hydrophilic powder and the jointing phase powder, if the hydrophilic powder is hydrophilic fumed silica, the printing power should increase 1-4 W when the mass percentage of the hydrophilic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances increase 0.8-1.2%; if the hydrophilic powder is hydrophilic glass bead, the printing power should increase 0.5-2 W when the mass percentage of the hydrophilic glass bead in the composites with controllable superhydrophilic and superhydrophobic interface performances increase 8-10%; and if the hydrophilic powder is hydrophilic mica powder, the printing power during forming should increase 0.5-2 W when the mass percentage of the hydrophilic mica powder in the composites with controllable superhydrophilic and superhydrophobic interface performances increase 4-6%. In some embodiments, if the composites with controllable superhydrophilic and superhydrophobic interface performances comprise the mixture of the hydrophobic powder and the jointing phase powder, the hydrophobic powder is hydrophobic fumed silica, the printing power should increase 3-6 W when the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances increase 0.8-1.2%; and if the hydrophobic powder is polytetrafluoroethylene powder, the printing power should increase 2-8 W when the mass percentage of the polytetrafluoroethylene powder in the composites with controllable superhydrophilic and superhydrophobic interface performances increase 4-6%. Based on the same inventive concept, the embodiment of the present invention further provides 3D printed parts, which are prepared by using the 3D printing method. Specifically,FIG.1is the diagram showing a 3D model of the to-be-manufactured printed part constructed by using a drawing software according to one embodiment, wherein the 3D model is a 3D shark model. FIG.2is the diagram showing a 3D model of the to-be-manufactured printed part constructed by using a drawing software according to another embodiment, wherein the 3D model is a 3D porous spiral model. FIG.3is the schematic diagram of a 3D model of the to-be-manufactured printed part constructed by using a drawing software according to another embodiment of the present invention, wherein the 3D model is flower-like shape. FIG.4is the schematic diagram of a 3D model of the to-be-manufactured printed part constructed by using a drawing software according to another embodiment of the present invention, wherein the 3D model is a 3D airplane model. The composites with controllable superhydrophilic and superhydrophobic interface performances and the 3D printing method of this application will be further described in the following specific embodiments. This portion describes the content of the present invention in combination with the specific embodiments, but should not be understood as limiting of the present invention. Unless specifically stated otherwise, the technical means used in the embodiments are conventional means familiar to those skilled in the arts. Embodiment 1 The embodiment of this application provides composites with controllable hydrophilic and hydrophobic performances, comprising the following raw materials: hydrophobic powder, hydrophilic powder and jointing phase powder. The hydrophobic powder selected hydrophobic fumed silica (purchased from Evonik Industries AG). The hydrophilic powder selected hydrophilic glass beads (purchased from Yuefeng Grinding Co., Ltd.). The jointing phase powder selected polypropylene (purchased from Wanhua Group Co., Ltd.). And the particle size of the hydrophobic fumed silica was ˜35 nm, the particle sizes of the hydrophilic glass beads and the polypropylene were ˜30 μm. Specifically, the masses of the hydrophobic fumed silica, the hydrophilic glass beads and the polypropylene are shown in Table 1. TABLE 1Masses of hydrophobic fumed silica,hydrophilic glass beads and polypropyleneMass percentage ofMass ofMass ofhydrophobic fumedMass ofhydrophobichydrophilicsilica in compositepolypropylenefumed silicaglass beads0.9 wt %582 g18 g1400 g1.2 wt %576 g24 g1400 g The preparation method for the composites with controllable superhydrophilic and superhydrophobic interface performances comprises the following steps: the hydrophobic fumed silica, the hydrophilic glass beads and the polypropylene were put in a stirrer for stirring and mixing for 2 h at 300 r/min; and the obtained mixture was sieved with a 60-mesh sieve to obtain the composites with controllable superhydrophilic and superhydrophobic interface performances. The embodiment of the present invention further provides a 3D printing method, comprising the following step: S1. Providing the composites with controllable superhydrophilic and superhydrophobic interface performances of the embodiment 1; S2. According to the 3D model for the to-be-manufactured printed part (in this embodiment, the 3D model used is the model shown inFIG.1), the composites with controllable superhydrophilic and superhydrophobic interface performances were formed by an SLS 3D printing process. Specifically, when the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances is 0.9 wt %, the printing parameters are as follows: the preheating temperature of 100° C., the laser power of 15 W, the laser scanning velocity of 1000 mm/s, the scanning interval of 0.1 mm, and the layer thickness of 0.1 mm. When the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances is 1.2 wt %, the laser scanning power is increased to 19 W without changing other printing parameters. The printed part requires to be naturally cooled for 3 h before being taken out. FIGS.5-6are the diagrams showing the hydrophobic performance of water droplets on the printed parts obtained in embodiment 1, wherein the corresponding mass percentages of the hydrophobic fumed silica in the composite ofFIG.5andFIG.6are 0.9 wt % and 1.2 wt %, respectively. InFIGS.5-6, the contact angles of the water droplets on the printed sample are ˜152° and ˜156°, respectively. Specifically, the testing method for the hydrophobic performance comprise the following steps: 5 μL of water droplets were added on the surface of the printed sample, the contact angles of the water droplets were recorded by the contact angle instrument. The printed sample was then subjected to a wear-resistance test, which was put on a sandpaper with 180 meshes, followed by placing a 100 g weight on the printed sample, moving the printed sample horizontally back and forth 10 cm as one cycle. The contact angles after different friction cycles were tested, as shown inFIG.7. Embodiment 2 The embodiment of this application provides composites with controllable superhydrophilic and superhydrophobic interface performances, comprising the following raw materials: hydrophobic powder, hydrophilic powder and jointing phase powder. The hydrophobic powder selected hydrophobic fumed silica. The hydrophilic powder selected hydrophilic glass beads (purchased from Yuefeng Grinding Co., Ltd.). The jointing phase powder selected phenolic resin (purchased from Wanhua Group Co., Ltd.). The particle sizes of the hydrophobic fumed silica (purchased from Evonik Industries AG), the hydrophilic glass beads and the phenolic resin were ˜35 nm, ˜30 μm and ˜30 μm, respectively. Specifically, the masses of the hydrophobic fumed silica, the hydrophilic glass beads and the phenolic resin are shown in Table 2. TABLE 2Masses of hydrophobic fumed silica,hydrophilic glass beads and phenolic resinMass percentage ofMass ofMass ofMass ofhydrophobic fumedphenolichydrophobichydrophilicsilica in compositeresinfumed silicaglass beads3 wt %340 g60 g1600 g4 wt %320 g80 g1600 g The preparation method for the composites with controllable superhydrophilic and superhydrophobic interface performances comprises the following steps: the hydrophobic fumed silica, the hydrophilic glass beads and the phenolic resin were put in a stirrer for stirring and mixing for2h at500r/min, and the mixture was sieved with a60-mesh sieve to obtain the composites. The embodiment of the present invention further provides a 3D printing method, comprising the following step: S1. The composites with controllable superhydrophilic and superhydrophobic interface performances according to embodiment 2 was provided. S2. According to the 3D model for the to-be-manufactured printed part (in this embodiment, the 3D model used is the model shown inFIG.2), the selective laser sintering process was used to enable the composites with controllable superhydrophilic and superhydrophobic interface performances to be formed. Specifically, when the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances is 3 wt %, the printing parameters are as follows: the preheating temperature of 70° C., the laser power of 13 W, the laser scan velocity of 3000 mm/s, the scanning interval of 0.1 mm, and the layer thickness of 0.1 mm. When the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances is 4 wt %, the laser power increases to 14 W without changing other printing parameters. When the printing process completes, the printed parts require to be naturally cooled for 1 h before being taken out. FIGS.8-9are the diagrams showing the hydrophobic performance of water droplets on the printed parts obtained in embodiment 2, wherein the corresponding mass percentages of the hydrophobic fumed silica in the composites are 3 wt % and 6 wt %, respectively. The contact angles of water droplets on the printed parts inFIGS.8-9are 153° and 161°, respectively. The printed sample was then subjected to a wear-resistance test, which was put on a sandpaper with 180 meshes, followed by placing a 100 g weight on the printed sample, moving the printed sample horizontally back and forth 10 cm as one cycle. The contact angles after different abrasion cycles were tested, as shown inFIG.7. Embodiment 3 The embodiment of this application provides composites with controllable superhydrophilic and superhydrophobic interface performances, comprising the following raw materials: hydrophobic powder, hydrophilic powder and jointing phase powder. The hydrophobic powder selected hydrophobic fumed silica. The hydrophilic powder selected hydrophilic calcium carbonate (purchased from Wanhua Group Co., Ltd.). The jointing phase powder selected epoxy resin (purchased from Wanhua Group Co., Ltd.). The particle sizes of the hydrophobic fumed silica (purchased from Evonik Industries AG), the hydrophilic calcium carbonate and the epoxy resin were ˜35 nm, ˜30 μm and ˜30 μm, respectively. Specifically, the masses of the hydrophobic fumed silica, the hydrophilic calcium carbonate and the epoxy resin are shown in Table 3. TABLE 3Masses of hydrophobic fumed silica,hydrophilic calcium carbonate and epoxy resinMass percentage ofMass ofMass ofMass ofhydrophobic fumedepoxyhydrophobichydrophilicsilica in compositeresinfumed silicacalcium carbonate0.8 wt %600 g16 g1400 g1.2 wt %1900 g24 g1400 g The preparation method for the composites with controllable superhydrophilic and superhydrophobic interface performances comprises the following steps: the hydrophobic fumed silica, the hydrophilic calcium carbonate and the epoxy resin were put in a stirrer for stirring and mixing for 1 h at 200 r/min, and the mixture was sieved with a 60-mesh sieve to obtain the composites. The embodiment of the present invention further provides a 3D printing method, comprising the following step: S1. The composites with controllable superhydrophilic and superhydrophobic interface performances according to embodiment 3 was provided; S2. According to the 3D model for the to-be-manufactured printed part (in this embodiment, the 3D model used is the model shown inFIG.1), the selective laser sintering process was used to enable the composites with controllable superhydrophilic and superhydrophobic interface performances to be formed. Specifically, when the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances is 0.8 wt %, the printing parameters are as follows: the preheating temperature of 60° C., the laser power of 12 W, the laser scan velocity of 1000 mm/s, the scanning interval of 0.1 mm, and the layer thickness of 0.1 mm. When the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances changes to 1.2 wt %, the laser scanning power increases to 14 W without changing other printing parameters. When the printing process completes, the printed parts require to be naturally cooled for 1 h before being taken out. FIGS.10-11are diagrams showing the hydrophobic performance of water droplets on the printed part obtained in embodiment 3, wherein the corresponding mass percentage of the hydrophobic fumed silica are 0.8 wt % and 1.2 wt %, respectively. The contact angles of water droplets on the printed part inFIGS.10-11are 155° and 162°, respectively. The printed sample was then subjected to a wear-resistance test, which was put on a sandpaper with 180 meshes, followed by placing a 100 g weight on the printed sample, moving the printed sample horizontally back and forth 10 cm as one cycle. The change of the contact angles after different abrasion cycles were tested, as shown inFIG.7. Embodiment 4 The embodiment of this application provides the composites with controllable superhydrophilic and superhydrophobic interface performances, comprising the following raw materials: hydrophobic powder, hydrophilic powder and jointing phase powder. The hydrophobic powder selected hydrophobic fumed silica. The hydrophilic powder selected hydrophilic glass beads (purchased from Yuefeng Grinding Co., Ltd.). The jointing phase powder selected phenolic resin (purchased from Wanhua Group Co., Ltd.). The particle sizes of the hydrophobic fumed silica (purchased from Evonik Industries AG), the hydrophilic glass beads and the phenolic resin were ˜35 nm, ·30 μm and ˜30 μm, respectively. Specifically, the masses of the hydrophobic fumed silica, the hydrophilic glass beads and the phenolic resin are shown in Table 4. TABLE 4Masses of hydrophobic fumed silica,hydrophilic glass beads and phenolic resinMass percentage ofMass ofMass ofMass ofhydrophobic fumedphenolichydrophobichydrophilicsilica in compositeresinfumed silicaglass beads0.1 wt %392 g2 g1600 g0.5 wt %390 g10 g1600 g0.6 wt %388 g12 g1600 g The preparation method for the composites with controllable superhydrophilic and superhydrophobic interface performances comprises the following steps: the hydrophobic fumed silica, the hydrophilic glass beads and the phenolic resin were put in a stirrer for stirring and mixing for 3 h at 400 r/min, and the mixture was sieved with a 60-mesh sieve to obtain the composites. The embodiment of the present invention further provides a 3D printing method, comprising the following step: S1. The composites with controllable superhydrophilic and superhydrophobic interface performances according to embodiment 4 was provided; S2. According to the 3D model for the to-be-manufactured printed part (in this embodiment, the used 3D model is the model shown inFIG.2), the selective laser sintering process was used to enable the composites with controllable superhydrophilic and superhydrophobic interface performances to be formed. Specifically, when the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances is 0.1 wt %, the printing parameters are as follows: the preheating temperature of 60° C., the laser power of 6 W, the laser scan velocity of 1000 mm/s, the scanning interval of 0.1 mm, and the layer thickness of 0.1 mm. When the mass percentages of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances change to 0.5 wt % and 0.6 wt %, the laser scanning powers should increase to 8 W and 9 W, respectively. When the printing process completes, the printed parts require to be naturally cooled for 1 h before being taken out. FIGS.12-14are the diagrams showing the wettability performance of water droplets on the printed parts obtained in embodiment 4, wherein the corresponding mass percentages of the hydrophobic fumed silica are 0.1 wt %, 0.5 wt % and 0.6 wt %, respectively. The contact angles of the water droplets on the printed parts inFIGS.12-14are 0°, 109° and 122°, respectively. The printed sample was then subjected to a wear-resistance test, which was put on a sandpaper with 180 meshes, followed by placing a 100 g weight on the printed sample, moving the printed sample horizontally back and forth 10 cm as one cycle. The change of the contact angles after different abrasion cycles were tested, as shown inFIG.7. Embodiment 5 The embodiment of this application provides the composites with controllable superhydrophilic and superhydrophobic interface performances, comprising the following raw materials: hydrophobic powder, hydrophilic powder and jointing phase powder. The hydrophobic powder selected hydrophobic fumed silica. The hydrophilic powder selected hydrophilic glass beads (purchased from Yuefeng Grinding Co., Ltd.). The jointing phase powder selected epoxy resin (purchased from Wanhua Group Co., Ltd.). The particle sizes of the hydrophobic fumed silica (purchased from Evonik Industries AG), the hydrophilic glass beads and the epoxy resin were ˜35 nm, ˜30 μm and ˜30 μm, respectively. Specifically, the masses of the hydrophobic fumed silica, the hydrophilic glass beads and the epoxy resin are shown in Table 5. TABLE 5Masses of hydrophobic fumed silica,hydrophilic glass beads and epoxy resinMass percentage ofMass ofMass ofMass ofhydrophobic fumedepoxyhydrophobichydrophilicsilica in compositeresinfumed silicaglass beads0.1 wt %592 g2 g1400 g0.5 wt %590 g10 g1400 g0.6 wt %588 g12 g1400 g The preparation method for the composites with controllable superhydrophilic and superhydrophobic interface performances comprises the following steps: the hydrophobic fumed silica, the hydrophilic glass beads and the epoxy resin were put in a stirrer for stirring and mixing for 3 h at 300 r/min, and the mixture was sieved with a 60-mesh sieve to obtain the composites. The embodiment of the present invention further provides a 3D printing method, comprising the following step: S1. The composites with controllable superhydrophilic and superhydrophobic interface performances according to embodiment 5 was provided. S2. According to the 3D model for the to-be-manufactured printed part (in this embodiment, the 3D model used is the model shown inFIG.1), the selective laser sintering process was used to enable the composites with controllable superhydrophilic and superhydrophobic interface performances to be formed. Specifically, when the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances is 0.1 wt %, the printing parameters are as follows: the preheating temperature of 60° C., the laser power of 10 W, the laser scan velocity of 1000 mm/s, the scanning interval of 0.1 mm, and the layer thickness of 0.1 mm. When the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances turn to 0.5 wt % and 0.6 wt %, the laser scanning power increases to 12 W and 13 W, respectively. When the printing process completes, the printed parts require to be naturally cooled for 1 h before being taken out. FIGS.15-17are diagrams showing the hydrophobic performance of water droplets on the printed part obtained in embodiment 5, wherein the corresponding mass percentages of the hydrophobic fumed silica in the composite are 0.1 wt %, 0.5 wt % and 0.6 wt %, respectively. The contact angles of the water droplets on the printed part inFIGS.15-17, are 0°, 112° and 132°, respectively. The printed sample was then subjected to a wear-resistance test, which was put on a sandpaper with 180 meshes, followed by placing a 100 g weight on the printed sample, moving the printed sample horizontally back and forth 10 cm as one cycle. The change of the contact angles after different abrasion cycles were tested, as shown inFIG.7. Embodiment 6 The embodiment of this application provides composites with controllable superhydrophilic and superhydrophobic interface performances, comprising the following raw materials: hydrophilic powder and jointing phase powder. The jointing phase powder selected hydrophilic phenolic resin (purchased from Henan Borun New Material Co., Ltd.). The hydrophilic powder selected hydrophilic glass beads (purchased from Yuefeng Grinding Co., Ltd.). The average particle sizes of the hydrophilic glass beads and the hydrophilic phenolic resin were ˜38 μm and ˜30 μm, respectively. Specifically, the masses of the hydrophilic glass beads and the hydrophilic phenolic resin are shown in Table 6. TABLE 6Masses of hydrophilic glass beads and hydrophilic phenolic resinMass percentage ofMass ofMass ofglass beads inhydrophilichydrophilicthe compositesphenolic resinglass beads60 wt %2000 g3000 g70 wt %1500 g3500 g80 wt %1000 g4000 g90 wt %500 g4500 g The preparation method for the composites with controllable superhydrophilic and superhydrophobic interface performances comprises the following steps: the hydrophilic glass beads and the hydrophilic phenolic resin were put in a ball mixer to be uniformly mixed at 400-800 r/min, and then sieved with a 80-mesh sieve to obtain the composites. The embodiment of this application further provides a 3D printing method, comprising the following steps: S1. The composites with controllable superhydrophilic and superhydrophobic interface performances according to embodiment 6 were provided; S2. According to the 3D model for the to-be-manufactured printed part inFIG.3, the selective laser sintering process was used to enable the composites with controllable superhydrophilic and superhydrophobic interface performances to be formed. Specifically, when the mass percentage of the hydrophilic glass beads in the composites with controllable superhydrophilic and superhydrophobic interface performances is 60 wt %, the printing parameters are as follows: the preheating temperature of 70° C., the laser power of 5 W, the laser scan velocity of 1000 mm/s, the scanning interval of 0.1 mm and the layer thickness of 0.1 mm. When the mass percentage of the hydrophilic glass beads in the composites with controllable superhydrophilic and superhydrophobic interface performances increase to 70 wt %, 80 wt % and 90 wt %, the laser scanning power needs to increase to 5.5 W, 6 W and 6.5 W, respectively. When the printing process completes, the printed parts require to be naturally cooled for 1 h before being taken out. FIG.18shows the test chart of time-sequenced contact angles of a water droplet on the surface of a printed part (the mass percentage of glass beads is 80 wt %) obtained in embodiment 6. The final contact angle of the water drops on the surface of the printed part is 0°. Specifically, the test method of water contact angle in air comprises the following steps: 5 μL water droplet is added onto the sample surface, and the change of water contact angles on the sample surface was recorded with a contact angle meter. FIG.19shows the underwater contact angle of carbon tetrachloride on the printed part (the mass percentage of glass beads is 80 wt %) obtained in embodiment 6. Underwater test comprises the following steps: the printed part is placed underwater, and then 5 μL carbon tetrachloride is added onto the printed part.FIG.19shows that the contact angle of carbon tetrachloride under water is 156±3°, which indicates that the printed part prepared by the invention has good underwater oleophobic performance. FIG.20is the schematic diagram of the relationship between the polishing cycles with flocking sandpaper (the mass percentage of glass beads is 80 wt %) and the contact angle of water droplets on the surface of the printed part.FIG.20shows that the superhydrophilic part prepared by the present invention has excellent wear resistance. The contact angle is still 0° after being polished with flocking sandpaper for 1000 times. Embodiment 7 The embodiment of this application provides composites with controllable superhydrophilic and superhydrophobic interface performances, comprising the following raw materials: hydrophobic powder and jointing phase powder. The jointing phase powder selected polypropylene (purchased from Wanhua Chemical Group Co., Ltd.). The hydrophobic powder selected hydrophobic fumed silica (purchased from Evonik Industries AG). The average particle sizes of the polypropylene and the hydrophobic fumed silica were ˜50 μm and ˜35 nm, respectively. Specifically, the masses of the polypropylene and the hydrophobic fumed silica are shown in Table 7. TABLE 7Masses of polypropylene and hydrophobic fumed silicaMass percentage ofMassMass ofhydrophobic fumedofhydrophobicsilica in compositepolypropylenefumed silica4 wt %1920 g80 g5 wt %1900 g100 g6 wt %1880 g120 g The preparation method for the composites with controllable superhydrophilic and superhydrophobic interface performances comprise the following steps: the polypropylene and the hydrophobic fumed silica were put in a ball mixer to be uniformly mixed at 400-800 r/min, and the mixture was sieved with a 80-mesh sieve to obtain the composites. The embodiment of this application further provides a 3D printing method, comprising the following steps: S1. The composites with controllable superhydrophilic and superhydrophobic interface performances according to embodiment 7 were provided; S2. According to the 3D model for the to-be-manufactured printed part inFIG.4, the selective laser sintering process was used to enable the composites with controllable superhydrophilic and superhydrophobic interface performances to be formed. Specifically, when the mass percentage of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances is 4 wt %, the printing parameters are as follows: the preheating temperature of 130° C., the laser power of 23 W, the laser scan velocity of 4000 mm/s, the scanning interval of 0.1 mm and the layer thickness of 0.1 mm. When the mass percentages of the hydrophobic fumed silica in the composites with controllable superhydrophilic and superhydrophobic interface performances increase to 5 and 6 wt %, the laser scanning powers need to increase to 26 W and 29 W, respectively. When the printing process completes, the printed parts require to be naturally cooled for 1 h before being taken out. FIG.21is the diagram of water contact angle and sliding angle on the printed part (the mass percentage of the hydrophobic fumed silica is 4%) obtained in embodiment 7, which has a contact angle of 158-162° and a roll angle of 5-8°. The contact angle and the roll angle were tested in air environment, wherein the contact angle was recorded by adding 5 μL of water droplet on the surface of the printed part, while the sliding angle is recorded by adding 10 μL of water droplet on the surface of the printed part. FIG.22is the statistical diagram of water contact angles on the printed part in embodiment 7 after the 50th, 100th, 200th, 400th, 600th, 800thand 1000thabrasion tests. The superhydrophobic printed part prepared by the present invention has excellent wear resistance, and the contact angle remains still ˜155° after 1000thabrasion tests. | 37,100 |
11858206 | DETAILED DESCRIPTION During a recoating process, a quantity of powder is deposited on one end of a build surface and then a recoater blade is pulled across the surface at a set height above the previous build layer. As the blade is pulled across the surface, the powder is pushed in front of the blade and only a thin layer of the powder is left behind after the blade passes. The thickness of this layer is set by the height of the blade above the previously processed layer and may be in the range of about 20 micrometers (μm) to 500 μm thick. However, the Inventors have recognized that one of the issues with using a solid blade recoating system is the interaction between the previously printed layer and the recoater blade. In some cases, defects formed in a previously printed layer may protrude up past the top of the nominal print height. If these defects extend up far enough, the defects may contact the recoater blade as it travels across the next build plane. This contact between the recoater blade and defects on a build surface may have different effects on the recoating process and subsequent build layers including, but not limited to: layer deformation, delamination and/or deformation of the printed part; pulling a printed part completely off a build plate; permanent damage to the recoater blade such as a nick or cut in the blade; an upward shifting of the entire blade to clear the defect; vibration of the recoater blade after passing the defect; and/or any other number of different types of effects that may occur due to the interaction of a recoater blade with a defect on a build surface. Depending on whether the recoater blade is made from a polymer or rubber material versus a harder metallic or ceramic blade, different effects may be more or less prevalent. For example, a polymer or rubber recoater blades may be at less risk of catastrophic damage or delamination of the previously printed part, but there is a much greater risk of damage such as cuts and nicks to the recoater blade which may cause uneven tracks in the recoated surface. Machine designs are possible that allow for easy or automatic exchange of recoater blades when interference contact damage to the blade is detected. However, if the interference contact is still present, the new blade may also be damaged. While interference contact between a previously printed material and a recoater blade will not always cause a problem with subsequent printed layers, the Inventors have recognized that in some cases an initial minor defect may cause a negative feedback where the defect grows in size over multiple subsequently deposited and fused layers such that a size of the growing defect may lead to large scale damage to the recoater or even failure of the entire print process. This type of negative feedback where each subsequent layer after an initial contact with a defect produces a larger defect and corresponding increased contact with the recoater blade can cause complete process failure. Alternatively, this negative feedback can cause a part failure after the part is complete. For example, if a layer of powder over a point is sufficiently thick compared to the nominal recoating thickness, when the point is processed, there may not be sufficient laser power to fully melt the layer in a solid weld to the previous layer. This weak point in the part can delaminate during the part lifetime causing complete part failure under load. Also this weak point may delaminate many layers later during the print process causing large scale deformation of the part and a complete print failure. This type of failure can also be very hard to troubleshoot as the cause of the delamination and part failure may be hundreds of layers separated from the actual failure point. In view of the above, the Inventors have recognized the need for a method to mitigate or reduce the likelihood of defects in a build surface growing in size during the formation of subsequent layers of a part. Accordingly, in some embodiments, a movable surface following behind a path of travel of a recoater blade, or moved over the build surface in a separate process, may induce a flow of fluid over the build surface by generating a boundary layer of the fluid on the movable surface. Based on the type of powder (particle mass, particle density, particle size, etc.), there is a minimum velocity before a moving fluid with a given density will start to have any effect on the powder. Below this velocity, the powder surface will not be substantially affected. Above this velocity, the moving fluid will start to entrain and move the powder. By positioning the movable surface a fixed height above the nominal new powder level height, the established boundary layer thickness can be set such that it has little to substantially no effect on powder that is at or below the nominal layer thickness. However, areas of powder that extend above the nominal layer thickness may start to protrude into the boundary layer of flowing fluid over the build surface. Powder that extends far enough into the boundary layer above a threshold height above the build surface may be subject to a fluid flow velocity that is at or above a minimum entrainment velocity of the powder particles. At this point, the boundary layer may entrain at least a portion, and in some instances substantially all, of the powder extending above the threshold height such that the entrained powder is removed from the build surface at the defect location. This may reduce the excess powder layer thickness at the defect location. While some of the entrained powder may remain in the entrained boundary layer, another portion of the powder may be ejected from the boundary layer due to centripetal forces. Depending on how the flow of fluid is handled, the entrained powder may either be removed from the system using a system such as a filter or vacuum and/or the released powder may be spread evenly over a much larger area than the initial area of excess powder thickness. In either case, this may drastically reduce the trend towards a negative feedback loop resulting in a defect growing in size in any given spot or area during subsequent layer formation. In view of the above, in one embodiment, a powder may be deposited onto the build surface of a recoater assembly with a desired nominal layer thickness using a recoater assembly. In some instances, this may include passing a recoater blade over the build surface to distribute the powder across the build surface. A fluid may be flowed across at least a portion of the build surface, which may be behind a path of travel of the recoater blade across the build surface in some embodiments. The flow of fluid may have a velocity profile that increases with increasing distance from the build surface such that powder deposited onto the build surface above a threshold height from the build surface may become entrained in the flow of fluid. For example, in some embodiments, the recoater assembly may include a powder entrainment system with a movable surface that may move relative to the underlying portion of the build surface. In instances where the powder entrainment system moves behind a path of travel of a recoater blade of the system, the moveable surface may move with a velocity relative to the build surface that is different from a velocity of the recoater blade relative to the build surface. In either case, the velocity of the movable surface relative to the underlying portion of the build surface may be sufficient to generate a boundary layer of the fluid to provide the desired velocity profile of the flow of fluid to entrain particles of the powder located above the threshold height. The methods and systems described herein may help to reduce the presence of excess powder over discrete areas as well as over tracks that extend along the length and/or width of a powder layer deposited onto a build surface of an additive manufacturing system. While in some embodiments excess powder may still be present on the surface, the excess powder may be distributed over a much larger area and the maximum thickness at any one point extending above the nominal thickness of a layer may be significantly reduced. This reduction in peak areas may help to prevent the occurrence of a negative feedback loop resulting in defects on a build surface growing in size during the deposition of subsequently deposited layers of material during a build process. This may result in both increased part quality and fidelity as well as increased operational lifetimes for components such as the recoater blade of an additive manufacturing system. Additionally, without wishing to be bound by theory, the larger the thickness of the initial excess powder height, the more effective the disclosed methods and systems become as the larger the thickness, the more the powder will extend into the induced boundary flow where the higher local gas velocity may result in increased entrainment of the excess powder. Thus, the disclosed systems become even more effective as the size of a defect and excess amounts of powder increase. However, embodiments in which the above-noted benefits are not present and/or in which different benefits are present in an additive manufacturing system implementing the methods and/or systems disclosed herein are also possible as the disclosure is not limited in this fashion. It should be understood that the methods and systems described herein may use any appropriate type of movable surface for generating a desired boundary layer to provide a flow of fluid with a desired velocity profile across at least a portion of a build surface of an additive manufacturing system. For example, in some embodiments, a powder entrainment system may include a rotatable roller with at least a portion of a surface of the roller, e.g. the portion of the roller surface oriented towards the build surface, disposed at a predetermined height above the build surface of an additive manufacturing system. Additionally, in some embodiments, an axis of rotation of the rotatable roller is parallel to the build surface. In another embodiment, the powder entrainment system may include a belt that includes a portion of the belt with a surface that is oriented towards the build surface and that is disposed at a predetermined height above the build surface of an additive manufacturing system. Accordingly, the belt may be operated such that the portion of the belt oriented towards and located proximate to the build surface may be moved relative to the build surface to generate a desired flow of fluid across the build surface. In yet another embodiment, a powder entrainment system may include a plurality of rotatable disks located at a predetermined height above the build surface of an additive manufacturing system. In some instances, each rotatable disc may have an axis of rotation that is angled relative to the underlying build surface (e.g. orthogonal to the build surface). Accordingly, it should be understood that any appropriate component capable of being moved relative to an underlying build surface to generate a boundary layer of fluid with a desired velocity profile to provide the desired flow of fluid across an adjacent portion of the build surface may be used as the disclosure is not so limited. Additionally, depending on the specific embodiment, a movable surface proximate to the build surface used to generate the boundary layer of flowing fluid may either move in the same direction as a direction of motion of the overall powder entrainment system, a direction that is opposite the direction of motion of the powder entrainment system, and/or any other appropriate direction as the disclosure is not so limited. As noted above, a minimum velocity of a fluid for entraining the particles of a powder deposited onto a build surface may depend on various parameters such as the particle mass, particle density, particle size, fluid density, and/or any other appropriate parameter. That said, in some embodiments, a minimum velocity for entraining the particles of a powder in a flow of fluid, which may also correspond to a threshold velocity of a fluid flow at a threshold height from a build surface of an additive manufacturing system, may be greater than or equal to 0.1 meters per second (m/s), 0.2 m/s, 0.3 m/s, 0.4 m/s, 0.5 m/s, 1 m/s, 1.5 m/s, and/or any other appropriate velocity. Correspondingly, the minimum entrainment velocity and/or threshold velocity of the flow of fluid may be less than or equal to 2.0 m/s, 1.5 m/s, 1 m/s, 0.5 m/s, 0.4 m/s, 0.3 m/s, and/or any other appropriate velocity. Combinations of the foregoing ranges are contemplated including, for example, a minimum entrainment velocity and/or threshold velocity of a flow of fluid for a given type of powder may be between or equal to 0.1 m/s and 2.0 m/s. However, other combinations of the above ranges and/or velocities both greater than and less than those noted above are also contemplated as the disclosure is not so limited. Additionally, the velocity of a fluid flow at different heights between a moving surface and a build surface may be measured in any appropriate manner including flow visualization methods; velocitometers; calculations and/or finite element analysis techniques based on the measured parameters of the fluid and the operating parameters of the moveable surface for determining the boundary flow between the moveable surface and build surface; hot wire anemometers; ultrasonic flow sensors, and/or any other appropriate method. To facilitate dispersing and/or removing powder particles located on a build surface that extend above a threshold height above the build surface, a powder entrainment system may be configured to provide flow of fluid with a velocity profile that is greater than or equal to a threshold velocity, such as a minimum entrainment velocity of the powder, at heights equal to or greater than the threshold height above the build surface in a direction parallel to a direction of gravity. The threshold height may be dependent on the nominal thickness of a corresponding powder layer and permitted layer thickness tolerances deposited on a build surface. Specifically, the build surface may correspond to a previously processed layer, a surface of a build plate, and/or any other appropriate surface that a powder layer to be processed is deposited on. Thus, the threshold height may be measured either from this build surface and/or from a nominal height of a powder layer deposited onto the build surface. In either case, in some embodiments, the threshold height above a build surface may be greater than or equal to 25 μm, 30 μm, 40 μm, 50 μm, 100 μm, 200 μm, and/or any other appropriate height above the build surface. Correspondingly, the threshold height may be less than or equal to 500 μm, 400 μm, 300 μm, 200 μm, 100 μm, 50 μm, 20 μm, and/or any other appropriate height above the build surface. Combinations of the foregoing ranges are contemplated including, for example, a threshold height that is between or equal to 5 μm and 500 μm above the build surface may be used. Alternatively, the threshold height may be measured from the nominal height of a powder layer deposited onto the build surface. In such an embodiment, the threshold height may be located at a height that is greater than or equal to μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 100 μm, and/or any other appropriate height above the nominal height of the powder layer disposed on the build surface. Correspondingly, the threshold height may be located at a height that is less than or equal to 100 μm, 50 μm, 40 μm, 30 μm, 20 μm, 10 μm, and/or any other appropriate height above the nominal height of the powder layer disposed on the build surface. Combinations of the foregoing are contemplated including, for example, a threshold height that is located at a height that is between or equal to 5 μm and 100 μm above the nominal height of a layer of powder disposed on a build surface. Of course, depending on the specific layer thickness and permitted tolerances, threshold heights both greater than and less than those noted above are contemplated as the disclosure is not limited in this fashion. It should be understood that any appropriate thickness of a powder layer may be used depending on the particular application. For example, appropriate thicknesses of powder layers sequentially deposited onto a build surface may be greater than or equal to 20 μm, 30 μm, 40 μm, 50 μm, 100 μm, 200 μm, 300 μm, and/or any other appropriate thickness. Correspondingly, the thickness of the sequentially deposited powder layers may be less than or equal to 500 μm, 400 μm, 300 μm, 200 μm, 100 μm, 50 μm, and/or any other appropriate thickness. Combinations of the foregoing are contemplated including, for example, a thickness of a powder layer deposited onto a build surface that is between or equal to 20 μm and 500 μm. Of course thicknesses of a powder layer both greater than and less than those noted above are also contemplated as the disclosure is not so limited. In addition to the above, a portion of a movable surface that is oriented towards a build surface and used to generate the desired flow of fluid may be disposed within a predetermined height of the build surface. This may also be referred to as an offset between the build surface and the portion of the movable surface oriented towards the build surface. For example, a portion of the movable surface that is oriented towards a build surface and used to generate a flow of fluid parallel to the build surface may be disposed at a height from the build surface that is greater than or equal to 0.5 millimeters (mm), 1.0 mm, 2.0 mm, 3.0 mm, 4.0 mm, 5.0 mm, and/or any other appropriate height. Correspondingly, the noted height may be less than or equal to 10.0 mm, 9.0 mm, 8.0 mm, 7.0 mm, 6.0 mm, and/or any other appropriate height. Combinations of the foregoing ranges are contemplated including, for example, a portion of a movable surface that is oriented towards the build surface may be located at a height over the underlying build surface that is between or equal to 0.5 mm and 10.0 mm. Of course, other combinations of the above-noted ranges, as well as heights both greater than and less than those noted above, are also contemplated as the disclosure is not limited in this fashion. It should be understood that a recoater assembly along with the corresponding recoater blade and powder entrainment system may be translated across a build surface using any appropriate translation direction, pattern, and/or velocity. For example, a recoater assembly may be translated across at least a portion of a build surface with a translational velocity parallel to the build surface that is greater than or equal to 5 mm/s, 10 mm/s, 20 mm/s, 50 mm/s, 100 mm/s, and/or any other appropriate velocity. Correspondingly, a velocity of the recoater assembly may be less than or equal to 200 mm/s, 150 mm/s, 100 mm/s, 50 mm/s, and/or any other appropriate velocity. Combinations of the foregoing ranges are contemplated including, for example, a velocity of the recoater assembly in a direction that is parallel to the underlying build surface that is between or equal to 5 mm/s and 200 mm/s, 25 mm sec and 100 mm/sec, and/or any other appropriate combination of the foregoing ranges. Of course, velocities both greater than and less than those noted above are also contemplated as the disclosure is not so limited. Various types of powders may be used in an additive manufacturing system which may have a range of different types of characteristics depending on the desired application. Possible powders may include, but are not limited to, aluminum, titanium, steel, stainless steel, copper alloys, and/or any other appropriate type of material. Exemplary parameters of these powders are provided below. However, it should be understood that the disclosed methods and systems may be used with any appropriate type of powder as the disclosure is not limited to only the types of powders and powder characteristics described herein. In some embodiments, a powder deposited onto a build surface of an additive manufacturing system may have an average particle size measured as the average maximum transverse dimension (e.g. average maximum diameter) of the powder. Accordingly, in some embodiments, an average maximum transverse dimension of the particles of a powder may be greater than or equal to 5 μm, 10 μm, 15 μm, 20 μm, 30 μm, 40 μm, 50 μm, and/or any other appropriate size. Correspondingly, the average maximum transverse dimension of the powder may be less than or equal to 100 μm, 90 μm, 80 μm, 70 μm, 60 μm, 50 μm, and/or any other appropriate size. Combinations of the foregoing ranges are contemplated including, for example, an average maximum transverse dimension of the particles of a powder that is between or equal to 5 μm and 100 μm, 15 μm and 50 μm, and/or any other appropriate combination of the foregoing ranges. Of course, powders with average sizes both greater than and less than those noted above are also contemplated as the disclosure is not so limited. Additionally, it should be understood that the average particle size (i.e. average maximum transverse dimension) may be measured using any appropriate particle size analysis method including, but not limited to, particle size analyzers using static light scattering, laser diffraction, staged sieving, and/or any other appropriate method as the disclosure is not so limited. In some embodiments, a powder deposited onto a build surface of an additive manufacturing system may be made from a material with a desired density. Depending on whether a polymeric or metal powder is used, the particles of a powder may have a density that is greater than or equal to 1 g/cm3, 2 g/cm3, 2.6 g/cm3, 3 g/cm3, 4 g/cm3, 5 g/cm3, and/or any other appropriate density. Correspondingly, the density of the particles of a powder may be less than or equal to 9 g/cm3, 8.9 g/cm3, 8 g/cm3, 7 g/cm3, 6 g/cm3, 5 g/cm3, and/or any other appropriate density. Combinations of the foregoing ranges are contemplated including, for example, a density that is between or equal to 1 g/cm3and 9 g/m3, 2.6 g/cm3and 8.9 g/cm3, and/or any other appropriate combination of the foregoing ranges. Of course, powders with particles having densities both greater than and less than those noted above are also contemplated as the disclosure is not so limited. In some embodiments, the density of a powder may simply be known due to the material it is made from. Alternatively, appropriate methods of measuring the density of a powder may include water displacement density measurements of the powder, though it should be understood that the disclosure is not limited to how the density of a material is measured. It should be understood that the additive manufacturing systems described herein may be operated using any appropriate type of fluid medium that a build surface might be exposed to. For example, for non-reactive materials that may be melted when exposed to oxygen (e.g. some polymers), the fluid may correspond to atmospheric air. Alternatively, the fluid may correspond to a relatively non-reactive gas such as helium, argon, krypton, xenon, radon, nitrogen, and/or any other appropriate gas depending on the intended application Additionally, an additive manufacturing system may be operated using a fluid having any appropriate pressure and/or density depending on the desired operating characteristics of the system. That said, in some instances, an additive manufacturing system may be operated using fluids with a pressure in a range between about 88 kPa and 102 kPa. However, embodiments in which different operating pressures are used including pressures both greater and less than those noted above are also contemplated. Depending on the particular embodiment, a recoater blade and/or a portion of a powder entrainment system that forms a movable surface for generating a boundary layer of fluid may be made out of any suitable type of material including, for example, a metal, ceramic, plastic, and/or rubber. Accordingly, it should be understood that the various embodiments disclosed herein are not limited to the specific types of materials, or combinations materials, that the individual components are made from. For the sake of clarity, the embodiments described relative to the figures illustrate powder entrainment systems that are moved together with a recoater blade such that the powder entrainment system is disposed behind and moves with the recoater blade in a direction of travel of the recoater blade over a build surface. However, it should be understood that a powder entrainment system may also be mounted to a secondary motion mechanism that moves separately from the portion of the recoater assembly that the recoater blade is attached to. Thus, in some embodiments, a powder entrainment system may be moved separately from the recoater blade in any desired direction as the disclosure is not limited in this fashion. Additionally, a powder entrainment system may either make a single pass over a recoated build surface, or it can be passed over the recoated surface multiple times as the disclosure is not limited to the number of times that a powder entrainment system is passed over a build surface and/or the pattern in which it is traversed across the build surface. Turning to the figures, specific non-limiting embodiments are described in further detail. It should be understood that the various systems, components, features, and methods described relative to these embodiments may be used either individually and/or in any desired combination as the disclosure is not limited to only the specific embodiments described herein. FIGS.1A-1Eshow one embodiment of a prior art system that may experience negative feedback during the deposition and fusion of subsequent layers of powder8on a build surface4leading to the growth of a defect. Specifically, as shown in the figures, a printed layer may produce a defect6corresponding to a high spot where the fused material extends upwards above the surrounding portions of the fused layers forming the build surface that each subsequent powder layer is deposited onto. This high spot can be caused by thermal stress and deformation that has accumulated over several previous layers, or may be caused by other issues such as clumping of previous powder layers or welding spatter from previous fused areas. If the defect is taller, i.e. extends above the nominal height, of the next layer, a recoater blade2of the system may contact the defect during translation of the recoater blade across the build surface. This interference contact between the recoater blade and the defect during recoater motion may cause the recoater blade to deform or deflect upward around the defect. This may result in more powder8being deposited over the contact point. If the next printed layer processes (i.e. melts) the powder over the previous high spot, this may result in a defect that extends even further above that printed layer than the previous defect did over the corresponding printed layer. As subsequent layers are deposited and fused, this process may continue to repeat leading to larger defects and increased interference with the recoater blade. Ultimately, this process may continue either until the recoater blade is damaged beyond use, the previously printed layers are damaged and deformed to a failure point, and/or until the recoating process fails because the recoater mechanism jams at the interference point between the defect and recoater blade. In addition to the specific contact interference between a defect and the recoater blade during powder deposition, the above-noted negative feedback can also propagate from the initial interference contact point to other portions of a build surface. Examples of different types of disturbances that may be formed in a powder layer deposited onto a build surface related to this contact interference is shown inFIGS.2A-2D.FIG.2Ashows a top view of a recoater blade2translating towards a defect6located on a build surface on which a powder layer8has been deposited. The defect is of an appropriate size such that contact between the recoater blade and the defect may occur during translation of the recoater blade. The interference between the recoater blade and the defect may cause excessive powder thickness around the contact point as well as in pockets10after the contact point if vertical vibrations are induced in the recoater assembly as a result of the interference contact, seeFIG.2B. Alternatively, the contact may cause enough damage to the recoater blade such that a nick or chip is formed in the recoater blade leading to the recoater blade forming a track12after the contact point where an increased amount of powder is deposited along the track relative to the surrounding portions of the build surface, seeFIG.2C.FIG.2Dshows how disturbances in the deposited powder layer may also occur across the width of the build plane as the contact between the recoater blade and one or more defects6may cause a vertical lifting of the entire recoater assembly. Subsequent vertical vibrations of the recoater blade may cause follow on tracks12that extend in a direction parallel to the recoater blade at a location on the build surface that is located after the defect relative to a direction of travel of the recoater blade. Combinations of interference patterns fromFIGS.2B-2Dmay also be produced though it should be understood that potential defects and patterns formed in the deposited powder layer other than those described in the figures are also possible. FIG.3depicts one embodiment of an additive manufacturing system100. The additive manufacturing system100may include a build surface102and a laser assembly104. Depending on whether or not the manufacturing of a part has already commenced, the build surface102may include a build plate, a portion of a printed part, a subsequently deposited and processed layer, and/or any other surface upon which a part or a portion of a part may be additively manufactured. The laser assembly104may include an optics assembly106configured to emit one or more laser beams108towards the build surface to melt powder disposed on the build surface in a desired pattern. Depending on the particular embodiment, the optics assembly may be movable relative to the build surface, though embodiments in which the lasers are scanned across the build surface using galvanomirrors or other appropriate optical steering mechanisms are also contemplated. The additive manufacturing system may also include a recoater assembly112which may include a recoater blade114and a powder entrainment system116. As described previously, the recoater assembly may be translated in a direction across at least a portion of a build surface during a powder recoating process. As elaborated on below, the powder entrainment system may follow behind a path of travel of the recoater blade though embodiments in which the powder entrainment system is translated across the build surface separately from the recoater blade are also contemplated. In the depicted embodiment, the powder entrainment system116includes a spinning rod disposed behind a path of travel of the recoater blade114. The rod has an axis of rotation that is substantially parallel to the underlying build surface102such that the spinning motion of the rod induces a boundary flow around the rod where at least a portion of the boundary flow is disposed between the rod, or other movable surface of a powder entrainment system, and the build surface. By changing the rotational velocity, the radius of the rod, and the height of the rotating rod above the new powder level, the shape and magnitude of the boundary layer relative to the underlying layer of powder can be controlled to disperse and/or remove powder located at a height greater than a threshold height above the build surface which may correspond to a previously deposited and processed layer and/or an underlying build plate. In some embodiments, an additive manufacturing system may additionally include a processor110which may include an associated memory configured to store processor-executable instructions to perform the methods described herein. The processor110may be operatively coupled to the laser assembly104, the recoater assembly112and any components therein, including but not limited to the optics assembly110, the powder entrainment system, and/or any other appropriate component of the additive manufacturing system. Accordingly, the processor may operate any desired components of the additive manufacturing system to perform the methods described herein. FIG.4is a schematic representation of an additive manufacturing system100, according to some embodiments. In the depicted embodiment, the additive manufacturing system100includes a build surface102, four support columns118, two support rails120, a recoater assembly112. The recoater assembly may include a recoater support122, a recoater blade housing124, a recoater blade114, and a powder entrainment system116as well as a build surface120. The four support columns and two support rails support the recoater assembly at a desired height and orientation above the build surface. The two support rails104may be connected to the four support columns102. In particular, each of the two support rails is connected to two of the four support columns102in a direction that is parallel to the depicted X axis. In some embodiments, the support rails104are coupled to the support columns102via translational attachments126. Thus, the translational attachments may allow ends of each support rail to translate vertically (i.e., in a direction parallel to the Z axis) along the support columns102to allow a height of the support rails and the associated recoater assembly to be controlled using any appropriate arrangement of actuators, not depicted. As noted above, the recoater assembly112includes a recoater support122, a recoater blade housing124, a recoater blade114, and a powder entrainment system116. The recoater blade housing may be configured to securely hold the recoater blade, and may be mounted to the recoater support. Similarly, in some embodiments, a powder entrainment system116may be mounted to the recoater blade housing, or other appropriate portion of the recoater assembly, such that the powder entrainment system may be translated with the recoater assembly across the build surface102. In the depicted embodiment, the powder entrainment system corresponds to a rotatable cylinder with an axis of rotation that it is oriented in a direction that is parallel to the underlying build surface. The rotatable cylinder, or other moveable surface of a powder entrainment system, may be driven using any appropriate actuator116aconfigured to drive the moveable surface in a desired direction. The recoater support may be coupled to the support rails120. In the depicted embodiment, the recoater support extends between the support rails along an axis parallel to the Y axis and perpendicular to the X axis. In particular, the recoater support is coupled to the support rails via recoater translational attachments128disposed at either end of the recoater support. This may allow the recoater support, and thus, the overall recoater assembly to translate horizontally across the build surface in a direction that is parallel to the build surface and the X axis along the support rails104using any appropriate type of associated actuator, not depicted. Depending on the particular embodiment, a distance between a recoater and a build surface may be measured and/or controlled via any suitable types of measurement or control systems. For example, vertical motion of a recoater assembly (e.g., along support columns118) may be driven by actuators such as ball screw driven stages, linear motor stages, linear actuators, pneumatic actuators, hydraulic actuators, and so on. Moreover, the position of such vertical motion stages may be tracked and/or measured via systems such as rotary encoders on ball screws, linear optical encoders, LVDT sensors, laser displacement sensors, and so on. For example, in one embodiment, a vertical motion stage may be driven by a ball screw driven linear actuator, and the position of the motion stage may be tracked via linear optical encoders. Of course, it should be appreciated that the current disclosure is not limited to any particular combination of types of vertical motion stages and/or systems for tracking or measuring the position of the motion vertical motion stages. Similarly, the systems disclosed herein may include any suitable types of motion stages for accommodating movement of the recoater assembly along the support rails. For example, the recoater assembly may be driven along the support rails via ball screw driven linear slides, belt driven linear actuators, pneumatic actuators, hydraulic actuators, and so on, and the position of the recoater assembly may be monitored via one or more of rotary encoders, linear optical encoders, LVDT sensors, laser displacement sensors, and so on. As discussed previously, in some embodiments, an additive manufacturing system100may include a processor110that is operatively coupled to the recoater assembly to control operation of powder dispensing, vertical and/or horizontal translation of the recoater assembly112, and/or operation of the powder entrainment system116. For example, the processor may be operatively coupled to one or more actuators associated with one or more of the attachments126and/or128, and the processor may control operation of each actuator to control a height of the recoater assembly relative to the build surface and/or motion of the recoater assembly across at least a portion of the build surface. Additionally, the processor may be operatively coupled to the powder entrainment system and may be configured to control operation of the powder entrainment system using any of the methods disclosed herein to mitigate the formation of defects extending above a nominal height of a powder layer disposed on the build surface102. FIG.5depicts a schematic embodiment of a powder layer130deposited onto a build surface102. The recoater blade of the recoater assembly is dragged across the surface of the build plate leaving a desired thickness of the powder layer behind a path of travel of the recoater blade. Correspondingly, a pile of powder132may build up on a front surface of the recoater blade relative to the direction of travel as the recoater blade is dragged across the build surface. The recoater system may also include a powder entrainment system116in the form of a rotatable cylinder, or other appropriate moveable surface that may be moved relative to the underlying build surface to induce a boundary flow adhered to the movable surface that may provide a flow of fluid between the movable surface and the build surface. For example, the rotatable cylinder may be rotated relative to the build surface with a rotational velocity “w” in either direction. Depending on the radius of the cylinder and the rotational speed of the cylinder, a boundary flow may be induced on the cylinder with any desired boundary layer height H B and velocity profile134, seeFIG.6. This boundary layer of fluid adhered to the surface of the rotating cylinder, or other movable surface of a powder entrainment system, may result in a flow of fluid between the build surface and a surface of the cylinder, or other movable surface of a powder entrainment system, oriented towards the build surface. Further, since the rotating rod may be located at a height well above the nominal new powder layer thickness, even defects from a previous print layer that may contact the recoater blade may still be well below the solid surface of the rotating rod so no contact between the defect and the rod may occur. Accordingly, as elaborated on below, this method may help to remove and/or disperse at least a portion, a majority, and in some instances substantially all of the excess powder deposited at a location of a defect which may help to limit the maximum height of excess powder deposited in a location which may reduce the risk of a negative feedback loop causing print problems during an additive manufacturing process. As shown inFIG.7, a rotatable cylinder forming a portion of a powder entrainment system116may be used to disperse and/or remove any excess powder of a powder layer130that extends far enough into the boundary layer around the spinning rod. Specifically, the velocity profile134of the boundary flow may increase in velocity from the build surface102towards the movable surface of the cylinder or other appropriate moveable surface oriented towards the build surface used to induce the flow of fluid. In the figure, a powder layer130has been deposited onto the build surface with a nominal layer height of H N and a permitted layer height tolerance H t that the powder layer may extend above the nominal layer height. Correspondingly, a threshold height above the build surface above which the powder may be dispersed and/or removed may correspond to HThwhich is the combined total of the nominal layer height and layer height tolerance. Correspondingly, an outer surface of the rotating cylinder oriented towards the build surface may be offset from the build surface by an offset height Ho. By selecting an appropriate combination of the cylinder size and rotational velocity, the velocity profile of the boundary flow may have a velocity that is equal to or greater than a minimum entrainment velocity of the powder of the powder layer at heights above the build surface that are greater than or equal to the threshold height. Accordingly, any excess powder that extends to a height greater than the threshold height relative to the build surface may either be removed and/or distributed over a much larger area due to the powder located at or above the threshold height being entrained in the flow of fluid while leaving the powder below the threshold height in the powder layer in a substantially undisturbed state. In some embodiments, it may be desirable to either increase the turbulence within a boundary flow adhered to a movable surface of a powder entrainment system and/or to provide pulsatile flow. Accordingly, while a solid smooth surface such as a solid rotating rod is depicted in other embodiments as illustrated inFIG.8, in some embodiments a movable surface of a powder entrainment system116used to induce a boundary flow may include a plurality of surface features disposed thereon. For example, in the depicted embodiment of a rotating cylinder, the rotating cylinder may include a plurality of surface features117with varying heights disposed on the surface. Specifically, surface features such as fins, protrusions, bumps, divots, dimples, channels, and/or any other appropriate surface future may be provided on a movable surface to provide a desired pattern of flow. While such a feature may be optional, these types of surface features may entrain more flow and/or add pressure variations (i.e. flow pulses) to the entrained flow which may aid in randomly dispersing excess powder on a build surface of a system and/or increasing the size of an induced boundary layer of fluid attached to the movable surface. Depending on whether or not a movable surface used to induce a boundary flow between a powder entrainment system116and a build surface moves in a direction that is the same or opposite from a direction of travel of the overall powder entrainment system, the resulting velocity profile134of the boundary layer may have a different shape. Specifically, as shown inFIG.9having a moving surface that moves in a direction opposite the direction of travel of the overall powder entrainment system results in a boundary flow with a velocity profile that initially increases in velocity in a direction oriented towards the movable surface prior to decreasing in velocity. Without wishing to be bound by theory, this is due to the first velocity profile134afrom rotation of the rod and the second velocity profile134bfrom translation of the powder entrainment system over the build surface at least partially canceling each other out. Correspondingly, when the movable surface of the powder entrainment system moves in the same direction as the direction of movement of the overall powder entrainment system, the velocity profiles are constructive such that the overall velocity profile134increases continuously in a direction oriented towards the movable surface of the depicted rotating cylinder, seeFIG.10. However, in general the translational speed of the powder entrainment system may be significantly slower than the relative velocity of the movable surface relative to the underlying build surface such that the relative directions of the overall translation of the system and direction of movement of the movable surface relative to the overall system may have little effect on the net boundary layer velocity profile shape. In some instances, it may be desirable to strip a portion of a boundary layer and the entrained powder from a movable surface to help disperse and/or remove the entrained powder. For example, as shown inFIG.11, a mask138may be positioned adjacent to the movable surface of a powder entrainment system116such as the depicted rotating cylinder. The mask may correspond to a structure that is contoured to at least a portion of the movable surface and may be disposed adjacent to the movable surface at a distance that is less than a thickness of the induced boundary flow attached to the movable surface. Accordingly, the mask may cause at least a portion of the boundary flow to be detached from the movable surface. While the mask has been depicted as being positioned on a leading edge of the rotatable cylinder relative to the indicated direction of motion, embodiments in which the mask is disposed on both a leading and/or trailing portions of a movable surface of a powder entrainment system are also contemplated, seeFIGS.12and13. In either case, the mask may serve to strip the boundary layer flow from the movable surface at a location close to entrainment point to either create a new fresh boundary layer close to the entrainment point or to strip the majority of the entrained flow after the entrainment point. In some embodiments, the mask, or other portion of the powder entrainment system or recoater assembly, may also be fitted with a vacuum port140connected to an appropriate vacuum source, not depicted. In the depicted embodiment, the vacuum port is oriented towards a location where the mask strips the boundary layer off of the movable surface though other arrangements are also contemplated. The use of a vacuum port may help to capture and remove at least a portion of the entrained powder which may reduce the quantity of a powder that is redeposited onto the build surface. While a rotatable cylinder has been depicted in the above embodiments, it should be understood that a rotatable cylinder is only one way of implementing a movable surface to induce a flow of fluid over the build surface of an additive manufacturing system. Other exemplary types of systems that may function as the movable surface of a powder entrainment system are elaborated on below. Accordingly, it should be understood that the current disclosure is not limited to any specific construction to induce a flow of fluid between a recoater assembly and a build surface to entrain powder particles located above a threshold height relative to the underlying build surface. FIGS.14-16depict another embodiment of a recoater assembly112with a powder entrainment system116. In the depicted embodiment, the recoater assembly includes a recoater blade114that traverses a build surface, not depicted, in a desired direction. The powder entrainment system116includes a plurality of rotatable disks142that are arranged in an array that extends along at least a portion of a length, and in some instances substantially all of the length, of the recoater blade. Each of the rotatable disks includes an axis of rotation that extends in a direction that is angled relative to the underlying build surface, such as in a direction that is perpendicular to the build surface. Accordingly, a bottom surface of each of the rotatable disks may be substantially parallel to the underlying build surface. By driving each of the disks to rotate about their rotational axes using one or more appropriate actuators, not depicted, the bottom surface of the disks oriented towards the build surface will rotate relative to the build surface which may induce a boundary flow of fluid between the rotating disks surfaces and the build surface in a manner similar to that described above though the relative speed of the boundary layer will be greatest at the outer most edge of the disks due to the translational speed of each point on the surfaces increasing with increasing radius. Accordingly, the induced flow between the disk and nominal powder layer can be used in order to entrain powders deposited at heights greater than a threshold height from a build surface in a manner similar to that noted above. Depending on the particular design, the disks can be arranged in straight arrays including one or more aligned rows of disks with minimal gaps between disks, seeFIG.15. Alternatively, the disks may be set in staggered arrays where separate rows of the disks may be offset from one another such that the disks in one row may overlap with gaps in an adjacent row which may result in every point in the powder layer being subject to at least two different flow conditions on each pass of the powder entrainment system, seeFIG.16. FIGS.17-18depict yet another embodiment of recoater assembly112including a powder entrainment system116with a movable surface that may be used to induce a boundary flow of fluid between a build surface102and a portion of a movable surface oriented towards the build surface. In this embodiment, the movable surface corresponds to a belt144that includes at least a portion that is positioned proximate to and/or oriented towards the build surface within an appropriate offset distance from the build surface as previously discussed. Similar to the above embodiments, the belt is located behind the recoater blade114relative to a path of travel of the recoater blade across the build surface. The belt may be associated with two or more rollers146which are arranged to guide the belt through a desired path of travel. The rollers may either be the same size and/or different sizes depending on the desired application. At least one of the rollers may be a drive roller with an associated actuator, not depicted, that is used to drive the belt in a desired direction relative to the underlying build surface. In the embodiment shown inFIG.17two rollers are positioned proximate to the build surface such that a portion of the belt extends in a direction substantially parallel to the underlying build surface for a predetermined length. Such an embodiment may be advantageous in that the boundary flow adhered to the moving belt may be applied over a broad area of the build surface. Alternatively, a single roller may be located proximate to the build surface such that the belt moves over a region of the build surface as it moves over the roller proximate to the build surface, seeFIG.18. This may cause the boundary flow attached to the belt to be applied over a smaller area corresponding to the portion of the roller oriented towards the build surface. Depending on the overall radius of the roller and corresponding thickness of the boundary layer, this may cause the boundary flow to apply flows of fluid with velocities above the minimum entrainment velocity of the powder over a relatively small portion of the build surface. As also depicted in the embodiment ofFIG.18, in some instances a vacuum port and/or mask, such as the combined mask and vacuum port138/140may be positioned proximate to a portion of the belt downstream from a location where the belt moves over the build surface relative to a direction of flow across the build surface. As discussed above, this may help to strip off and/or remove the boundary flow and entrained powder from the moving belt. The above-described embodiments of the technology described herein can be implemented in any of numerous ways. For example, the embodiments may be implemented using hardware, software or a combination thereof. When implemented in software, the software code can be executed on any suitable processor or collection of processors, whether provided in a single computing device or distributed among multiple computing devices. Such processors may be implemented as integrated circuits, with one or more processors in an integrated circuit component, including commercially available integrated circuit components known in the art by names such as CPU chips, GPU chips, microprocessor, microcontroller, or co-processor. Alternatively, a processor may be implemented in custom circuitry, such as an ASIC, or semicustom circuitry resulting from configuring a programmable logic device. As yet a further alternative, a processor may be a portion of a larger circuit or semiconductor device, whether commercially available, semi-custom or custom. As a specific example, some commercially available microprocessors have multiple cores such that one or a subset of those cores may constitute a processor. Though, a processor may be implemented using circuitry in any suitable format. Further, it should be appreciated that a computing device may be embodied in any of a number of forms, such as a rack-mounted computer, a desktop computer, a laptop computer, or a tablet computer. Additionally, a computing device may be embedded in a device not generally regarded as a computing device but with suitable processing capabilities, including a Personal Digital Assistant (PDA), a smart phone, tablet, or any other suitable portable or fixed electronic device. Also, a computing device may have one or more input and output devices. These devices can be used, among other things, to present a user interface. Examples of output devices that can be used to provide a user interface include display screens for visual presentation of output and speakers or other sound generating devices for audible presentation of output. Examples of input devices that can be used for a user interface include keyboards, individual buttons, and pointing devices, such as mice, touch pads, and digitizing tablets. As another example, a computing device may receive input information through speech recognition or in other audible format. Such computing devices may be interconnected by one or more networks in any suitable form, including as a local area network or a wide area network, such as an enterprise network or the Internet. Such networks may be based on any suitable technology and may operate according to any suitable protocol and may include wireless networks, wired networks or fiber optic networks. Also, the various methods or processes outlined herein may be coded as software that is executable on one or more processors that employ any one of a variety of operating systems or platforms. Additionally, such software may be written using any of a number of suitable programming languages and/or programming or scripting tools, and also may be compiled as executable machine language code or intermediate code that is executed on a framework or virtual machine. In this respect, the embodiments described herein may be embodied as a processor readable storage medium (or multiple computer readable media) (e.g., a computer memory, one or more floppy disks, compact disks (CD), optical disks, digital video disks (DVD), magnetic tapes, flash memories, RAM, ROM, EEPROM, circuit configurations in Field Programmable Gate Arrays or other semiconductor devices, or other tangible computer storage medium) encoded with one or more programs that, when executed on one or more processors, perform methods that implement the various embodiments discussed above. As is apparent from the foregoing examples, a processor readable storage medium may retain information for a sufficient time to provide computer-executable instructions in a non-transitory form. Such a processor readable storage medium or media can be transportable, such that the program or programs stored thereon can be loaded onto one or more different computing devices or other processors to implement various aspects of the present disclosure as discussed above. As used herein, the term “processor-readable storage medium” encompasses only a non-transitory processor-readable medium that can be considered to be a manufacture (i.e., article of manufacture) or a machine. Alternatively or additionally, the disclosure may be embodied as a processor readable medium other than a processor-readable storage medium, such as a propagating signal. The terms “program” or “software” are used herein in a generic sense to refer to any type of computer code or set of computer-executable instructions that can be employed to program a computing device or other processor to implement various aspects of the present disclosure as discussed above. Additionally, it should be appreciated that according to one aspect of this embodiment, one or more computer programs that when executed perform methods of the present disclosure need not reside on a single computing device or processor, but may be distributed in a modular fashion amongst a number of different computers or processors to implement various aspects of the present disclosure. Processor-executable instructions may be in many forms, such as program modules, executed by one or more processors. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Typically the functionality of the program modules may be combined or distributed as desired in various embodiments. The embodiments described herein may be embodied as a method, of which an example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments. While the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art. Accordingly, the foregoing description and drawings are by way of example only. | 59,204 |
11858207 | DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS Embodiments of the present invention relate to methods and systems for conducting quality assurance monitoring during additive manufacturing processes. Additive manufacturing or the incremental and sequential assembly or construction of a part through the combination of material addition and applied energy, takes on many forms and currently exists in many specific implementations and embodiments. 3D printing or additive manufacturing is any of various processes for making a three dimensional part of virtually any shape from a 3D model or from an electronic data file derived from a scan of a model or from a 3D CAD rendering. The various processes have in common the sintering, curing or melting of liquid, powdered or granular raw material, layer by layer using ultraviolet light or a high power laser, or electron beam, respectively. An electron beam process (EBF3) was originated by NASA Langley Research Laboratory. It uses solid wire as the feed stock in a vacuum environment as well as when possible, in zero gravity space capsules. The process is notable for its sparing use of raw material. A focused high power electron beam is translated and creates a melt pool on a metallic surface into which the wire raw material is fed under the guidance of a coded deposition path. It has been used to produce components in sizes from fractions of an inch to tens of feet, limited only by the size of the vacuum chamber and the amount and composition of the wire feedstock that is available. Selective heat sintering (SHS) uses thermoplastic powders that are fused by a heated printhead. After each layer is fused, it is lowered by a moveable baseplate and a layer of fresh thermoplastic powder is replenished in preparation for the next traversal of the printhead. Selective laser sintering (SLS) uses a high power laser to fuse thermoplastic powders, metal powders and ceramic powders. This is also a scanning technology where the laser path for each layer is derived from a 3D modeling program. During the construction process, the part is lowered by a moveable support by exactly one powder layer thickness to maintain the laser's focus on the plane of the powder. Direct metal laser sintering (DMLS), nearly identical to SLS, has been used with nearly any metal or alloy. Selective laser melting (SLM) has been used for titanium alloys, chromium/cobalt alloys, stainless steels and aluminum. Here, the material is not sintered but is completely melted using a high power laser to create fully dense components in a layer-wise fashion. Fused deposition modelling (FDM), is an extrusion process where a heated nozzle melts and extrudes small beads of material that harden immediately as they trace out a pattern. The material is supplied as a thermoplastic filament or as a metal wire wound on a coil and unreeled through the supply nozzle. The nozzle position and flow is computer controlled in three dimensions. One way of measuring and characterizing the quality of a metal part made with an additive manufacturing process is to add a number of temperature characterizing sensors to an additive manufacturing tool set that monitor and characterize the heating and cooling that occurs during formation of each layer of the part. This monitoring and characterizing can be provided by sensors configured to precisely monitor a temperature of portions of each layer undergoing heating and cooling at any given time during the manufacturing operation. When a heating source along the lines of a laser produces the heat necessary to fuse each layer of added material, the heated portion of the layer can take the form of a weld pool, a size and temperature of which can be recorded and characterized by the sensors. Real-time or post-production analysis can be applied to the recorded data to determine a quality of each layer of the part. In some embodiments, recorded temperatures for each part can be compared and contrasted with temperature data recorded during the production of parts having acceptable material properties. In this way, a quality of the part can be determined based upon characterization of any temperature variations occurring during production of the part. These and other embodiments are discussed below with reference toFIGS.1-9; however, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. FIG.1shows a block diagram describing how QUALITY100is related to various elements related to an additive manufacturing process. QUALITY100is defined as the ability of a manufactured part or article to meet the PERFORMANCE REQUIREMENTS101of the larger system of which it is a part. These PERFORMANCE REQUIREMENTS101are functions of the engineering system (e.g. aircraft, automobile, etc.) but they imply certain PROPERTIES102of the part that must be met. Examples of such properties include but are not limited to: physical part dimensions, part surface roughness and surface quality, static tensile strength, thermo-physical properties (e.g. density, thermal conductivity, etc.), life and dynamic endurance properties such as fatigue strength, impact strength, fracture toughness, etc. The PROPERTIES102of a part made out of any substance are determined by the MATERIAL STRUCTURE103of the matter comprising the part as well as the DEFECT DISTRIBUTION104of anomalies, defects, or other imperfections that exist within the part—either on its surface or in its volume. Both the MATERIAL STRUCTURE103and the DEFECT DISTRIBUTION104are function of the PROCESSING CONDITIONS105that made the part. PROCESSING CONDITIONS105can be dictated by CONTROLLABLE PROCESS INPUTS106, UNCONTROLLED PROCESS VARIATIONS107, and ENVIRONMENTAL DISTURBANCES108. The result of CONTROLLABLE PROCESS INPUTS106, UNCONTROLLED PROCESS VARIATIONS107, and ENVIRONMENTAL DISTURBANCES108is the set of physical behaviors that occurs while the manufacturing or additive manufacturing process in occurring, and these are known as IN-PROCESS PHYSICAL BEHAVIORS109. Along with each IN-PROCESS PHYSICAL BEHAVIOR109, there may be one or more variables that can be used to either directly or indirectly measure the current state of the manufacturing process. These are called IN-PROCESS STATE VARIABLES110. They are STATE VARIABLES in the true sense of the definition, namely that a complete knowledge of these IN-PROCESS STATE VARIABLES110completely describes the current state of the manufacturing process. For example, IN-PROCESS STATE VARIABLES110can include a rate at which various regions of the part heat up or cool down. The cooling rate can be extrapolated by measuring a temperature of a surface of one or more regions of the part as it cools. In some embodiments, temperature data can be optically determined by sensors such as a pyrometer, infrared camera, and/or photodiode. Temperatures obtained in this way can also be utilized to make determinations about the values of other state variables such as times at which solidification and melting occur. State variables can also include a peak temperature reached for a given area or portion of the material being used to form the part. Therefore, one way of determining QUALITY100of a part produced by an additive manufacturing operation is to measure parameters during the additive manufacturing operation that can be used to determine the IN-PROCESS STATE VARIABLES110. A CORRELATION BETWEEN IN-PROCESS STATE VARIABLES AND POST-PROCESS QUALITY111therefore exists and forms the basis for some of the embodiments of the present invention described herein. InFIG.2, a more concise restatement of the description above is as follows: By measuring IN-PROCESS STATE VARIABLES200, it is possible to understand the current state of the process; by knowing the current state of the process, it is possible to understand the IN. PROCESS PHYSICAL BEHAVIORS201and to classify them as being NOMINAL202or OFF-NOMINAL203. This classification is predicated upon the existence of a FEASIBLE PROCESS SPACE204as defined in the coordinate system of the IN-PROCESS STATE VARIABLES200, and by definition the process is in a NOMINAL202state when it is within the bounds of the FEASIBLE PROCESS SPACE204. It should be noted that while FEASIBLE PROCESS SPACE204appears to be a two dimensional space, that in fact many more variables can contribute towards defining FEASIBLE PROCESS SPACE204. Therefore, according to some embodiments of the present invention, the state variables are utilized to define the feasible process space rather than the input variables that are used for operating the system. The input variables, for example, laser power and scan speed, which are typically used to define the feasible process space, result in in-process physical behaviors, for example, melt pool temperature. For example, in some embodiments, other in-process physical behaviors include melt pool temperature gradient, melt pool volume, melt pool natural frequency of oscillation, melt pool vaporization, melt pool spectral emission, such as melt pool infrared emission and melt pool optical emission, and the like. Both intrinsic (i.e., dependent on the melt pool volume) and extrinsic (i.e., not dependent on the melt pool volume) physical behaviors are included in the range of in-process physical behaviors included in the present invention. As described more fully herein, these in-process physical behaviors can be measured to provide in-process variables, also referred to as state variables. This method of in-process quality control can be applied to a very wide range of manufacturing processes. However, within the scope of Additive Manufacturing processes, it is useful to consider the class of Additive manufacturing processes in which there is a moving molten or otherwise plasticized or thermally affected region that travels across the surface of the part that is being built up. Either the material to be added is pre-placed as in the case of a powder bed process, or could be added to the molten or plasticized or otherwise thermally affected region. FIG.3. shows the key physical phenomena occurring during such an Additive Manufacturing process as described above. The substrate300is the part that is being built up. An energy source301impinges on the surface of the substrate300. Energy source301has a translational velocity302, specified by the symbol V, and while it moves along some trajectory on the substrate300it creates a molten or plasticized or otherwise thermally affected region303. Immediately in the wake of the moving thermally affected region303there is a thermally cycled region304of the substrate300that has been thermally affected and has cooled back down to the nominal temperature of the substrate300. For example in the case of a laser sintering process occurring on a preplaced powder bed, the thermally cycled region304corresponds to the track of powders just melted and solidified/sintered by the moving energy source301. This thermally cycled region304will in general have a profile305below the surface of the substrate300. Considering an overall energy balance for the moving energy source301, there will be radiated and conducted energy that also carries valuable signal and information content with respect to the key physical phenomena occurring in the thermally affected region303. For example, heat conduction306, indicated by a heat flux Q, will result in heat flow from the thermally affected region303and the thermally cycled region304. This flux will in general be normal to the contour of the profile305of the thermally affected region below the surface of the substrate300. Additionally, there will be radiated signals and information307that could be in the form of optical radiation or acoustic radiation in the case that the Additive Manufacturing process in question occurs in some controlled atmosphere and not in a vacuum. Lastly, there could be back-reflected signals308that could be 100% collinear with the incident energy source301or could be at a slight offset angle. For example, in the case that the incident energy source301is a laser that operates in the near infrared, the back-reflected signal308may be optical radiation that travels back through the laser optics but that does not interfere with the incident beam as the incident beam is in the near infrared. These signals and others, which could indicate the state of the machine and the state of the process, collectively constitute the IN-PROCESS STATE VARIABLES that define the current state of the IN-PROCESS PHYSICAL BEHAVIORS that determine QUALITY. FIG.4Ais a schematic diagram illustrating a quality control system400according to an embodiment of the present invention. The quality control system400can be utilized in conjunction with Additive Manufacturing processes in which the moving heat source is a laser and the material addition could be either through the sequential pre-placement of layers of metal powders to form a volume of powder401, as depicted, on a powder bed402, or the material addition could be accomplished by selectively placing powder straight into the molten region generated by the moving laser on the part. The volume of powder401has several distinct build regions403, which are being built up. In the case of the depicted embodiment, the buildup is accomplished by the application of the heat source to the material build regions403, which causes the deposited powder in those regions to melt and subsequently solidify into a part having a desired geometry. The various regions403could be different portions of the same part, or they could represent three entirely different parts, as depicted. As illustrated inFIG.4A, a witness coupon404is provided. Witness coupon404is a standardized volume element that will be called a witness coupon, which allows the sampling of every production build and which represents a small and manageable but still representative amount of material which could be destructively tested for metallurgical integrity, physical properties, and mechanical properties. For every layer that is put down, the witness coupon404also has a layer of material put down concurrent to the layer being processed in the distinct build regions403. There is an optical sensor405, for example a pyrometer, directly interrogating the witness coupon404. For purposes of clarity, optical sensor405is represented as a pyrometer herein although it will be evident to one of skill in the art that other optical sensors could be utilized. The pyrometer405is fixed with respect to the powder bed402and collects radiation from a fixed portion of the volume of powder401, i.e., the witness coupon404. In the instance where the Additive Manufacturing process includes a scanning laser impinging on powder bed402, the laser source406emits a laser beam407that is deflected by a partially reflective mirror408. Partially reflective mirror408can be configured to reflect only those wavelengths of light that are associated with wavelengths of laser beam407, while allowing other wavelengths of light to pass through partially reflective mirror408. After being deflected by mirror408, laser beam407enters scan head409. Scan head409can include internal x-deflection, y-deflection, and focusing optics. The deflected and focused laser beam407exits the scan head409and forms a small, hot, travelling melt pool410in the distinct build regions403being melted or sintered layer by layer. Scan head409can be configured to maneuver laser beam407across a surface of the volume of powder401at high speeds. It should be noted that in some embodiments, laser beam407can be activated and deactivated at specific intervals to avoid heating portions of the volume of powder401across which scan head409would otherwise scan laser beam407. Melt pool410emits optical radiation411that travels back through scan head409and passes through partially reflective mirror408to be collected by optical sensor412. The optical sensor412collects optical radiation from the travelling melt pool410and therefore, images different portions of the volume of powder401as the melt pool410traverses the volume of powder. A sampling rate of optical sensor412will generally dictate how many data points can be recorded as melt pool410scans across the volume of powder401. The optical sensor412can take many forms including that of a photodiode, an infrared camera, a CCD array, a spectrometer, or any other optically sensitive measurement system. As an example, if a spectrometer is utilized, data related to the chemical content of the melt pool can be obtained, providing insight into the materials/species that are vaporized from the melt pool as well as, or in addition to insight into the materials/species that are remaining in the melt pool. In addition to pyrometer405and optical sensor412, quality control system400can also include optical sensor413. Optical sensor413can be configured to receive optical information across a wide field of view414so that real time monitoring of substantially all of the volume of powder401can be realized. As with optical sensor412, optical sensor413can take many forms including that of a photodiode, an infrared camera, a CCD array, and the like. By adding optical sensor413to quality control system400, which continuously monitors all of the volume of powder401, quality control system400gains an additional set of sensor data that includes Eulerian data for any point on the volume of powder401. In configurations where optical sensor413is setup to distinguish relative amounts of emitted heat, readings from pyrometer405can be used to calibrate optical sensor413so that heat readings across the entire surface of the volume of powder401can be continuously recorded and analyzed for irregularities. Additionally, quantitative temperature information can be measured at all locations of the volume of powder401using optical sensor413. FIG.4Bshows an alternative arrangement in which a second pyrometer415can be arranged to monitor another witness coupon416. By including a second pyrometer, when abnormalities occur that place a temperature gradient outside of known-good operating parameters while melt pool410passes through witness coupon404, witness coupon416can be used to validate conditions for the particular layer that corresponds to the out of parameter heat excursion. In some embodiments, analysis could switch entirely to witness coupon416given such a circumstance occurring. In this way, one abnormality occurring at the wrong place and/or time no longer compromises the ability of the part to be characterized by analysis of the witness coupon. In some embodiments, an accuracy of the first and second pyrometers could be quite different. For example, first pyrometer405could have a substantially higher sensitivity to temperature than pyrometer415. Other variations between the pyrometers are also possible such as, for example, a size of the footprint in which each pyrometer samples. While bothFIGS.4A and4Bshow and demonstrate the use of a witness coupon, it should be understood that in some cases once a manufacturing operation is well understood, one or more of the pyrometers can instead be focused on a portion of one of build regions403. While such a configuration may preclude the destructive analysis of a portion of a production part, once the process is well understood, confidence in the described thermal analysis may be high enough to accept a part without destructive analysis of a witness coupon for production runs in which thermal heat excursions don't exceed a predetermined threshold. In yet another embodiment, when multiple parts are being concurrently manufactured, one of the parts can take the form of the witness coupon. In this way, one out of a number of parts having the same size and geometry can be analyzed to provide additional insight into temperature characteristics experienced by the other parts, and even more closely predict grain structure of the other parts being concurrently produced. When melt pool410passes through the region of witness coupon404, both the Eulerian pyrometer405(i.e., the pyrometer405interrogates a fixed portion of the region of the metal material that is being additively constructed, thereby providing measurements in a stationary frame of reference) and the Lagrangian optical sensor412(i.e., the optical sensor412images the location at which the laser energy is incident, thereby providing measurements in a moving frame of reference) are looking at the same region in space. At the witness coupon, signals from the Eulerian pyrometer405, Lagrangian optical sensor412, and optical sensor413will be present, a condition that can be associated with the witness coupon. Calibration of the readings from the sensors can thus be performed when the melt pool overlaps the witness coupon. In an embodiment in which a narrowly focused Eulerian photodetector collecting radiation only from the region of the witness coupon (not shown) is provided in conjunction with the witness coupon, calibration of the optical sensor412can be performed when the melt pool overlaps with the witness coupon. In some embodiments, a narrowly focused photodiode is focused on the area of the witness coupon. In these embodiments, the photodiode collects spectral emissions from the witness coupon, which is converted to a weld pool when the laser source passes through the witness coupon. The spectral emissions can be ultraviolet, visible, or infrared depending on the temperature of the melt pool. In some implementations, multiple photodiodes can be utilized to capture spectral emission over a number of spectral bandwidths. The photodiode can be used to collect the spectral emissions and these measurements can be correlated to the state variables, such as the size of the weld pool, the temperature of the weld pool, weld pool temperature gradient, and the like. One of ordinary skill in the art would recognize many variations, modifications, and alternatives. InFIG.5, the witness coupon area500for a given layer is shown. The Lagrangian optical sensor412will operate at a finite sampling rate as the beam scans the area of the witness coupon, and it will collect data at discrete sampling locations501. The Eulerian pyrometer will examine a fixed field of view502that is located within the larger area of the witness coupon500. In general, there will be a set of Lagrangian optical sensor readings503(which can be considered as the field of view of the optical sensor412) that fall within the field of view of the Eulerian pyrometer502. This will hold true on a layer by layer basis. Therefore in the witness coupon500, both Lagrangian and Eulerian measurements will be available. Furthermore, the witness coupon500will be subject to post-process destructive examination. Therefore there will be a change to further correlate microstructural and even mechanical properties data to the correlations conducted layer by layer during the build. Although the Lagrangian optical sensor readings503are illustrated as smaller than the field of view of the Eulerian pyrometer502, this is not required by the present invention. In some embodiments, an optical imaging sensor could be utilized as the optical sensor412to provide imaging of the area of the witness coupon, as well as other areas. In these embodiments, in-process state variables, such as the weld pool size could be determined using data collected by the optical sensor412. One of ordinary skill in the art would recognize many variations, modifications, and alternatives. Generally speaking, the Lagrangian optical sensor signal will be a function of the optical or infrared energy radiated from the weld pool and collected back through the scanner optics into the optical detector. This will have several factors that will determine an overall transfer function that will link the radiation emitted at the source to the signal measured at the detector. Most generically, the transfer function may be represented as: T=T{ε,dA,F(x,y),ρmirror,σsensor} (1) Where c is the emissivity of the weld pool area that is radiating, dA is the weld pool area that is radiating and is considered small with respect to the area of the output lens of the scanner unit, F(x,y) is the view factor relating the small area of the weld pool to the area of the output lens on the scanner, ρmirroris the wavelength dependent reflectivity of the mirror which splits the sensor signal whilst allowing the primary laser energy to pass through, and σsensoris the wavelength-dependent sensitivity of the optical sensor with respect to the incident radiation. The general relationship between the signal measured by the optical sensor and the energy emitted or radiated by the weld pool at a given location and a given time is therefore given by: S(x,y,t)=T(x,y)·Eweldpool(x,y,t) (2) The view factor can be approximated as shown inFIG.6. The small area of the weld pool600is represented by dA1and the area of the exit lens for the scan head601is represented by A2. The weld pool is in the plane of a top layer of the powder bed but is generally not directly beneath the exit lens of the scan head601and is displaced by a distance602in the plane represented by a. The work height603is the distance from the exit lens601for the scan head to the powder bed and is represented by h. The exit lens of the scan head601has a radius604which is represented by r. The view factor is given by the following mathematical relationship, which was originally derived by Hamilton and Morgan: Fd1-2=12[1-Z-2R2(Z2-4R2)1/2]where(3)H=ha,R=ra,andZ=1+R2+H2(4) The variable a can also be related to the x and y position on the plane of the powder bed. If we assume that the position directly below the center of the exit lens of the scan head is the origin of a coordinate system in the plane of the powder bed, then the variable a is related to the x and y position of the weld pool by the relationship: a=√{square root over (x2+y2)} (5) These x and y positions can in turn be found from the drive signals that control the beam deflection within the scan head. For example, in a high speed laser scanner, these x and y positions may be controlled by mirrors which are actuated by high frequency response galvanometers. The reflectivity of the mirror will be defined in terms of a range of wavelengths over which the mirror will reflect the radiation within that wavelength with a high degree of reflectivity, and outside of that range the mirror will be essentially transmissive. Therefore the mirror reflectivity rmirrorwill be very high for radiation emanating from the weld pool and coming back up through the exit lens for the scan head in some observation window of frequencies as defined by: ωMIN<ωRADIATION<ωMAX(6) The sensitivity of the optical sensor depends specifically on the type of sensor utilized. For example, a typical sensitivity curve for a silicon photodiode is shown inFIG.7. The curve describes the efficiency with which light is converted into current. The y-axis ofFIG.7therefore is the conversion efficiency. The x-axis ofFIG.7is the frequency of the incident radiation which is collected by the photodiode. It is therefore seen that the transfer function as described in Equation 1 can in fact be derived by knowing the various factors defined in Equations 3-5 and the sensitivity of the sensor as described inFIG.7. Therefore it is possible to perform a transformation which can bring the radiation collected at any arbitrary position in the powder bed or plane of the part into the reference frame of any other region of the part so that a comparison can be effected. More specifically in this invention, such a comparison will be made between the witness region and any other region of the part. A specific example will now be discussed that will further explain how such a transfer function could be used to effectively compare a witness coupon directly below the center of the exit lens of the scan head to any arbitrary region in the part or powder bed plane. In general, the radiation flux collected at the exit lens to the scan head and the flux radiated by the weld pool are related by the view factor shown in Equations 2-4. The mirror will have minimum and maximum cutoff frequencies which define the window of frequencies of radiation which will be allowed to pass through to the photodiode collector. The photodiode collector will have conversion efficiency as specified byFIG.7and the average conversion efficiency is related to the cutoff frequencies of the mirror by the relationship: faverage=f(ωMIN)+f(ωMAX)2(7) Where the efficiencies at the respective cutoff frequencies can be found fromFIG.7. Therefore, the overall transfer function relating the energy radiated from the weld pool at any (x,y) point and at any time t to the electrical signal as measured by the sensor (in this case the photodiode) could be represented to a first order by: S(x,y,t)=T(x,y)·Eweldpool(x,y,t)=ε·faverage·Fd1-2(x,y)*Eweldpool(x,y,t) (8) Where S(x,y,t) is the sensor signal from the emitted radiation when the weld pool was at location (x,y) at time t, and Eweldpool(x,y,t) is the actual emitted radiation in energy per unit time per unit area radiated from location (x,y) at time t. Therefore to accurately compare the energy emitted at any given location to that at another location, we must solve Equation 7 for Eweld pool: Eweldpool(x,y,t)=S(x,y,t)ε·faverage·Fd1-2(x,y)(9) Therefore Equation 9 should be used to normalize the as-measured optical signal to more accurately compare data taken at different (x,y) locations in the powder bed or the plane of the part being sequentially built layer by layer. FIG.8Ais a flowchart illustrating a process800for establishing a baseline parameter set for building a part according to an embodiment of the present invention. Referring toFIG.8A, the method includes collecting and analyzing overlapping Eulerian and Lagrangian sensor data during one or more additive manufacturing operations using nominal parameter ranges (801). In some embodiments, the overlapping portion of the sensor data coincides with material that is separate and distinct from a part being constructed (sometimes this portion can be referred to as a witness coupon), while in other embodiments, the overlapping sensor data coincides with a portion of the part itself. In cases where the overlapping sensor data is located within the part itself, that portion of the part may need to be removed if verification of the micro-structural integrity of that portion is desired without destroying the part. The Eulerian and Lagrangian sensor data can be collected from multiple sensors such as pyrometers, infrared cameras, photodiodes and the like. The sensors can be arranged in numerous different configurations; however, in one particular embodiment a pyrometer can be configured as a Eulerian sensor focused on a fixed portion of the part, and a photodiode or other optical sensors, can be configured as a Lagrangian sensor, which follows the path of a heating element that scans across the part. Data collection begins by testing nominal parameter ranges (i.e., those parameters or control inputs which are likely to result or have resulted in acceptable microstructure and/or acceptable mechanical properties and/or acceptable defect structures for a particular metal being utilized). In some embodiments, a user may begin with more or less precise parameter ranges when establishing the nominal parameter ranges. It should be understood that beginning with a more precise nominal parameter range can reduce the number of iterations needed to yield a sufficient number of data points falling within the nominal parameter ranges for a particular part. When a witness coupon is being utilized, it should be appreciated that the Lagrangian data can be transformed using the transfer function as indicated in Equation 9 for the region of the witness coupon. Once a sufficient number of data points corresponding to the part having acceptable material properties have been collected, additional additive manufacturing operations are conducted using off-nominal parameter ranges. During these manufacturing operations, overlapping Eulerian and Lagrangian sensor data are collected and analyzed (802). Similar to the data collection method used with the nominal data collection, the sensors can focus on the same portion of the part utilized for the collection of nominal data. The Lagrangian data will again be transformed with the aid of Equation 9. Off-nominal parameter ranges are those parameter ranges (e.g., laser power, scan speed, etc.) that have been verified to result in unacceptable microstructure and/or mechanical properties and/or defect structures as determined by post-process destructive analysis of the witness coupon or equivalent regions of the build. Off-nominal data collection can include multiple part builds to establish boundaries or thresholds at which a part will be known to be defective. Off-nominal data collection can also include test runs in which laser power is periodically lowered or raised using otherwise nominal parameters to help characterize what effect temporary off parameter glitches can have on a production part. As described more fully below, collection and analysis of the in-process sensor data during a set of manufacturing processes using the off-nominal parameter conditions can be used to define the in-process limits for the in-process sensor data. Embodiments of the present invention, therefore, measure attributes of the process (i.e., in-process sensor data) in addition to measuring attributes of the part manufactured. At803, one or more portions of the part at which the Eulerian and Lagrangian sensor data overlaps (i.e. the witness coupon) are analyzed to help produce a baseline dataset. There are generally three kinds of analysis that could be performed on the witness coupon, or an equivalent region of the part. First, the microstructure could be examined in detail. This includes, but is not limited to, such analyses as grain size, grain boundary orientation, chemical composition at a macro and micro scale, precipitate size and distribution in the case of age hardenable alloys, and grain sizes of prior phases which may have formed first, provided that such evidence of these previous grains is evident. The second category of evaluations that could be conducted are mechanical properties testing. This includes, but is not limited to, such analyses as hardness/micro-hardness, tensile properties, elongation/ductility, fatigue performance, impact strength, fracture toughness and measurements of crack growth, thermos-mechanical fatigue, and creep. The third series of evaluations that could be conducted on witness coupons or equivalent regions of the build are the characterization of defects and anomalies. This includes, but is not limited to, analysis of porosity shape, size and distribution, analysis of crack size and distribution, evidence of inclusions from the primary melt, i.e., those form during the gas atomization of the powders themselves, other inclusions which may have inadvertently entered during the Additive Manufacturing process, and other common welding defects such as lack of fusion. It should also be noted that in certain cases a location of the witness coupon or focus of the pyrometer can be adjusted to provide a more accurate representation of particularly critical portions of the part. At step804, once both in-process sensor data (Eulerian and transformed Lagrangian data) as well as post-process data (microstructural, mechanical, and defect characterizations) have been collected, it is possible to use a wide variety of outlier detection schemes804and/or classification scheme that can bin the data into nominal and off-nominal conditions. Also, the process conditions resulting in a specific set of post-process data are characterized, the associated in-process data collected while the sample was being made. This in-process data, both Eulerian and Lagrangian, can be associated and correlated to the post-process sample characterization data. Therefore, a linkage can be made between distinct post-process conditions and the process signatures in the form of in-process data that produced those post-process conditions. More specifically, feature extracted from the in-process data can be directly linked and correlated to features extracted from the post-process inspection. In some embodiments, the data collected during manufacturing using the nominal parameter range will be distinct from the data collected during manufacturing using the off-nominal parameter ranges, for example, two distinct cluster diagrams. One of ordinary skill in the art would recognize many variations, modifications, and alternatives. At step805, once such features are established and correlated both in the real-time and post-process regimes, a process window can be defined based on the in-process limits of both Eulerian and Lagrangian data corresponding to nominal conditions, i.e., those conditions that have been verified to result in acceptable microstructure and/or acceptable mechanical properties and/or acceptable defect structures as determined by post-process destructive analysis of the witness coupon or equivalent regions in the build. Therefore the practical import of achieving this state is that the process may be defined to be in a nominal regime by virtue of actual in-process measurements directly corresponding to the physical behaviors occurring in the additive manufacturing process, as opposed to defining such a process window by using ranges of the machine settings, or other such variables included in a process parameter set, which are further removed from the process. In other words, embodiments of the present invention differ from conventional systems that only define process parameters. Embodiments of the present invention determine the in-process data for both nominal parameter ranges (801) and off-nominal ranges (802), providing an “in-process fingerprint” for a known set of conditions. Given that established baseline dataset, it is possible, for each material of interest and each set of processing conditions, to accurately predict the manufacturing outcome for a known-good product with desired metallurgical and/or mechanical properties. It should be appreciated that the specific steps illustrated inFIG.8Aprovide a particular method of establishing a baseline parameter set for building a part according to an embodiment of the present invention. Other sequences of steps may also be performed according to alternative embodiments. For example, alternative embodiments of the present invention may perform the steps outlined above in a different order. Moreover, the individual steps illustrated inFIG.8Amay include multiple sub-steps that may be performed in various sequences as appropriate to the individual step. Furthermore, additional steps may be added or removed depending on the particular applications. One of ordinary skill in the art would recognize many variations, modifications, and alternatives. Now the attention is shifted to the practical use of such a process window in a production environment. FIG.8Bis a flowchart illustrating a process806for classifying a quality of a production level part based upon the established baseline parameter set according to an embodiment of the present invention.FIG.8Bshows process806describing the use of the baseline dataset in a build scenario. The baseline dataset can be established using the method illustrated inFIG.8A. Block807represents the collection, during an additive manufacturing process, of Lagrangian data from (x,y) locations distributed throughout the build plane and Eulerian data from a fixed location within the build plane. In one particular embodiment, the Lagrangian data can be collected by a photodiode and the Eulerian data can be collected by a pyrometer. The fixed location can be a witness coupon or a portion of the part that will be subsequently removed for testing. In some embodiments, the Lagrangian data can be collected from all locations in the build plane and the Eulerian data can only be collected at the fixed region of the witness coupon, although the present invention is not limited to this implementation. In other embodiments, a subset of all possible locations is utilized for collection of the Lagrangian data. The Lagrangian data is collected in the fixed region of the witness coupon as the melt pool passes through the witness coupon region. One of ordinary skill in the art would recognize many variations, modifications, and alternatives. Block808describes a verification process that can be executed to determine whether the Eulerian and Lagrangian data collected within the fixed location is free of data points falling outside the nominal baseline dataset (i.e., within the region defined by the baseline dataset). The same classification and outlier detection scheme as was implemented during the establishment of the baseline in process800can be used to perform this verification. In other words, this step establishes that overlapping Eulerian and Lagrangian sensor readings taken during an actual production run corresponds to overlapping Eulerian and Lagrangian sensor readings recorded under nominal conditions as part of the baseline data set. Block809describes the comparison of Lagrangian data collected at one or more (x,y) positions to the Lagrangian data collected in the fixed location. In some embodiments, the Lagrangian data collected at each of the (x,y) positions is compared to the Lagrangian data collected from the fixed region associated with the witness coupon. Thus, a set of in-process Lagrangian data associated with portions or all of the build platform can be compared with a set of in-process data from the witness coupon region. This step can be carried out subsequent to block808when it is established that the Lagrangian data from the fixed location in the production run was within the range of nominal conditions described in the baseline dataset. Accordingly, the embodiment illustrated inFIG.8Bcompares the Lagrangian data set associated with some or all of the build platform areas with the Lagrangian data set from the witness coupon, as well as verifies that the in-process data is within the limits of the baseline dataset. In optional block810when the verification and comparison from blocks808and809are completed successfully at all desired sampling points in the part, then the entire part is by logical inference, also within the limits of the nominal baseline data set. Block811can provide a useful verification of a parts quality/conformance to the baseline dataset. Block811describes an additional verification that is carried out to verify that no anomalies exist in the Lagrangian signal of the build that did not exist in the baseline. As an example, short temporal anomalies and/or highly localized may physically represent some irregularity in the powder sintering, presence of a foreign object in the powder bed, a fluctuation in the laser power, melting at a highly localized level, or the like. An indication of an anomaly can then be provided to a system operator as appropriate. In response to the indication, a quality engineer may require that the part undergo additional testing to determine if the temporal anomaly will impact part performance. The verification process in811can differ from that performed in808since the time scale associated with the verification processes can be significantly different. Additionally, differing thresholds can be utilized to provide the appropriate filtering function. For example, the verification process can be applied to every data point collected that exceeds a fairly substantial threshold value while the process in808might only consider a smaller number of data points (i.e. at a reduced sampling rate) with a much lower threshold for irregular measurements. In some embodiments, block811can be optionally performed and is not required by the present invention. In some embodiments, the order of the verification processes in808and811is modified as appropriate to the particular application. In some embodiments, the verification process in811can be conducted using data from a different sensor than that used in block808, for example the sensor associated with the verification can be a high speed camera sampling temperature data thousands of times per second. This high speed sensor could have a lower accuracy than a sensor associated with block808as it would be designed to catch very substantial but transitory deviations from the baseline dataset. Lastly, block812describes an optional process. This optional process can be carried out when an overall confidence with the production part process is still in doubt. In such a case, material corresponding to the fixed location can be destructively tested to ensure that the post-process metallurgical, mechanical or defect-related features of the build witness coupon are within the same limits as those for a nominal baseline witness coupon. In some embodiments, the aforementioned destructive testing can be performed only periodically or in some cases not at all. It should be noted that as part of the method of producing production parts, computer numerical control (CNC) machinery used to drive the additive machining toolset can also be responsible for executing certain actions based on the aforementioned sensor data. For example, multiple thresholds can be established and correlated with various actions taken by the CNC machinery. For example, a first threshold could trigger recording of an out of parameters event, a second threshold could prompt the system to alert an operator of the tool set, while a third threshold could be configured to cease production of the part. Conversely, if any of these conditions are not met and if the (x,y) location of the Lagrangian data is known, then that specific region of the build or production run may be categorized as “off-nominal,” or potentially suspect and potentially containing microstructure, mechanical properties, or defect distributions that are unacceptable. ThereforeFIGS.8A-8Bshow embodiments of the present invention as it pertains to the use of in-process Eulerian and Lagrangian data in a production run, the relationship to baseline data and specifically baseline data taken from witness coupons made under nominal conditions known to produce acceptable post-process features, and the methodology by which the in-process Eulerian and Lagrangian data during build run together with the witness coupon associated with the build run may be used to accept a build run as nominal, i.e. representative of the baseline made using process conditions known to produce an acceptable microstructure and/or acceptable mechanical properties and/or acceptable defect distributions. It should be appreciated that the specific steps illustrated inFIG.8Bprovide a particular method of classifying a quality of a production level part based upon the established baseline parameter set according to an embodiment of the present invention. Other sequences of steps may also be performed according to alternative embodiments. For example, alternative embodiments of the present invention may perform the steps outlined above in a different order. Moreover, the individual steps illustrated inFIG.8Bmay include multiple sub-steps that may be performed in various sequences as appropriate to the individual step. Furthermore, additional steps may be added or removed depending on the particular applications. One of ordinary skill in the art would recognize many variations, modifications, and alternatives. FIG.9more concisely describes the logic flow of the decision process that is described in this invention to determine if a given production build should be accepted as nominal based on real-time, in-process data. There are FOUR decision boxes in this flowchart, and all four of the conditions must generally be met in order to categorize a build or production run as being acceptable based on real-time, in-process data (both Eulerian and Lagrangian). It should be noted that subsequent analysis and risk management logic can be applied to accept parts that fall short of meeting all the conditions. The first step of the decision tree900determines whether or not the portion of the build that includes overlapping Eulerian and Lagrangian sensor data (e.g. the witness coupon) is within the nominal, “known-good” range that constitute the baseline dataset. When the witness coupon of the production run does not have Eulerian and Lagrangian in-process data to support this premise, then the production run is labelled potentially suspect. The second step of the decision tree901establishes whether or not the Lagrangian data collected at one or more (x,y) locations in the build corresponds to the Lagrangian data collected in the region of the witness coupon for that same build. In some embodiments, as discussed above, the Lagrangian data can be collected for every location of interest in the build platform or for a subset of the locations in the build platform. As an example, a map of the part can be overlaid with the build platform to utilize the Lagrangian data for locations that correspond to the geometry of the part being manufactured. In other embodiments, the Lagrangian data is collected for portions of the build platform that correspond to the laser path or for portions of the build platform that correspond to the laser path when the laser is on. One of ordinary skill in the art would recognize many variations, modifications, and alternatives. The third step of the decision tree establishes whether or not the post-process features measured on the witness coupon associated with the build are within the nominal, “known-good” range of post-process features measured on witness coupons which constitute the baseline data set. Finally, the fourth step of the decision tree establishes that there are no extraneous anomalous events in the Lagrangian data collected at any (x,y) location, i.e. are there any features seen the Lagrangian data of the build that were not seen in the baseline Lagrangian data. This additional step and final step is necessary, because outlier detection and classification are based on features. It is possible that over time new features that were not in the original baseline dataset may appear in the Lagrangian data. In order to effectively make a classification or implement an outlier detection scheme to compare data from a production run to data from a baseline data set, features are first extracted from the real-time data. For an exemplary embodiment of this invention, suppose that the Eulerian sensor is a multi-color pyrometer, and suppose that the Lagrangian sensor is a silicon photodiode. Furthermore in the exemplary embodiment, the heat source is a scanning laser or electron beam, and the material addition is accomplished by pre-placement of powders between sintering layers. The table below describes features that may be extracted from the respective Eulerian and Lagrangian in-process data so that an effective comparison can be made between features in the baseline data set and features in the production run being assessed. EULERIAN FEATURESLAGRANGIAN FEATURESScan Peak Temperature: when thePhotodiode RMS: In the case of alaser or electron beam passes directlylaser-basedthrough the pyrometer field of view,process, the photodiode signal is thethis feature is the peak temperature ofback-reflected radiation emitted byprocess during the high speedthe weld pool and collected backexcursion of the laser or electron beamthrough the optics and through aspot through the field of view.beam splitter. This feature is theRMS, or root mean square, of thissignal intensity after theTransformation correction ofEquation 9 has been applied.Scan Heating Rate: when the laser orPhotodiode Standard Deviation: Inelectron Beam passes directly throughthe case of a laser-based process, thethe pyrometer field of view, thisphotodiode signal is the back-reflectedfeature is the maximum heating rate ofradiation emitted by the weld pool andprocess during the high speedcollected back through the optics andexcursion of the laser or electron beamthrough a beam splitter. This featurespot through the field of view.is the standard deviation of this signalintensity after the Transformationcorrection of Equation 9 has beenapplied.Scan Cooling Rate: when the laser orPhotodiode Frequency Spectrum: Inelectron beam passes directly throughthe case of a laser-based process, thethe pyrometer field of view, this featurephotodiode signal is the back-reflectedis the maximum cooling rate of processradiation emitted by the weld pool andduring the high speed excursion of thecollected back through the optics andlaser or electron beam spot through thethrough a beam splitter. This featurefield of view.is the frequency spectrum of thissignal intensity after theTransformation correction of Equation9 has been applied.Bulk Peak Temperature: when thePhotodiode Skew: In the case of alaser or electron beam is not in thelaser-based process, the photodiodefield of view of the pyrometer, thesignal is the back-reflected radiationmaterial will still exhibit a backgroundemitted by the weld pool and collectedthermal profile, and this feature is theback through the optics and through apeak temperature associated with thisbeam splitter. This feature is the skewbackground thermal profile.of this signal intensity after theTransformation correction of Equation9 has been applied.Bulk Heating Rate: when the laser orPhotodiode Kurtosis: In the case of aelectron beam is not in the field oflaser-based process, the photodiodeview of the pyrometer, the materialsignal is the back-reflected radiationwill still exhibit a background thermalemitted by the weld pool and collectedprofile, and this feature is theback through the optics and through amaximum heating rate associated withbeam splitter. This feature is thethis background thermal profile.kurtosis of this signal intensity afterthe Transformation correction ofEquation 9 has been applied.Bulk Cooling Rate: when the laser orelectron beam is not in the field ofview of the pyrometer, the materialwill still exhibit a background thermalprofile, and this feature is themaximum cooling rate associated withthis background thermal profile. Note that all of these features may also be averaged over a given layer. Also, the Lagrangian data collected over the same region of the witness coupon where the Eulerian data is also being collected may be considered as a separate feature even though it is a subset of all of the Lagrangian features. Additionally, with respect to the classification and outlier detection schemes, there are several possibilities. A few of these are listed in the Table below, but it is understood that a multitude of possible schemes could be implemented and would still fall within the spirit and intent of this invention. POSSIBLE CLASSIFICATION SCHEMES ANDOUTLIER DETECTION METHODSMahalanobis Distance (MD): this is a good method on account of the fact that it properlyaccounts for covariance in a multivariate feature space, and has a simple, non-subjectiveinterpretation in that the MD-distance squared may be fitted to a Chi-Squared distribution,and the critical value of the Chi-Squared distribution at a given confidence level willdetermine the outlier cutoff value of the MD distance.Extreme Value Statistics: utilizing for example the Generalized Extreme Value Distributionas opposed to a Chi-Squared Distribution (but still specifying a given confidence level), andsimilar analysis of outliers could be performed on any individual feature or set of features.Arbitrary Limits: In lieu of algorithmically defined limits, there can be user-defined limitsbased on engineering experience. This is a practical alternative in some instances but runsthe risk of introducing human subjectivity as well as difficulty in assessing the true falsenegative/false positive rates. Even though all of the steps inFIGS.8A,8B and9may be followed rigorously and the part is deemed acceptable based on in-process, real-time data, there still exists the question of sufficiency of the in-process data to fully characterize the quality of the component. Therefore in addition to the steps shown inFIGS.8A,8B and9, there will need to be additional correlations with other physically independent post-process non-destructive inspection methods. Over time, these additional checks can be phased out or can be relegated to an infrequent, periodic sampling to ensure that the in-process, real-time data is still sufficiently capturing the process physics to enable such a quality inference as described inFIGS.8A,8B and9to be made. However, even other non-destructive inspection methods such as ultrasonic and x-ray will have their own sensitivity, resolution, accuracy, probability of detection, false positive and false negative rates that will in general be different than those for the in-process real time measurements. So, as with any inspection method, there will be some residual risk that cannot be mitigated, short of destroying the component and exhaustively investigating its microstructure, mechanical properties and defect distributions. In fact such periodic completely destructive evaluations of actual production parts may be needed on an infrequent, periodic basis. Such evaluations will serve to further strengthen the validity of the correlations between the in-process, real-time data and part quality, but they are very costly and time-consuming and must therefore be kept to an absolute minimum required. The specific details of such periodic sampling both for nondestructive as well as destructive evaluations to continuously check the validity of the in-process product acceptance approach will depend on the specific Additive Manufacturing applications. For example medical and aerospace will have different requirements as compared to automotive and power generation, and similarly for each specific domain where Additive Manufacturing is to be used to make functional, structural engineering components. In the preferred embodiment described herein there are additional modalities in which the present invention may be used to facilitate manufacturing operations based on Additive Manufacturing. The Table below enumerates different scenarios that frequently arise in production, and specifically how the present invention addresses quality issues and problems in each if these scenarios. SCENARIOSOLUTION TO QUALITY PROBLEMSMovement of machine tools from oneThe quality question herein is the re-qualification ofphysical location to another.a machine after it has been physically moved and/orpartially disassembled to facilitate the move. Thepresent invention offers a specific, platform-independent method for directly addressing such aquality concern: i) immediately prior to disassemblyand move, a new baseline data set is captured thatdocuments the machine state as well as the witnesscoupons that are produced by the machine while inphysical location 1; ii) this baseline data set is usedas the starting baseline data set for the re-qualification of the machine in physical location 2;iii) the methodology of FIG. 9 is applied to ensurethat the machine in its new configuration is able toproduce samples consistent with the previouslyrecorded baseline made immediately prior tomachine disassembly and move; iv) if this is the case,the machine is declared re-qualified without furthereffort needed.Machine parameters transferred fromAlthough two machines are of the same make andone machine to another, bothmodel, they can have differences due to condition,machines are of the same make andmaintenance, etc. which result in different productionmodel but are physically distinctoutcomes. Using the methodology described in thismachines with different histories andpresent invention, the following method may beperhaps different conditions ofemployed to determine if the two machines aremaintenance.identical: i) collect a new baseline data set or utilizeexisting baseline data set on machine 1; ii) collect anew baseline data set or utilize existing baseline dataset on machine 2; iii) compare all aspects of the twobaselines using one the classification and/or outlierdetection schemes mentioned above; iv) if thebaselines are not from the same population, adjustone or the other machine until the in-process data asevidenced by additional witness coupon runs areidentical or can be statistically grouped within thesame population.Manufacturing process transferredThis is generally the most difficult transition, as forfrom one machine type to anotherAdditive Manufacturing machines there can be veryMachine type.different scan strategies and local scan parameters.For example, laser power, laser spot size, laser travelspeed, and line spacing/scan overlap are insufficientto fully describe the differences between onemachine and another. Therefore the in-process datacapture in this instance as described in this presentinvention is critical to minimizing experimentaliterations and to ensuring that two parts made on twodifferent machines will in fact have similarmicro structure and properties. The method foraccomplishing this using the invention describedherein is identical to the description above fortransferring parameter between identical machines,but with the following modifications: i) the machineparameter settings on the two machines will mostlylikely be different; ii) scan strategies, to the extentthat they can be controlled as inputs, should be madeto be as close as possible; iii) adjustment to scanstrategies on the target machine may be needed toachieve results similar to the original machine, andiv) all of the sample level iteration could be done onwitness coupons assuming that Eulerian andLagrangian data are available on both machines. There are some logical extensions and generalizations to the embodiments as described above, and these will now be described. First, the description of the embodiments above involves the use of a witness coupon for both development and during a build. If there is another alternate method of establishing the microstructure, mechanical properties, and defect distributions that result from a specific set of processing conditions, then this could be equally acceptable as a substitute for the witness coupon, i.e. the witness coupon is a desirable, but not absolutely necessary, component of this invention. In some embodiments, multiple witness coupons are utilized as appropriate. It is also understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims. | 63,253 |
11858208 | DETAILED DESCRIPTION In some examples of three-dimensional (3D) printing, a binder fluid is selectively applied to a layer of build material on a build platform, thereby patterning a selected region of the layer, and then another layer of the build material is applied thereon. The binder fluid is then selectively applied to this other layer, and these processes may be repeated to form a green part (referred to herein as an “intermediate structure”) of a 3D part/object that is ultimately to be formed. The binder fluid may be capable of penetrating the layer of the build material onto which it is applied, and/or spreading around an exterior surface of the build material and filling void spaces between particles of the build material. The binder fluid can include binder particles, such as polymer latex particles, that when cured, temporarily hold the build material of the 3D intermediate structure together. The 3D intermediate structure may be moved from the build platform to a separate device for heating to remove the binder particles and to sinter the build material particles of the patterned intermediate structure to form the 3D part/object. The examples disclosed herein introduce digitally-controlled boron-based hardening agents into this binder fluid based 3D printing process. Boron-containing hardening agents may be selectively applied, e.g., using an inkjet printhead, to the intermediate structure as it is being built or after it is built. Selective application of the hardening agent by digital inkjet printing methods enables the hardness to be engineered spatially and volumetrically at the voxel-scale. This enables a reinforcement structure to be strategically built into the body of the 3D object. The agents and methods disclosed herein enable predictable, systematic, and reproducible hardening of 3D printed metal objects. The methods disclosed herein utilize inkjet compatible hardening agent(s) and binder fluid(s), as well as metal-based build materials. By “inkjet compatible,” it is meant that the hardening agent or binder fluid can be ejected from a thermal inkjet printhead, a piezoelectric inkjet printhead, or both types of printheads. The printheads may be drop-on-demand inkjet printheads or continuous inkjet printheads. The agents and fluids may have a surface tension ranging from about 20 mN/m to about 40 mN/m, which are suitable for jetting. In another example, the agents and fluids may have a surface tension ranging from about 20 mN/m to about 30 mN/m. Throughout this disclosure, a weight percentage that is referred to as “wt % active” refers to the loading of an active component of a dispersion or other formulation that is present in the hardening agent, binder fluid, and/or build material composition. For example, a boron-containing hardener, such as boron carbide nanoparticles, may be present in a water-based formulation (e.g., a stock solution or dispersion) before being incorporated into the hardening agent. In this example, the wt % actives of the boron carbide nanoparticles accounts for the loading (as a weight percent) of the boron carbide nanoparticles solids that are present in the hardening agent, and does not account for the weight of the other components (e.g., water, etc.) that are present in the stock solution or dispersion with the boron carbide nanoparticles. The term “wt %,” without the term actives, refers to either i) the loading of a 100% active component that does not include other non-active components therein, or ii) the loading of a material or component that is used “as is” and thus the wt % accounts for both active and non-active components. Hardening Agent Examples of the hardening agent include a boron-containing hardener selected from the group consisting of a water dispersible boron-containing hardener present in an amount ranging from about 6 wt % to about 15 wt %, and a water soluble boron-containing hardener present in an amount ranging from greater than 1 wt % to about 20 wt %, and a jettable liquid vehicle, wherein the hardening agent is devoid of a pigment and a dye. The water dispersible boron-containing hardener is selected from the group consisting of boron carbide (CB4), boron nitride (BN), silicon borides, aluminum borides, alkali metal borides, alkaline earth metal borides, transition metal borides, lanthanide borides, and combinations thereof. Examples of suitable silicon borides include silicon triboride (SiB3), silicon tetraboride (SiB4), silicon hexaboride (SiB6), or SiBn, where n=14, 15, 40. Examples of suitable aluminum borides AlB2and AlB12. Examples of suitable alkali metal and alkaline earth metal borides include LiB6, NaB6, KB6, MgB2, MgB4, CaB4, CaB6, SrB6, and BaB6. Examples of transition metal and lanthanide borides include TiB, VB, CrB, MnB, FeB, CoB, NiB, ZrB2, NbB, MoB, MoB2, WB, WB2, LaB4, LaB6, NdB4, NdB6, SmB4, SmB6, etc. Any of the water dispersible boron-containing hardeners that are included may have an average particle size (e.g., mean diameter, which may be calculated using a number distribution or a volume distribution.) ranging from about 2 nm to about 100 nm. In another example, the water dispersible boron-containing hardeners may have a particle size ranging from about 10 nm to about 50 nm. As mentioned, the water dispersible boron-containing hardeners may be present in an amount ranging from about 6 wt % to about 15 wt %, based on the total weight of the hardening agent. As other examples, the water dispersible boron-containing hardeners may be present in an amount ranging from about 7.5 wt % to about 14.5 wt %, or from about 10 wt % to about 15 wt %, or from about 7 wt % to about 9 wt %, etc., based on the total weight of the hardening agent. When the water dispersible boron-containing hardener is used in the hardening agent, the hardening agent may also include a polymeric dispersant. Some specific examples of suitable dispersants include sodium polyacrylate, poly(ammonium acrylate-co-methyl acrylate), poly(acrylic-co-maleic) acid, poly(acrylic-co-methacrylic) acid, polyacrylamide, ammonium methacrylate, dimethylaminoethyl methacrylate, a water soluble acrylic acid polymer (e.g., CARBOSPERSE® K7028 available from Lubrizol), water soluble styrene-acrylic acid copolymers/resins (e.g., JONCRYL® 296, JONCRYL® 671, JONCRYL® 678, JONCRYL® 680, JONCRYL® 683, JONCRYL® 690, etc. available from BASF Corp.), a high molecular weight block copolymer with pigment affinic groups (e.g., DISPERBYK®-190 available BYK Additives and Instruments), water soluble styrene-maleic anhydride copolymers/resins, polyurethanes, and polyurethane-based block copolymers. Whether a single polymeric dispersant is used or a combination of dispersants is used, the total amount of dispersant(s) in the hardening agent may range from about 0.1 wt % active to about 5 wt % active based on the total weight of the hardening agent. In an example, the total amount of dispersant(s) in the hardening agent may be about 0.2 wt % active based on the total weight of the hardening agent. The water soluble boron-containing hardener is selected from the group consisting of boric acid and a borate. Any acid containing a boron atom may be used. Examples of suitable acids include boric acid (H3BO3), metaboric acid (HBO2), tetraboric acid (H2B4O7), pentaboric acid (HB5O8), and fluoroboric acid (HBF4). Any borate may also be used. Sodium tetraborate decahydrate, also known as borax, is one example of a suitable borate. Other examples of suitable borates include ammonium borate, lithium borate, hydrated lithium borate, sodium borate, hydrated sodium borate, potassium borate, hydrated potassium borate, hydrated aluminum borate, potassium metaborate, hydrated potassium metaborate, sodium metaborate, hydrated sodium metaborate, hydrated ammonium tetraborate, lithium tetraborate, hydrated lithium tetraborate, hydrated potassium tetraborate, disodium tetraborate, hydrated ammonium pentaborate, and hydrated sodium peroxoborate. Tetrafluoroborate salts have very high solubility in water and may be used in the hardening agent disclosed herein. Examples of suitable tetrafluoroborate salts include sodium tetrafluoroborate (NaBF4) and sodium tetrafluoroborate (KBF4). Some tetraarylborates are also water soluble, and may be used in the hardening agent disclosed herein. Examples of suitable tetraarylborates include lithium tetraphenylborate (LiB(C6H5)4) and sodium tetraphenylborate (NaB(C6H5)4). As mentioned, the water soluble boron-containing hardeners may be present in an amount ranging from greater than 1 wt % to about 50 wt %, based on the total weight of the hardening agent. The amount included may depend upon the water solubility of the given hardener. The water soluble boron-containing hardeners that have a lower solubility (e.g., up to 10 g/100 mL, or 10% soluble) may be used in lower amounts within the given range, e.g., from greater than 1 wt % to about 10 wt %. As examples, water soluble boron-containing hardeners having water solubility ranging from about 2 g/100 mL to about 6 g/100 mL may be used in amounts ranging from greater than 1 wt % to about 6 wt %. The water soluble boron-containing hardeners that have a higher solubility (e.g., greater than 10 g/100 mL, or 10% soluble) may be used in higher amounts within the given range, e.g., from 6 wt % to about 50 wt %. As examples, water soluble boron-containing hardeners having water solubility ranging from about 75 g/100 mL to about 120 g/100 mL may be used in amounts ranging from about 12 wt % to about 20 wt %. The relatively high amounts of the water dispersible boron-containing hardeners do not deleteriously affect the jettability of the hardening agent. This may be due, in part, to the fact that the hardening agent is devoid of a pigment and a dye. “Devoid of,” as used herein, means that no pigment or dye is present in the hardening agent. The hardening agent also includes a jettable liquid vehicle. By “liquid vehicle,” it is meant that the liquid(s) into which the boron-containing hardener is introduced. By “jettable,” it is meant that that the hardening agent is dispensable from an inkjet printhead. In the examples disclosed herein, the jettable liquid vehicle includes water, a co-solvent, and an additive selected from the group consisting of a surfactant, and combinations thereof. In some examples, the vehicle of the hardening agent consists of a co-solvent and/or a surfactant, and a balance of water. In other examples, other additives may also be included, such as anti-microbial agent(s), chelating agent(s), and/or combinations thereof. The vehicle includes at least some water (e.g., deionized water, purified water). The amount of water may depend, in part, on the type of jetting architecture that is to be used. For example, if the hardening agent is to be jettable via thermal inkjet printing, water may make up 35 wt % or more of the hardening agent. In one example, water makes up from about 70 wt % to about 75 wt % of the total weight of the hardening agent. For another example, if the hardening agent is to be jettable via piezoelectric inkjet printing, water may make up from about 25 wt % to about 30 wt % of the hardening agent, and 35 wt % or more of the hardening agent may be an organic co-solvent, such as ethanol, isopropanol, acetone, etc. Classes of organic co-solvents that may be used in the hardening agent include aliphatic alcohols, aromatic alcohols, diols, triols or other polyols, glycol ethers, polyglycol ethers, lactams, formamides, acetamides, glycols, and long chain alcohols. Some of the co-solvents may also function as a humectant. Examples of suitable co-solvents include primary aliphatic alcohols, secondary aliphatic alcohols, 1,2-alcohols (e.g., 1,2-butanediol), 1,3-alcohols, 1,5-alcohols, 1,6-hexanediol or other diols (e.g., 1,5-pentanediol, 2-methyl-1,3-propanediol, 2-ethyl-2-(hydroxymethyl)-1,3-propanediol, etc.), glycerol, ethylene glycol alkyl ethers, propylene glycol alkyl ethers, higher homologs (C6-C12) of polyethylene glycol alkyl ethers, triethylene glycol, tetraethylene glycol, tripropylene glycol methyl ether, N-alkyl caprolactams, unsubstituted caprolactams, 2-pyrrolidone, 1-methyl-2-pyrrolidone, N-(2-hydroxyethyl)-2-pyrrolidone, both substituted and unsubstituted formamides, both substituted and unsubstituted acetamides, and ethoxylated glycerin, which has the following formula: in which the total of a+b+c ranges from about 5 to about 60, or in other examples, from about 20 to about 30. An example of the ethoxylated glycerin is LIPONIC® EG-1 (LEG-1, glycereth-26, a+b+c=26, available from Lipo Chemicals). Any combination of the listed co-solvents may also be used. The co-solvent(s) may be present in the hardening agent in a total amount ranging from about 1 wt % to about 50 wt % based upon the total weight of the hardening agent, depending upon the jetting architecture of the applicator. In an example, the total amount of the co-solvent(s) present in the hardening agent ranges from about 15 wt % to about 25 wt % based on the total weight of the hardening agent. In some examples, the vehicle of the hardening agent includes surfactant(s) to improve the jettability of the hardening agent. Examples of suitable surfactants include a self-emulsifiable, non-ionic wetting agent based on acetylenic diol chemistry (e.g., SURFYNOL® SEF from Evonik Degussa), a non-ionic fluorosurfactant (e.g., CAPSTONE® fluorosurfactants, such as CAPSTONE® FS-35, from Chemours), and combinations thereof. In other examples, the surfactant is an ethoxylated low-foam wetting agent (e.g., SURFYNOL® 440 or SURFYNOL® CT-111 from Evonik Degussa) or an ethoxylated wetting agent and molecular defoamer (e.g., SURFYNOL® 420 from Evonik Degussa). Still other suitable surfactants include non-ionic wetting agents and molecular defoamers (e.g., SURFYNOL® 104E from Evonik Degussa) or water soluble, non-ionic surfactants (e.g., TERGITOL™ TMN-6, TERGITOL™ 15-S-7, or TERGITOL™ 15-S-9 (a secondary alcohol ethoxylate) from The Dow Chemical Company or TECO® Wet 510 (polyether siloxane) available from Evonik Degussa). Yet another suitable surfactant includes alkyldiphenyloxide disulfonate (e.g., the DOWFAX™ series, such a 2A1, 3B2, 8390, C6L, C10L, and 30599, from The Dow Chemical Company). Whether a single surfactant is used or a combination of surfactants is used, the total amount of surfactant(s) in the hardening agent may range from about 0.01 wt % active to about 1 wt % active based on the total weight of the hardening agent. In an example, the total amount of surfactant(s) in the hardening agent may range from about 0.4 wt % to about 0.75 wt % active based on the total weight of the hardening agent. In some examples, the vehicle of the hardening agent includes an anti-microbial agent. Suitable anti-microbial agents include biocides and fungicides. Example anti-microbial agents may include the NUOSEPT™ (Troy Corp.), UCARCIDE™ (Dow Chemical Co.), ACTICIDE® B20 (Thor), ACTICIDE® M20 (Thor), and combinations thereof. Other examples include an aqueous solution of 1,2-benzisothiazolin-3-one (e.g., PROXEL® GXL from Arch Chemicals, Inc.), quaternary ammonium compounds (e.g., BARDAC® 2250 and 2280, BARQUAT® 50-65B, and CARBOQUAT® 250-T, all from Lonza Ltd. Corp.), and an aqueous solution of methylisothiazolone (e.g., KORDEK® MLX from The Dow Chemical Co.). The anti-microbial agent(s) may be added in any amount ranging from about 0.01 wt % active to about 0.05 wt % active, based on the total weight of the hardening agent. In some examples, the vehicle of the hardening agent includes a chelating agent. Chelating agents (or sequestering agents) may be included in the vehicle of the hardening agent to eliminate the deleterious effects of heavy metal impurities. Examples of chelating agents include disodium ethylenediaminetetraacetic acid (EDTA-Na), ethylene diamine tetra acetic acid (EDTA), and methylglycinediacetic acid (e.g., TRILON® M from BASF Corp.). Whether a single chelating agent is used or a combination of chelating agents is used, the total amount of chelating agent(s) in the hardening agent may range from greater than 0 wt % active to about 1 wt % active based on the total weight of the hardening agent. In an example, the chelating agent(s) is/are present in the hardening agent in an amount of about 0.08 wt % active (based on the total weight of the hardening agent). Binder Fluid The binder fluid is a fluid that includes water and polymer particles that are effective for binding layers of particulate build material when forming a 3D intermediate structure. In some examples, the polymer particles are latex particles. Latex particles refer to any polymer (homopolymer, co-polymer, or heteropolymer) that is capable of being dispersed in an aqueous medium. The polymer (latex) particles may have several different morphologies. In one example, the polymer particles can include two different copolymer compositions, which may be fully separated core-shell polymers, partially occluded mixtures, or intimately comingled as a polymer solution. In another example, the polymer particles can be individual spherical particles containing polymer compositions of hydrophilic (hard) component(s) and/or hydrophobic (soft) component(s) that can be interdispersed. In one example, the interdispersion can be according to IPN (interpenetrating networks) although it is contemplated that the hydrophilic and hydrophobic components may be interdispersed in other ways. In yet another example, the polymer particles can be composed of a hydrophobic core surrounded by a continuous or discontinuous hydrophilic shell. For example, the particle morphology can resemble a raspberry, in which a hydrophobic core can be surrounded by several smaller hydrophilic particles that can be attached to the core. In yet another example, the polymer particles can include 2, 3, or 4 or more relatively large polymer particles that can be attached to one another or can surround a smaller polymer core. In a further example, the polymer particles can have a single phase morphology that can be partially occluded, can be multiple-lobed, or can include any combination of any of the morphologies disclosed herein. In some examples, the polymer particles can be homopolymers. In other examples, the polymer particles can be heteropolymers or copolymers. In an example, a heteropolymer can include a hydrophobic component and a hydrophilic component. In this example, the heteropolymer can include a hydrophobic component that can include from about 65% to about 99.9% (by weight of the heteropolymer), and a hydrophilic component that can include from about 0.1% to about 35% (by weight of the heteropolymer). In one example, the hydrophobic component can have a lower glass transition temperature than the hydrophilic component. Examples of monomers that may be used to form the hydrophobic component of the heteropolymer polymer (latex) particles include C4 to C8 alkyl acrylates or methacrylates, styrene, substituted methyl styrenes, polyol acrylates or methacrylates, vinyl monomers, vinyl esters, ethylene, maleate esters, fumarate esters, itaconate esters, or the like. Some specific example monomers can include, C1 to C20 linear or branched alkyl (meth)acrylate, alicyclic (meth)acrylate, alkyl acrylate, styrene, methyl styrene, polyol (meth)acrylate, hydroxyethyl (meth)acrylate, or a combination thereof. In one specific class of examples, the polymer (latex) particles can be a styrene (meth)acrylate copolymer. In still another example, the polymer (latex) particles can include a copolymer with copolymerized methyl methacrylate being present at about 50 wt % or greater, or copolymerized styrene being present at about 50 wt % or greater. Both can be present, with one or the other at about 50 wt % or greater in a more specific example. The term “(meth)acrylate” or “(meth)acrylic acid” or the like refers to monomers, copolymerized monomers, etc., that can either be acrylate or methacrylate (or a combination of both), or acrylic acid or methacrylic acid (or a combination of both). In some examples, the terms “(meth)acrylate” and “(meth)acrylic acid” can be used interchangeably, as acrylates and methacrylates are salts and esters of acrylic acid and methacrylic acid, respectively. Furthermore, mention of one compound over another can be a function of pH. Furthermore, even if the monomer used to form the polymer was in the form of a (meth)acrylic acid during preparation, pH modifications during preparation or subsequently when added to an ejectable fluid, such as a binder fluid, can impact the nature of the moiety as well (acid form vs. salt or ester form). Thus, a monomer or a moiety of a polymer described as (meth)acrylic acid or as (meth)acrylate should not be read so rigidly as to not consider relative pH levels, ester chemistry, and other general organic chemistry concepts. In still other examples, the polymer (latex) particles in the binder fluid include polymerized monomers of vinyl chloride, vinylidene chloride, vinylbenzyl chloride, vinyl ester, styrene, ethylene, maleate esters, fumarate esters, itaconate esters, α-methyl styrene, p-methyl styrene, methyl methacrylate, hexyl acrylate, hexyl methacrylate, hydroxyethyl acrylate, butyl acrylate, butyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, octadecyl acrylate, octadecyl methacrylate, stearyl methacrylate, 2-phenoxyethyl methacrylate, isobornyl acrylate, tetrahydrofurfuryl acrylate, benzyl methacrylate, benzyl acrylate, ethoxylated nonyl phenol methacrylate, isobornyl methacrylate, ethylene glycol dimethacrylate, diethylene glycol dimethacrylate, triethylene glycol dimethacrylate, cyclohexyl methacrylate, trimethyl cyclohexyl methacrylate, t-butyl methacrylate, n-octyl methacrylate, lauryl acrylate, lauryl methacrylate, trydecyl methacrylate, alkoxylated tetrahydrofurfuryl acrylate, isodecyl acrylate, dimethyl maleate, dioctyl maleate, acetoacetoxyethyl methacrylate, diacetone acrylamide, N-vinyl imidazole, N-vinylcarbazole, N-Vinyl-caprolactam, pentaerythritol tri-acrylate, pentaerythritol tetra-acrylate, pentaerythritol tri-methacrylate, pentaerythritol tetra-methacrylate, glycidol acrylate, glycidol methacrylate, tetrahydrofuryl acrylate, tetrahydrofuryl methacrylate, diacetone acrylamide, t-butyl acrylamide, divinylbenzene, 1,3-butadiene, acrylonitrile, methacrylonitrile, combinations thereof, derivatives thereof, or mixtures thereof. These monomers include low glass transition temperature (Tg) monomers that can be used to form the hydrophobic component of a heteropolymer. In some examples, a composition of the polymer (latex) particles can include acidic monomer(s). In some examples, the acidic monomer content can range from 0.1 wt % to 5 wt %, from 0.5 wt % to 4 wt %, or from 1 wt % to 2.5 wt % of the polymer particles with the remainder of the polymer particle being composed of non-acidic monomers. Example acidic monomers can include acrylic acid, methacrylic acid, ethacrylic acid, dimethylacrylic acid, maleic anhydride, maleic acid, vinylsulfonate, cyanoacrylic acid, vinylacetic acid, allylacetic acid, crotonoic acid, fumaric acid, itaconic acid, sorbic acid, angelic acid, cinnamic acid, styrylacrylic acid, citraconic acid, glutaconic acid, aconitic acid, phenylacrylic acid, acryloxypropionic acid, aconitic acid, phenylacrylic acid, acryloxypropionic acid, vinylbenzoic acid, N-vinylsuccinamidic acid, mesaconic acid, methacroylalanine, acryloylhydroxyglycine, sulfoethyl methacrylic acid, sulfopropyl acrylic acid, styrene sulfonic acid, sulfoethylacrylic acid, 2-methacryloyloxymethane-1-sulfonic acid, 3-methacryoyloxypropane-1-sulfonic acid, 3-(vinyloxy)propane-1-sulfonic acid, ethylenesulfonic acid, vinyl sulfuric acid, 4-vinylphenyl sulfuric acid, ethylene phosphonic acid, vinyl phosphoric acid, vinyl benzoic acid, 2-acrylamido-2-methyl-1-propanesulfonic acid, combinations thereof, derivatives thereof, or mixtures thereof. These acidic monomers are higher Tg hydrophilic monomers, than the low Tg monomers above, and can be used to form the hydrophilic component of a heteropolymer. Other examples of high Tg hydrophilic monomers can include acrylamide, methacrylamide, monohydroxylated monomers, monoethoxylated monomers, polyhydroxylated monomers, or polyethoxylated monomers. In an example, the selected monomer(s) can be polymerized to form a polymer, heteropolymer, or copolymer with a co-polymerizable dispersing agent. The co-polymerizable dispersing agent can be a polyoxyethylene compound, such as a HITENOL® compound (Montello Inc.) e.g., polyoxyethylene alkylphenyl ether ammonium sulfate, sodium polyoxyethylene alkylether sulfuric ester, polyoxyethylene styrenated phenyl ether ammonium sulfate, or mixtures thereof. Any suitable polymerization process can be used to form the polymer particles. In some examples, an aqueous dispersion of latex particles can be produced by emulsion polymerization or co-polymerization of any of the above monomers. In one example, the polymer (latex) particles can be prepared by polymerizing high Tg hydrophilic monomers to form the high Tg hydrophilic component and attaching the high Tg hydrophilic component onto the surface of the low Tg hydrophobic component. In another example, the polymer (latex) particles can be prepared by polymerizing the low Tg hydrophobic monomers and the high Tg hydrophilic monomers at a ratio of the low Tg hydrophobic monomers to the high Tg hydrophilic monomers that ranges from 5:95 to 30:70. In this example, the low Tg hydrophobic monomers can dissolve in the high Tg hydrophilic monomers. In yet another example, the polymer (latex) particles can be prepared by polymerizing the low Tg hydrophobic monomers, then adding the high Tg hydrophilic monomers. In this example, the polymerization process can cause a higher concentration of the high Tg hydrophilic monomers to polymerize at or near the surface of the low Tg hydrophobic component. In still another example, the polymer (latex) particles can be prepared by copolymerizing the low Tg hydrophobic monomers and the high Tg hydrophilic monomers, then adding additional high Tg hydrophilic monomers. In this example, the copolymerization process can cause a higher concentration of the high Tg hydrophilic monomers to copolymerize at or near the surface of the low Tg hydrophobic component. Other suitable techniques, specifically for generating a core-shell structure, can include grafting a hydrophilic shell onto the surface of a hydrophobic core, copolymerizing hydrophobic and hydrophilic monomers using ratios that lead to a more hydrophilic shell, adding hydrophilic monomer (or excess hydrophilic monomer) toward the end of the copolymerization process so there is a higher concentration of hydrophilic monomer copolymerized at or near the surface, or any other method can be used to generate a more hydrophilic shell relative to the core. In one specific example, the low Tg hydrophobic monomers can be selected from the group consisting of C4 to C8 alkyl acrylate monomers, C4 to C8 alkyl methacrylate monomers, styrene monomers, substituted methyl styrene monomers, vinyl monomers, vinyl ester monomers, and combinations thereof; and the high Tg hydrophilic monomers can be selected from acidic monomers, unsubstituted amide monomers, alcoholic acrylate monomers, alcoholic methacrylate monomers, C1 to C2 alkyl acrylate monomers, C1 to C2 alkyl methacrylate monomers, and combinations thereof. The resulting polymer latex particles can exhibit a core-shell structure, a mixed or intermingled polymeric structure, or some other morphology. In some examples, the polymer (latex) polymer can have a weight average molecular weight (Mw, g/mol) that can range from about 5,000 Mw to about 2,000,000 Mw. In yet other examples, the weight average molecular weight can range from about 100,000 Mw to about 1,000,000 Mw, from about 100,000 Mw to about 500,000 Mw, from about 150,000 Mw to about 300,000 Mw, or from about 50,000 Mw to about 250,000 Mw. Weight average molecular weight (Mw) can be measured by Gel Permeation Chromatography with polystyrene standard. In some examples, the polymer (latex) particles can be latent and can be activated by heat (which may be applied iteratively during 3D intermediate structure formation or after 3D intermediate structure formation). In these instances, the activation temperature can correspond to the minimum film formation temperature (MFFT) or a glass transition temperature (Tg) which can be greater than ambient temperature. As mentioned herein, “ambient temperature” may refer to room temperature (e.g., ranging about 18° C. to about 22° C.). In one example, the polymer (latex) particles can have a MFFT or Tgthat can be at least about 15° C. greater than ambient temperature. In another example, the MFFT or the Tgof the bulk material (e.g., the more hydrophobic portion) of the polymer (latex) particles can range from about 25° C. to about 200° C. In another example, the polymer (latex) particles can have a MFFT or Tgranging from about 40° C. to about 120° C. In yet another example, the polymer (latex) particles can have a MFFT or Tgranging from about 0° C. to about 150° C. In a further example, the polymer latex particles can have a Tgthat can range from about −20° C. to about 130° C., or in another example from about 60° C. to about 105° C. At a temperature above the MFFT or the Tgof a latent latex polymer particle, the polymer particles can coalesce and can bind materials, such as the metal-based build material particles. The polymer (latex) particles can have a particle size that can be jetted via thermal ejection or printing, piezoelectric ejection or printing, drop-on-demand ejection or printing, continuous ejection or printing, etc. In an example, the particle size (volume-weight mean diameter) of the polymer (latex) particles can range from about 1 nm to about 400 nm. In yet other examples, a particle size of the polymer particles can range from about 10 nm to about 300 nm, from about 50 nm to about 250 nm, from about 100 nm to about 250 nm, or from about 25 nm to about 250 nm. In some examples, the polymer particles can have a particle size that can be jetted via thermal ejection or printing, piezoelectric ejection or printing, drop-on-demand ejection or printing, continuous ejection or printing, etc. In these examples, the particle size of the polymer particles be about 100 nm or more. In some examples, the polymer (latex) particles have a glass transition temperature higher than 60° C. and an average particle size of 1 nm or more. In examples of the binder fluid, the polymer particles can be present, based on a total weight of the binder fluid, in an amount ranging from about 1 wt % active to about 40 wt % active. In other more detailed examples, the polymer particles can be present in an amount ranging from about 5 wt % active to about 30 wt % active, from about 12 wt % active to about 22 wt % active, from about 15 wt % active to about 20 wt % active, from about 10 wt % active to about 20 wt % active, or from about 6 wt % active to about 18 wt % active, based on the total weight of the binder fluid. In addition to the polymer particles, the binder fluid includes a binder fluid vehicle. In one example, the binder fluid vehicle is water. In another example, the binder fluid vehicle includes water, co-solvent(s), and one or more additives, such as surfactant(s) and/or dispersing agent(s), anti-microbial agent(s), viscosity modifier(s), pH adjuster(s), chelating agent(s), and the like. In one example, water can be present at from about 30 wt % to 100 wt % of the binder fluid vehicle component—excluding polymer particles—based on a total weight of the vehicle. Put another way, the water can be present at from about 60 wt % to about 99 wt %, from about 65 wt % to 90 wt %, or from about 70 wt % to about 85 wt %, based on a total weight of the binder fluid. The co-solvent can be present in the binder fluid in an amount ranging from about 0.5 wt % to about 50 wt %, based on a total weight of the binder fluid. Any of the co-solvents described for the hardening agent may be used in the binder agent. Some specific examples include propyleneglycol ether, dipropyleneglycol monomethyl ether, dipropyleneglycol monopropyl ether, dipropyleneglycol monobutyl ether, tripropyleneglycol monomethyl ether, tripropyleneglycol monobutyl ether, dipropyleneglycol monophenyl ether, 2-pyrrolidone, 2-methyl-1,3-propanediol (MP-diol), and combinations thereof. In some examples, the binder fluid co-solvent can be a high boiling point solvent, which can have a boiling point of at least about 110° C. Any examples of the surfactant and/or dispersant set forth herein for the hardening agent may be used in the binder fluid. The surfactant or combinations of surfactants can be present in the binder fluid in an amount ranging from about 0.1 wt % active to about 5 wt % active in its respective fluid based on the total weight, and in some examples, can be present at from about 0.5 wt % active to about 2 wt % active. The dispersant or combinations of dispersants can be present in the binder fluid in an amount ranging from about 0.1 wt % active to about 5 wt % active in its respective fluid based on the total weight, and in some examples, can be present at from about 0.5 wt % active to about 2 wt % active. With respect to anti-microbial agents, any compound set forth for the hardening agent can be included in the binder fluid. In an example, the anti-microbial agent may be present in an amount ranging from about 0.0001 wt % active to about 1 wt % active. With respect to chelating agents, any compound set forth for the hardening agent can be included in the binder fluid. In an example, the example binder fluids may include a total amount of chelating agent that ranges from greater than 0 wt % to about 2 wt % active. Viscosity modifiers and buffers may also be present, as well as other additives to modify properties of the binder fluid. In some examples, the binder fluid can also include from about 0.1 wt % to about 1 wt % of an anti-kogation agent, based on a total weight of the binder fluid. Kogation refers to the deposit of dried solids on a thermal inkjet printhead. An anti-kogation agent can be included to prevent the buildup of dried solids on the printhead. Examples of suitable anti-kogation agents can include oleth-3-phosphate (commercially available as CRODAFOS™ O3A or CRODAFOS™ N-3 acid), dextran 500 k, CRODAFOS™ HCE (phosphate-ester from Croda Int.), CRODAFOS® N10 (oleth-10-phosphate from Croda Int.), or DISPERSOGEN® LFH (polymeric dispersing agent with aromatic anchoring groups, acid form, anionic, from Clariant), etc. Combined Hardening Agent and Binder Agent The examples disclosed herein describe a hardening agent and a separate binder agent. Separate agents allow for the patterning of the 3D object (with the binder agent) and the patterning for the case-hardened portions of the 3D object to be separately controlled. However, it is to be understood that the boron-containing hardener (of the hardening agent) and the polymer particles (of the binder agent) may be combined into a single hardening/binder agent. The combined hardening/binder agent may include the boron-containing hardener, the polymer particles, and any example of the vehicle described herein for the hardening agent and/or the binder agent. This combined hardening/binder agent may be useful, for example, when it is desirable to case-harden throughout the 3D object, as described in reference toFIGS.3A and3B. This combined hardening/binder agent may also be used with a separate binder agent. For example, the separate binder agent may be used to pattern portion(s) of the 3D object that are not to be case-hardened, and the combined hardening/binder agent may be used to pattern portion(s) of the 3D object that are to be case-hardened. Metal-Based Build Materials In the examples disclosed herein, the build material can include any metal build material. The phrase “metal build material” refers to particles of a metal or a metal alloy. In an example, the metal particles are a single phase metallic material composed of one element. In this example, the sintering temperature may be below the melting point of the single element. An example of these metal particles includes titanium. In another example, the metal particles are composed of two or more elements, which may be in the form of a single phase metallic alloy or a multiple phase metallic alloy. In these other examples, sintering generally occurs over a range of temperatures. Examples of these metal particles include low- to medium-carbon stainless steels, ferrous alloys, nickel alloys, cobalt alloys, or titanium alloys. In low-carbon stainless steel, the carbon level is 0.3% or less. In medium-carbon stainless steel, the carbon level ranges from about 0.31% to about 0.6%. Specific alloy examples can include stainless steel 304/304L (low-carbon), stainless steel GP1 (low-carbon), stainless steel 17-4PH (low-carbon), stainless steel 316/316L (low-carbon), stainless steel 430L (low carbon), titanium 6Al4V, titanium 6Al-4V ELI7, and cobalt-chromium super alloys, such as stellite. While several example alloys have been provided, it is to be understood that other alloys may be used. The temperature(s) at which the metal particles sinter together is/are above the temperature of the environment in which the patterning portion of the 3D printing method is performed, e.g., patterning at from about 18° C. to about 100° C. In an example, sintering (which may include de-binding and sintering) takes place at a temperature ranging from about 500° C. to about 3,500° C. In some examples, the metal particles may have a melting point ranging from about 500° C. to about 3,500° C. In other examples, the metal particles may be an alloy having a range of melting points. The particle size of the metal-based build material can be similarly sized or differently sized. In one example, the D50 particle size of the metal-based build material can range from 0.5 μm to 200 μm. In some examples, the particles can have a D50 particle size distribution value that can range from about 2 μm to about 150 μm, from about 1 μm to about 100 μm, from about 1 μm to about 50 μm, etc. Individual particle sizes can be outside of these ranges, as the “D50 particle size” is defined as the particle size at which about half of the particles are larger than the D50 particle size and about half of the other particles are smaller than the D50 particle size. The particle size may be a volume-weighted mean diameter. The shape of the particles of the particulate build material can be spherical, non-spherical, random shapes, or a combination thereof. The metal-based build material may be used alone in a build material composition, or may be used with other additives. Any of the metal-based build material compositions disclosed herein include from about 80 wt % to 100 wt % of the metal-based build material particles (based on the total weight of the composition). In other examples, the metal-based build material particles can be present in the composition in amounts ranging from about 90 wt % to 100 wt %, or from about 95 wt % to 100 wt %, or in an amount of 100 wt %. When the metal particles are present in the build material composition in an amount less than 100 wt %, the remainder of the build material composition may be made up of additives, such as flow aids (e.g., in amounts ranging from about 0.05 wt % to about 0.2 wt %), polymer powder material, etc. Multi-Fluid Kits and 3D Printing Kits The hardening agent and the binder fluid may be part of a multi-fluid kit for three-dimensional printing. In an example, the multi-fluid kit includes a binder agent, and a hardening agent, which includes a boron-containing hardener selected from the group consisting of a water dispersible boron-containing hardener present in an amount ranging from about 6 wt % to about 15 wt %, and a water soluble boron-containing hardener present in an amount ranging from about 1 wt % to about 20 wt % and a jettable liquid vehicle, wherein the hardening agent is devoid of a pigment and a dye. The hardening agent, the binder fluid, and the metal-based build material may be part of a three-dimensional printing kit. Three Dimensional Printing Methods In the 3D printing methods disclosed herein, the binder fluid is used to pattern an intermediate structure, and then high temperature heating is used to remove the polymer particles from the structure and sinter the metal-based build material together to form the 3D object. Also in the 3D printing methods disclosed herein, the hardening agent is used to case-harden desirable regions of the 3D object. FIG.1is a flow diagram illustrating examples of the method100. Generally, the method100includes: based on a 3D object model, patterning individual layers of a metal build material with a binding agent to form an intermediate structure (reference numeral102); and based on the 3D object model, patterning a case-hardened portion of a 3D object by one of: selectively depositing a hardening agent onto at least some of the individual layers of the metal build material; or selectively depositing the hardening agent onto an outermost surface of the intermediate structure; wherein the hardening agent includes: a boron-containing hardener selected from the group consisting of a water dispersible boron-containing hardener present in an amount ranging from about 6 wt % to about 15 wt %, and a water soluble boron-containing hardener present in an amount ranging from about 1 wt % to about 20 wt %, wherein the water soluble boron-containing hardener is selected from the group consisting of borax and boric acid, and a jettable liquid vehicle and wherein the hardening agent is devoid of a pigment and a dye. FIG.2A through2Dillustrate an example of the 3D printing method100where the hardening agent10(FIG.2B) is applied after the intermediate structure12(FIG.2B) is patterned and cured. As shown inFIG.2A, the metal (e.g., stainless steel) build material14is deposited from a build material source16onto a build platform18where it can be flattened or smoothed, such as by a mechanical roller or other flattening mechanism or technique. In this example, the binder fluid20can be ejected onto the metal build material14in a particular layer22from a fluid ejector24(such as a thermal inkjet printhead or a piezoelectric inkjet printhead). The fluid ejector24allows for (spatially) selective patterning of the metal build material14layer-by-layer. The location(s) of the selectively applied binder fluid20can be selected to correspond with a layer of a 3D printed object, such as from a 3D object model or computer model. The patterned portion(s) of the layer22of the metal build material14are shown at reference numeral26. The binder fluid20can be applied in a single pass or over multiple passes. The metal build material layer22may be heated. Heat (h), such as from a heat source28, may be used to remove water from the binder fluid20throughout the patterning process. This heating temperature is 120° C. or less. In an example, this temperature may range from about 50° C. to about 100° C. In one example, heat (h) can be applied from overhead, e.g., prior to application of the next layer of metal build material14, or after multiple layers are patterned. In another example, heat (h) can be provided by the build platform18from beneath the metal build material14. In still another example, heat (h) can be applied from the build material source16(which preheats the metal build material14) prior to dispensing it on the build platform18or a previously applied and patterned layer. Any of these heating methods may be used in combination. After each individual layer22is patterned with binder fluid20, the build platform18can be dropped a distance of (x), which can correspond to at least the thickness of a patterned layer in one example, so that another layer of the metal build material14can be added thereon and patterned with the binder fluid20. The process can be repeated on a layer-by-layer basis until all of the desired layers are patterned in accordance with a 3D object model to form the intermediate structure12, as shown inFIG.2B. The ejector(s)24deposit the binder fluid20in a pattern that corresponds to the layers of the 3D object, and the resulting intermediate structure12can be in any orientation. For example, the intermediate structure12can be printed from bottom to top, top to bottom, on its side, at an angle, or any other orientation. The orientation of the intermediate structure12can also be formed in any orientation relative to the layering of the metal build material14. For example, the intermediate structure12can be formed in an inverted orientation or on its side relative to the build layering within the metal build material14. The orientation of the build within the metal build material14can be selected in advance or even by the user at the time of printing, for example. After all of the desired regions of the layers22of metal build material14are patterned with the binder fluid20to define the intermediate structure12, heating all of the individually patterned layers may be performed. This heating is performed at a temperature ranging from about 120° C. to about 200° C. At this temperature range, heating coalesces the (latex) polymer particles from the binder fluid20in the patterned portion(s)26to form a strong polymer film throughout the intermediate structure12. This cures the 3D intermediate structure12, and any non-patterned metal build material14surrounding the 3D intermediate structure12remains non-cured. In this example of the method100(as shown inFIG.2B), the hardening agent10is selectively deposited onto an outermost surface of the intermediate structure12. This example of the method100may be desirable for case-hardening at the surface of the 3D object that is ultimately formed. When the hardening agent10is applied, it may be desirable for the intermediate structure12to be at a temperature that allows the vehicle of the hardening agent10to evaporate in a controlled manner without evaporating or decomposing the boron-containing hardener. Otherwise, the cured polymer binder particles may dissolve or the hardening agent10may penetrate too deeply into the intermediate structure. The hardening agent10can be ejected onto the surface of the intermediate structure12(e.g., the outermost layer of patterned and cured build material) in a particular pattern from a fluid ejector24′ (e.g., thermal inkjet ejector, piezoelectric ejector). The fluid ejector24′ enables the hardening agent10to be applied to a specific surface location. The hardening agent10can be applied in a single pass or over multiple passes, which delivers some or all of the desired concentration of the boron-containing hardener to the intermediate structure12. In addition to the number of print passes, other parameters, such as percentage of firing print nozzles, drop weight produced by the printhead, the percent solids of the boron-containing hardener in the hardening agent10, may affect the concentration of the boron-containing hardener that is delivered. Any of these parameters may be adjusted or accounted for to deliver a specific boron-containing hardener concentration per unit volume of the metal build material14. The intermediate structure12is more porous than the final 3D object30(FIG.2D), and thus the droplets of the hardening agent10are able to better infiltrate into the porous matrix of the intermediate structure12. The boron-containing hardener becomes trapped in the voids and interstices of the metal build material14as/after the hardening agent vehicle evaporates. The boron-containing hardener may diffuse further during sintering. The cured 3D intermediate structure12, with the hardening agent10applied to the surface thereof, may then be exposed to an extraction process to remove non-patterned metal build material14. An example of the wet extraction process is shown inFIG.2C. As shown inFIG.2C, the non-patterned portions of the metal build material14(e.g., the stainless steel particles not bound by the cured polymer binder particles) may be removed from the intermediate structure12by exposure to water. Water exposure may be accomplished by spraying the 3D intermediate structure12with water using wet extraction tool(s)32, such as a hose and a sprayer, a spray gun, etc. Water exposure may also be accomplished by sonicating the intermediate structure12in a water bath. Water exposure may also be accomplished by soaking the intermediate structure12in water. In some examples, the water may be heated (e.g., to a temperature ranging from about 22° C. to about 80° C. In some examples, dry extraction of non-patterned metal build material14from the intermediate structure12may be used in place of wet extraction. Vibratory or compressive forces may be applied to the metal build material14to facilitate breaking apart of any caked up non-patterned metal build material14. Any other non-patterned metal build material14that remain bound to the intermediate structure12may be removed by light bead blasting or cleaning with a brush and/or an air jet. In some examples, the intermediate structure12may be cleaned after extraction to remove any remaining non-patterned metal build material14from its surface. In an example, cleaning may be performed with a brush and/or an air jet. After the extraction and/or the cleaning of the intermediate structure12, the intermediate structure12may be heated to form the sintered 3D object30(FIG.2D). As shown inFIG.2D, the 3D intermediate structure12can be moved to a heating device36, such as a sintering oven. In one example, the heating can be at a temperature ranging from about 500° C. to about 3,500° C. At lower temperatures within the range, the network of the polymer particles can thermally degrade, thereby de-binding the 3D intermediate structure12, and at the higher temperatures within the range, the stainless steel (or other metal) particles are sintered together. In another example, the de-binding and sintering temperatures can be in the range of from about 600° C. to about 1,500° C., or from about 800° C. to about 1,200° C. The de-binding temperature range can vary, depending on the composition of the network (e.g., polymer particles). The sintering temperature range can vary, depending on the stainless steel or other metal build material that is used. In one example, the sintering temperature can range from about 10° C. below the melting temperature of the metal-based build material to about 50° C. below the melting temperature of the metal-based build material. In another example, the sintering temperature can range from about 100° C. below the melting temperature of the metal-based build material to about 200° C. below the melting temperature of the metal-based build material. The sintering temperature can also depend upon the particle size and period of time that heating occurs, e.g., at a high temperature for a sufficient time to cause particle surfaces to become physically merged or composited together. For example, a sintering temperature for stainless steel can be about 1,400° C. Temperatures outside of these ranges can be used as determined on a case by case basis. In some examples, the boron-containing hardener may be capable of diffusing at one or more temperatures within the de-binding and sintering temperature range. If it is desirable for the boron-containing hardener to diffuse further into the intermediate structure12(and the final 3D object30), the method100may include heating the intermediate structure12to a temperature that aids in diffusion of the boron-containing hardener (wherein this temperature is below a sintering temperature of the metal build material14), holding the intermediate structure12at the temperature for a predetermined time; and then heating the intermediate structure12to the sintering temperature. In some examples, the heating device36can include an inert atmosphere to avoid oxidation of the metal particles. In one example, the inert atmosphere can be oxygen-free and can include a noble gas, an inert gas, or combination thereof. For example, the inert atmosphere can include a noble gas or an inert gas selected from argon, nitrogen, helium, neon, krypton, xenon, radon, hydrogen, or a combination thereof. The resulting 3D object30, as shown inFIG.2D, has a hardened portion34. The hardened portion34has been boronized, and provides the 3D object30surface with enhanced mechanical properties (hardness, wear resistance). Referring now toFIG.3AandFIG.3B, another example of the 3D printing method100is depicted where the hardening agent10is applied layer-by-layer as the intermediate structure12′ is patterned. The example of the method100shown inFIGS.3A and3Bis similar to the example shown inFIGS.2A and2B, except that the hardening agent10is selectively applied during the patterning of the intermediate structure12′ rather than after the intermediate structure12is patterned and cured. Unlike the example described in reference toFIGS.2A and2B, this example of the method100is suitable for case-hardening at desirable portions throughout the 3D object that is ultimately formed. In particular, the hardening agent10may be applied wherever it is desirable for the 3D object to be case hardened. As shown inFIG.3A, one or more portion(s)26of one individual build material layer(s)12is/are patterned with both the binder fluid20and the hardening agent10. The fluid20and agent10may be applied sequentially in the same pass of the fluid ejectors24,24′ or in separate passes of the fluid ejectors24,24′. If desirable, other portions26may be patterned with the binder fluid20but not with the hardening agent10. In this example, another build material layer22may be applied on the previously patterned layer. The processes of patterning with the binder fluid20and (where desirable) the hardening agent10, may be repeated with this additional build material layer. Patterning may be repeated for each layer that is to be included in the intermediate structure12. Heating (h) may be used to remove water from the binder fluid20throughout the patterning process. After all of the layers22are patterned with the binder fluid20and (where desirable) the hardening agent10, the intermediate structure12′ is formed, as shown inFIG.3B. In the example shown inFIG.3B, the outermost layers and regions of the patterned portion26are patterned with both the binder fluid20and the hardening agent10, and the middle region of the patterned portion26is patterned with the binder fluid20alone. This type of pattern provides the exterior of the 3D object with the case hardened portion. The fluids20,10may be dispensed in any suitable pattern, and in some instances, the hardening agent10is applied wherever the binder fluid20is applied. The intermediate structure12′ may then be exposed to heat to cure the (latex) polymer particles from the binder fluid20in the patterned portion(s)26. This heating is performed at a temperature ranging from about 120° C. to about 200° C. This heating process forms the strong polymer film throughout the intermediate structure12′, and any non-patterned metal build material14surrounding the 3D intermediate structure12′ remains non-cured. The 3D intermediate structure12′ may be extracted as described in reference toFIG.2C, and exposed to higher temperatures (e.g., de-binding and sintering) as described in reference toFIG.2Dto form the final 3D object having case-hardened portions throughout its three-dimensional structure. This is unlike the 3D object30shown inFIG.2D, which has a case-hardened surface34. The example of the method100shown inFIGS.3A and3Bmay be desirable because it enables the ability to tailor the concentration of the boron-containing hardener for each layer22and to apply the boron-containing hardener in particular portion(s) of individual layer(s)22. The layer-by-layer process may be particularly suitable for hardening out-of-plane surfaces (such as the vertical surfaces of a gear tooth) in a straightforward manner. The layer-by-layer process may also be suitable for forming a reinforcement structure throughout a portion of the 3D object. A reinforcement structure is a portion of a 3D object that had been patterned with both the binder fluid20and the hardening agent10. The pattern of the reinforcement structure is such that it increases the mechanical strength of the 3D object without the hardening agent10having to be applied throughout the entire 3D object. Some examples of suitable reinforcement structures38A,38B,38C are shown inFIGS.4A,4B, and4C. In the example 3D object30A shown inFIG.4A, the reinforcement structure38A is a lattice. This reinforcement structure38A can be created by depositing the hardening agent10in a lattice pattern throughout the layers22. In this example, the layers22are also patterned with the binder agent20in a cubed pattern. In the example 3D object30B shown inFIG.4B, the reinforcement structure38B is an anisotropic lattice. This reinforcement structure38B can be created by depositing the hardening agent10in an anisotropic lattice pattern throughout the layers22. In this example, the layers22are also patterned with the binder agent20in a cubed pattern. In the example 3D object30C shown inFIG.4C, the reinforcement structure38C includes multiple starburst shaped objects. This reinforcement structure38C can be created by depositing the hardening agent10in individual starburst patterns throughout the layers22. In this example, the layers22are also patterned with the binder agent20in a cubed pattern. Still further, layer-by-layer patterning with the hardening agent10enables one to create a gradient in the hardness profile through the 3D object30. In this example, the method100includes varying an amount of the hardening agent10that is applied to create a gradient profile of the boron-containing hardener throughout a predetermined depth of the intermediate structure12, and ultimately the 3D object that is formed. In one example of the layer-by-layer process, several layers22are patterned with the binder fluid20, and then the outermost layers (e.g., the last 3-10 layers) are patterned with both the hardening agent10and the binder fluid30. The amount of the hardening agent10may be varied throughout the outermost layers to form the gradient. It is to be understood that the ranges provided herein include the stated range and any value or sub-range within the stated range, as if such values or sub-ranges were explicitly recited. For example, from about 0.5 wt % to about 2 wt % should be interpreted to include not only the explicitly recited limits of from about 0.5 wt % to about 2 wt %, but also to include individual values, such as about 0.85 wt %, about 1.9 wt %, etc., and sub-ranges, such as from about 0.9 wt % to about 1.5 wt %, etc. Furthermore, when “about” is utilized to describe a value, this is meant to encompass minor variations (up to +/−10%) from the stated value. Reference throughout the specification to “one example”, “another example”, “an example”, and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the example is included in at least one example described herein, and may or may not be present in other examples. In addition, it is to be understood that the described elements for any example may be combined in any suitable manner in the various examples unless the context clearly dictates otherwise. In describing and claiming the examples disclosed herein, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. While several examples have been described in detail, it is to be understood that the disclosed examples may be modified. Therefore, the foregoing description is to be considered non-limiting. | 60,401 |
11858209 | The accompanying drawings are intended to depict embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. DETAILED DESCRIPTION In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner and achieve similar results. Although the embodiments are described with technical limitations with reference to the attached drawings, such description is not intended to limit the scope of the disclosure and all of the components or elements described in the embodiments of this disclosure are not necessarily indispensable. Referring now to the drawings, embodiments of the present disclosure are described below. In the drawings for explaining the following embodiments, the same reference codes are allocated to elements (members or components) having the same function or shape and redundant descriptions thereof are omitted below. Hereinafter, a three-dimensional fabricating apparatus according to embodiments of the present disclosure will be described with reference to the accompanying drawings. External configuration of three-dimensional modeling apparatus FIG.1is a top view of a three-dimensional fabricating apparatus (an example of a fabricating apparatus) according to an embodiment of the present disclosure.FIG.2is a side view of the three-dimensional fabricating apparatus illustrated with a part of the three-dimensional fabricating apparatus cut away according to an embodiment of the present disclosure.FIG.3is a cross-sectional view of a powder chamber of the three-dimensional fabricating apparatus according to an embodiment of the present disclosure.FIG.4is a perspective view of a main part of the three-dimensional fabricating apparatus according to an embodiment of the present disclosure.FIG.5is a perspective view of the powder chamber and a perspective view of a liquid discharge unit of the three-dimensional fabricating apparatus according to an embodiment of the present disclosure. A three-dimensional fabricating apparatus601(also referred to as a powder fabricating apparatus or a powder-particle fabricating apparatus) according to embodiments of the present disclosure includes a fabricating device1and a fabricating unit5. The fabricating device1forms a fabrication layer30, which is a layered three-dimensional object formed by binding powder (powder particles). The fabricating unit5discharges a fabrication liquid10to a powder layer31spread in a layered manner in the fabricating device1to fabricate a three-dimensional object. The fabricating device1is an example of a powder layer forming device and includes a powder chamber11and a flattening roller12as a rotator which is a flattening member (recoater). The flattening member may be, for example, a plate (blade) in place of a rotator. The powder chamber11includes a supply chamber21to supply powder20and a fabrication chamber22in which the fabrication layer30is laminated to fabricate a three-dimensional object. A bottom of the supply chamber21is movable in a vertical direction (height direction) as a supply stage23. Similarly, a bottom of the fabrication chamber22is movable in the vertical direction (height direction) as a fabrication stage24. A three-dimensional object in which the fabrication layer30is laminated is fabricated on the fabrication stage24. For example, as illustrated inFIG.4, the supply stage23is moved up and down in directions indicated by arrow Z (height direction) by a motor27. Similarly, the fabrication stage24is moved up and down in the directions indicated by arrow Z by a motor28. Hereinafter, the directions indicated by arrow Z simply referred to as “Z directions”. The powder chamber11has a box shape, and includes two chambers, i.e., the supply chamber21and the fabrication chamber22, each having an open upper surface. The supply stage23is disposed inside the supply chamber21so as to be raised and lowered. The fabrication stage24is disposed inside the fabrication chamber22so as to be raised and lowered. Side faces of the supply stage23are disposed so as to be in contact with inner side faces of the supply chamber21. Side faces of the fabrication stage24are disposed so as to be in contact with inner side faces of the fabrication chamber22. Upper surfaces of the supply stage23and the fabrication stage24are kept horizontal. As illustrated inFIG.5, a surplus powder receiving chamber29including the peripheries of the supply chamber21and the fabrication chamber22is provided adjacent to the fabrication chamber22. The powder20is transferred by the flattening roller12when the powder layer31is formed, and a surplus of the powder20falls into the surplus powder receiving chamber29. A powder supply device554(seeFIG.6) is provided above the supply chamber21, and the surplus powder20that has fallen into the surplus powder receiving chamber29is returned to the supply chamber21by the powder supply device554. During an initial operation of fabricating or when the amount of powder in the supply chamber21decreases, the powder in a tank of the powder supply device554is supplied to the supply chamber21. Examples of a method of conveyance of the powder for powder supply include a screw conveyor method using a screw, an air conveyance method using air, or the like. The flattening roller12supplies the powder20supplied onto the supply stage23of the supply chamber21to the fabrication chamber22and flattens the powder20to form the powder layer31. The flattening roller12is moved by a reciprocating mechanism25so as to reciprocate (in directions indicated by arrow Y (hereinafter, Y directions) illustrated inFIGS.2and4relative to a stage surface (surface on which the powder20is placed) of the fabrication stage24. The flattening roller12is rotationally driven by a motor26. The flattening roller12transfers and supplies the powder20from the supply chamber21to the fabrication chamber22, and flattens the surface of the powder20to form the powder layer31which is a layered powder having a predetermined thickness. The flattening roller12is a rod-shaped member longer than the inner dimension of each of the fabrication chamber22and the supply chamber21(the width of a portion to which the powder is supplied or charged), and is reciprocated in the Y directions (in other words, along a sub-scanning direction) along the stage surface of the fabrication stage24by the reciprocating mechanism25. The flattening roller12is rotationally driven by the motor26illustrated inFIG.4to horizontally move to pass above the supply chamber21and the fabrication chamber22from the outside of the supply chamber21. Thus, the powder20is transferred and supplied onto the fabrication chamber22, and the flattening roller12flattens the powder20while passing over the fabrication chamber22to form the powder layer31. Further, as illustrated inFIG.2, the flattening roller12is provided with a powder removing plate13. The powder removing plate13moves together with the flattening roller12in a state in which the powder removing plate13is in contact with a peripheral surface of the flattening roller12, and removes the powder20adhering to the flattening roller12. The three-dimensional fabricating apparatus601according to the present embodiment is described on the assumption that the powder chamber11of the fabricating device1includes the two chambers, i.e., the supply chamber21and the fabrication chamber22. However, only the fabrication chamber22may be provided and the powder20may be supplied from a powder supply device to the fabrication chamber22and flattened by the flattening roller12. The fabricating unit5includes a liquid discharge unit50that discharges the fabrication liquid10to the powder layer31on the fabrication stage24. The fabricating unit includes a slider72movably held by a guide71disposed on a base7, and the entire fabricating unit5can reciprocate in the Y directions (in other words, along the sub-scanning direction) orthogonal to directions indicated by arrow X (hereinafter, X directions) inFIG.4. The entire fabricating unit5is reciprocated in the Y direction by a Y-direction scanning mechanism552(illustrated inFIG.6) described later. The liquid discharge unit50is an example of a fabrication liquid discharge unit and includes a carriage51and, for example, two liquid discharge heads (hereinafter simply referred to as “heads”)52aand52bprovided on the carriage51. Note that the number of heads is not limited to two and may be one or three or more. The liquid discharge unit50is provided to be movable up and down in the Z directions illustrated inFIG.4together with guides54and55, and is moved up and down in the Z directions by a Z-direction lifting mechanism551(illustrated inFIG.6) described later. The carriage51(seeFIG.1) is movably held by the guide54and the guide55. The guide54and the guide55are held by side plates70on both sides of the fabricating unit5so as to be movable vertically. The carriage51is reciprocated by an X-direction scanning mechanism550(illustrated inFIG.6), which will be described later, via a main scanning movement mechanism including a motor, a pulley, and a belt, in the X directions which are main scanning directions. In each of the two heads52aand52b(hereinafter, referred to as “heads52” when not distinguished from each other), two nozzle rows are arranged in which a plurality of nozzles that discharge the fabrication liquid10are aligned. The head configuration and the liquid to be discharged are not limited to the above-described configuration. A plurality of tanks60containing these liquids are mounted on a tank mounter56. The liquid in each tank60is supplied to the heads52aand52bvia supply tubes or the like. A maintenance mechanism61that performs maintenance and recovery of the heads52of the liquid discharge unit50is provided on one side in the X direction. The maintenance mechanism61includes caps62and a wiper63. The maintenance mechanism61brings the caps62into close contact with the nozzle surfaces (the surfaces on which the nozzles are formed) of the heads52and sucks the fabrication liquid10from the nozzles to discharge the powder clogged in the nozzles and the fabrication liquid having a high viscosity. Thereafter, the nozzle surface of the heads52are wiped by the wiper63to form meniscuses of the nozzles (in a state in which the inside of the nozzles is in a negative pressure state). When the fabrication liquid10is not discharged, the maintenance mechanism61covers the nozzle surfaces of the heads52with the caps62to prevent mixing of the powder20into the nozzles and drying of the fabrication liquid10. Hardware Configuration FIG.6is a block diagram of a hardware configuration of the three-dimensional fabricating apparatus601according to an embodiment of the present disclosure. InFIG.6, a controller500of the three-dimensional fabricating apparatus601includes a central processing unit (CPU)501, a read only memory (ROM)502, a random access memory (RAM)503, and a non-volatile random access memory (NVRAM)504. The CPU501controls the entire three-dimensional fabricating apparatus601. The ROM502stores various programs such as a fabrication program for causing the CPU501to execute three-dimensional fabrication control other than fixed data and the like. The RAM503temporarily stores fabrication data and the like. The NVRAM504is a non-volatile memory that retains data even while the device is powered off. The CPU501, the ROM502, and the RAM503mainly form a main control unit500A. The controller500includes an application specific integrated circuit (ASIC)505that processes input and output signals for controlling the entire three-dimensional fabricating apparatus601in addition to various signal processing performed on image data. The controller500includes an external interface (external I/F)506for transmitting and receiving fabrication data and the like to and from a fabrication data generation apparatus600, which is an external device. The fabrication data generation apparatus600is an apparatus that generates fabrication data obtained by slicing a fabricated object in a final form into fabrication layers, and includes an information processing apparatus such as a personal computer. Further, the controller500includes an input and output unit (I/O)507for capturing detection signals of various sensors, and a head drive controller508that controls driving of each of the heads52aand52bof the liquid discharge unit50. The CPU501and the head drive controller508are examples of a discharge controller. The controller500includes a motor driver510that drives a motor of a X-direction scanning mechanism550to move the carriage51of the liquid discharge unit50in the X directions (i.e., the main scanning directions), and a motor driver512that drives a motor of a Y-direction scanning mechanism552to move the fabricating unit5in the Y directions (or along the sub-scanning directions). In addition, the controller500includes a motor driver511to that drives a motor of a Z-direction lifting mechanism551to move (lift up and down) the carriage51of the liquid discharge unit50in the Z directions. The elevation in the Z directions may elevate the entire fabricating unit5. The controller500includes a motor driver513that drives a motor27to raise and lower the supply stage23, and a motor driver514that drives a motor28to raise and lower the fabrication stage24. The controller500includes a motor driver515that drives a motor553of the reciprocating mechanism25to move the flattening roller12, and a motor driver516that drives the motor26to rotationally drive the flattening roller12. Further, the controller500includes a supply system driver517that drives the powder supply device554to supply the powder20to the supply chamber21, and a maintenance driver518that drives the maintenance mechanism61of the liquid discharge unit50. The I/O507of the controller500is supplied with detection signals indicating temperature and humidity as environmental conditions of the three-dimensional fabricating apparatus601, which are detected by a temperature and humidity sensor560, and is also supplied with detection signals of other sensors. An operation panel522for inputting and displaying information necessary for the three-dimensional fabricating apparatus601is connected to the controller500. Note that a three-dimensional fabricating system includes the fabrication data generation apparatus600and the three-dimensional fabricating apparatus601. Fabricating OperationFIGS.7A,7B,7C,7D, and7Eare diagrams of an operation flow in which the three-dimensional fabricating apparatus601fabricates a fabricated object.FIG.7Aillustrates a state in which the first fabrication layer30is formed on the fabrication stage24of the fabrication chamber22. When the next fabrication layer30is formed on the first fabrication layer30, as illustrated inFIG.7A, the supply stage23of the supply chamber21is raised in a Z1 direction, and the fabrication stage24of the fabrication chamber22is lowered in a Z2 direction. At this time, the lowering distance of the fabrication stage24is set such that a distance between an upper surface (surface of a powder layer) of the fabrication chamber22and a lower portion (lower tangent portion) of the flattening roller12is Atl. The distance Δt1 corresponds to the thickness of a powder layer31to be formed next. The distance Δt1 is preferably about several tens μm to 100 μm. Next, as illustrated inFIG.7B, the flattening roller12is moved in a Y2 direction toward the fabrication chamber22while the flattening roller12is rotated in a forward direction (i.e., a direction indicated by arrow inside the flattening roller12inFIG.7B). Thus, the powder20located above the upper surface level of the supply chamber21is transferred and supplied to the fabrication chamber22(powder supply). Furthermore, as illustrated inFIG.7C, the flattening roller12is moved in parallel with the stage surface of the fabrication stage24of the fabrication chamber22to form, as illustrated inFIG.7D, the powder layer31having the predetermined thickness Δt1 on the fabrication layer30of the fabrication stage24(flattening). After the powder layer31is formed, the flattening roller12is moved in the Y1 direction and returned to the initial position as illustrated inFIG.7D. In the present embodiment, the flattening roller12can move while maintaining the constant distance from the upper surface levels of the fabrication chamber22and the supply chamber21. The flattening roller12can move while maintaining the constant distance from the upper surface levels of the fabrication chamber22and the supply chamber21. Therefore, while conveying the powder20onto the fabrication chamber22by the flattening roller12, the powder layer31having the uniform thickness Δt1 can be formed on the fabrication chamber22or on the fabrication layer30that has been already formed. Then, as illustrated inFIG.7E, droplets of fabrication liquid10are discharged from the head52of the liquid discharge unit50to form and laminate the next fabrication layer30on the powder layer31(fabrication). Note that, for the fabrication layer30, for example, when the fabrication liquid10discharged from the head52is mixed with the powder20, adhesives contained in the powder dissolve and bond together. Thus, particles of the powder20bind together to form the fabrication layer30. Subsequently, the above-described step of forming the powder layer31by supplying and flattening powder and the above-described step of discharging the fabrication liquid10by the heads52are repeated to form a new fabrication layer30. At this time, the new fabrication layer30and the fabrication layer30thereunder are integrated to constitute a part of a three-dimensional fabricated object. Thereafter, the forming step of the powder layer31by supplying and flattening the powder20and the step of discharging the fabrication liquid10with the heads52are repeated a required number of times to complete the fabrication of the three-dimensional fabrication object (fabricated object). Behavior of Powder Surface on Landing of Fabrication Liquid10in Comparative Examples FIGS.8A,8B,8C,8D, and8Eillustrate a behavior of a powder surface when droplets of fabrication liquid10land on the powder surface during fabrication by a three-dimensional fabricating apparatus according to a comparative example.FIGS.8A,8B,8C,8D, and8Eare enlarged schematic views of droplets10aof the fabrication liquid10and powder20as the fabrication powder. InFIGS.8A,8B,8C,8D, and8E, the powder20transferred and supplied from the supply chamber21to the fabrication chamber22by the flattening roller12is accumulated in the fabrication chamber22at a density close to a bulk density (a density calculated by filling the powder in a container having a predetermined volume and setting the internal volume as a volume). However, the density of the powder20depends on the material or the particle size distribution of the powder20. FIG.8Ais a diagram illustrating a state in which droplets10adischarged from a liquid discharge head52are dropped onto a powder layer31.FIG.8Bis a diagram illustrating a state in which the droplets10aland on the powder layer31. In the case of the present comparative example, a part of the powder on the surface of the powder layer31is flicked off by the kinetic energies of the droplets10aas illustrated inFIG.8B. As a result, asperities are formed on the surface of the powder layer31as illustrated inFIG.8C. Next,FIG.8Cis a diagram illustrating a state in which droplets10bas second droplets are dropped.FIG.8Dis a diagram illustrating a state in which powder is transferred and supplied from the supply chamber21to the fabrication chamber22and accumulated in the fabrication chamber22. As illustrated inFIG.8C, gaps (voids) are formed in the fabrication layer30due to the asperities that have been formed when the droplets10aland on the powder layer30. In the above-described state, when new powder is laminated by the flattening roller12as illustrated inFIG.8D, gaps305are formed between the fabrication layer30that has been formed and a newly laminated powder layer31as illustrated inFIG.8E, thus causing the density of the fabricated object to be reduced. Further, the powder flicked off when the droplets10aland on the powder layer31adheres to the nozzle surface of the liquid discharge head52moving above the powder layer31. As a result, non-discharge or discharge bending (deviation of discharge position) of the droplets of the liquid discharge head52occurs and a streak-like defect occurs in the fabricated object. Droplet Discharge Control According to Embodiment Next, droplets discharge control in the three-dimensional fabricating apparatus601according to an embodiment of the present disclosure is described with reference toFIGS.9A,9B,9C,9D, and9E.FIG.9Ais a diagram illustrating a state in which droplets10adischarged from a liquid discharge head52are dropped onto a powder layer31.FIG.9Bis a diagram illustrating a state in which the droplets10aland on the powder layer31.FIG.9Cis a diagram illustrating a state in which droplets10bas second droplets are dropped.FIG.9Dis a diagram illustrating a state in which powder is transferred and supplied from the supply chamber21to the fabrication chamber22and accumulated in fabrication chamber22. In the three-dimensional fabricating apparatus601according to the present embodiment, the droplets10aland on the powder layer31after the powder layer31is formed. The droplets10bas the second droplets land on a region at least partially overlapping with a region on which the droplets10bhave landed. Thereafter, the next powder layer31is formed. That is, after the powder layer31is formed, droplets discharged from the head52are dropped so that a plurality of regions on which the droplets land at least partially overlap before the next powder layer31is formed. In the case of the three-dimensional fabricating apparatus601according to the present embodiment, the head drive controller508, with the drive control of the CPU501, controls the head52so that the head52discharges the droplets10aas the first droplets having smaller kinetic energy than the droplets10bas the second droplets as illustrated inFIG.9A. A plurality of droplets is discharged to each one pixel on the powder layer31. That is, the droplets10bas the second droplets are discharged so that at least some of the droplets10boverlaps the droplets10aas the first droplets. When two or more droplets10bas the second droplets are discharged so that at least a part of the region on which the droplets10bland overlaps the region on which the droplets10ahave landed, preferably the head52is controlled so that the kinetic energy of the nth droplet is smaller than the kinetic energy of the (n+1)-th droplet. In other words, the head52is controlled so that the (n+1)-th droplet has a larger kinetic energy than the kinetic energy of the nth droplet.FIG.9Aillustrates droplets10ahaving a small mass as an example of a droplet having a small kinetic energy. When the above-described droplets10aland on the powder layer31, the kinetic energy of the droplets10ais small. Therefore, as illustrated inFIG.9B, the number of powder particles flicked off from the surface of the powder layer31and the speed of the flicked powder particles are small. As a result, the asperities of the powder layer31after the droplets10aland on the powder layer31becomes small. Next, the head drive controller508, with the drive control of the CPU501, controls the head52so that the head52discharges the droplets10bas the second droplets having normal kinetic energy as illustrated inFIG.9C. The droplets10bas the second droplets have larger kinetic energy than the droplets10aas the first droplets. That is, the three-dimensional fabricating apparatus601according to the present the embodiment discharges the droplets10aas the first droplets as droplets having a smaller size than normal droplets, and discharges droplets10bhaving a normal size after the second droplets. When the droplets10bas the second droplets are dropped, the droplets10aas the first droplets have penetrated into the powder layer31, as illustrated inFIG.9C. Thus, the powder particles on the surface of the powder layer31are unlikely to move. As a result, even when the droplets10bas the second droplets land on the powder layer31, the powder particles on the surface of the powder layer31are hardly flicked off and there are few asperities formed on the powder layer31, and the formed asperities are also small. In this state, when the flattening roller12accumulates the powder as illustrated inFIG.9D, the asperities of the powder layer31being small can reduce the size of the gaps formed in the fabrication layer30. Such small gaps, as illustrated inFIG.9E, can increase the density of the fabricated object. Thus, a fabricated object having high properties such as strength, durability, and thermal conductivity can be obtained. In addition, the three-dimensional fabricating apparatus601according to the present embodiment can reduce the flying up of the powder20. Thus, the adhesion of the powder20to the nozzle surface can be reduced and the discharge failure such as the discharge bending or non-discharge can be prevented, thus preventing the streak-like defect from occurring in the fabricated object. The CPU501illustrated inFIG.6executes at least following three steps based on a droplet discharge program stored in a storage device such as the ROM502. First, the CPU501executes a powder layer forming step to form the powder layer31. Second, the CPU501executes a first fabrication liquid discharging step to discharge the fabrication liquid10onto the powder layer31. Third, the CPU501executes a second fabrication liquid discharging step to discharge the fabrication liquid10having a higher kinetic energy than the fabrication liquid10discharged in the first fabrication liquid discharging step to a region at least partially overlapping with a region to which the fabrication liquid10is discharged in the first fabrication liquid discharging step. Thus, the above-described effects can be obtained. Prototype Experimental Results Prototype experimental results of the above-described three-dimensional fabricating apparatus601are described below. In this prototype experiment, a silicon-based aluminum alloy (AlSi10Mg) was used as the powder20. The size of the fabricated object used for the experiment is 40 mm in the main scanning direction, 20 mm in the sub-scanning direction, and 5 mm in the layering direction. The fabricated object was fabricated under fabrication conditions described in Tables 1 to 11 below. First, Table 1 below describes an example in which the head drive controller508controls such that the discharge amount of the droplets10aas the first droplets is half of the discharge amount of the droplets10bas the second droplets (8 pL and 16 pL, respectively), and the discharge speed of the droplets10aas the first droplets is about two thirds of the discharge speed of the droplets10bas the second droplets (5 m/s and 7 m/s, respectively) in a same scan (the amount and speed of discharge of the droplets10aand10bin the same scan are changed). The discharge amount of the droplets10aas the first droplets is smaller than the discharge amount of the droplets10bas the second droplets and the discharge speed of the droplets10aas the first droplets is slower than the discharge speed of the droplets10bas the second droplets. Thus, the kinetic energy of the droplets10aas the first droplets can be made smaller, and the flying up of the powder can be restrained. TABLE 1First dropletsSecond dropletsLamination pitch [μm]84.7Number of discharging of droplets2Same scan or different scansSame scanSpecific gravity [g/cm3]1.161.16Surface energy [mN/m]3232Discharge amount [pL]816Discharge speed [m/s]57Kinetic energy [J]0.120.45Resolution (main scanning direction ×300 × 300300 × 300sub-scanning direction) [dpi2] Next, Table 2 below describes an example in which the head drive controller508controls such that the discharge amount of the droplets10aas the first droplets is set to half of the discharge amount of the droplets10bas the second droplets in a same scan, and the discharge speed and the like are set to be the same between the droplets10aand the droplets10b(only the discharge amounts of the droplets10aand10bin the same scan are changed). Setting the discharge amount of the first droplets to be smaller than the discharge amount of the second droplets can reduce the kinetic energy of the first droplets and restrain flying up of the powder. TABLE 2First dropletsSecond dropletsLamination pitch [μm]84.7Number of discharging of droplets2Same scan or different scansSame scanSpecific gravity [g/cm3]1.161.16Surface energy [mN/m]3232Discharge amount [pL]816Discharge speed [m/s]66Kinetic energy [J]0.170.33Resolution (main scanning direction ×300 × 300300 × 300sub-scanning direction) [dpi2] Next, Table 3 below describes an example in which the head drive controller508controls such that the discharge speed of the droplets10aas the first droplets is set to about two thirds of the discharge speed of the droplets10bas the second droplets (5 m/s and 7 m/s, respectively) in the same scan, and the discharge amount and the like are set to be the same between the first droplets and the second droplets (only the discharge speed of the first droplets and the second droplets in the same scan are changed). Setting the discharge speed of the first droplets to be lower than the discharge speed of the second droplets can reduce the kinetic energy of the first droplets and restrain the flying up of the powder. TABLE 3The discharge speed of the droplets 10a as the first droplets issmaller than the discharge speed of the droplets 10b as thesecond droplets. Thus, the kinetic energy of the droplets10a as the first droplets is smaller than the kineticenergy of the droplets 10b as the second droplets.First dropletsSecond dropletsLamination pitch [μm]84.7Number of discharging of droplets2Same scan or different scansSame scanSpecific gravity [g/cm3]1.161.16Surface energy [mN/m]3232Discharge amount [pL]1212Discharge speed [m/s]57Kinetic energy [J]0.170.34Resolution (main scanning direction ×300 × 300300 × 300sub-scanning direction) [dpi2] Next, Table 4 below is an example in which the head drive controller508changes the discharge amount and the discharge speed of first droplets10a, second droplets10b, and third droplets10cin a same scan. In this example, the head drive controller508controls the discharge amount and the discharge speed of the droplets10a,10b, and10csuch that the first droplets (droplets10a)<the second droplets (droplets10b)<the third droplets (droplets10c). For example, the head drive controller508controls the discharge amounts of the first droplets (droplets10a), the second droplets (droplets10b), and the third droplets (droplets10c) to 6 pL, 8 pL, and 16 pL, respectively. In addition, the head drive controller508controls the discharge speeds of the first droplets (droplets10a), the second droplets (droplets10b), and the third droplets (droplets10c) to 5 m/s, 6 m/s, and 7 m/s, respectively (the amounts and speeds of the first droplets10a, the second droplets10b, and the third droplets10cin the same scan are changed). Setting the discharge amounts and the discharge speeds of the first droplets, the second droplets, and the third droplets such that the first droplets<the second droplets<the third droplet can control the kinetic energy to be enlarged in a stepwise manner from the first droplets to the third droplets, and can restrain the flying up of the powder. TABLE 4Cases of three droplets are compared.FirstSecondThirddropletsdropletsdropletsLamination pitch [μm]84.7Number of discharging of droplets3Same scan or different scansSame scanSpecific gravity [g/cm3]1.161.161.16Surface energy [mN/m]323232Discharge amount [pL]6810Discharge speed [m/s]567Kinetic energy [J]0.090.170.28Resolution (main scanning direction ×300 × 300300 × 300300 × 300sub-scanning direction) [dpi2] Next, Table 5 below describes an example in which the head drive controller508controls such that the discharge amount of the droplets10aas the first droplets is set to half of the discharge amount of the droplets10bas the second droplets (8 pL and 16 pL, respectively) in different scans and the discharge speed of the droplets10aas the first droplets is set to about two thirds of the discharge speed of the droplets10bas the second droplets (5 m/s and 7 m/s, respectively) in the different scans (in other words, the discharge amounts and discharge speeds of the first droplets and the second droplets in the different scans are changed). Discharging the first droplets and the second droplets in different scans allows the first droplets to be sufficiently wet and spread on the powder before the second droplets land on the powder, and can restrain flying up of the powder particles when the second droplets land on the powder. TABLE 5First dropletsSecond dropletsLamination pitch [μm]84.7Number of discharging of droplets2Same scan or different scansDifferent scansSpecific gravity [g/cm3]1.161.16Surface energy [mN/m]3232Discharge amount [pL]816Discharge speed [m/s]57Kinetic energy [J]0.120.45Resolution (main scanning direction ×300 × 300300 × 300sub-scanning direction) [dpi2] Next, Table 6 below describes an example in which the head drive controller508sets the resolution of the droplets10aas the first droplets in the main scanning direction and the sub-scanning direction to be higher than the resolution of the droplets10bas the second droplets in the same scan, sets the discharge amount of the droplets10aas the first droplets to be greatly reduced to one eighths of the discharge amount of the droplets10bas the second droplets (2 pL and 16 pL, respectively), and sets the discharge speed of the droplets10aas the first droplets is about two thirds of the discharge speed of the droplets10bas the second droplets (5 m/s and 7 m/s, respectively) (in other words, the resolution and discharge amount of the droplets10aare significantly reduced and the discharge speeds of the droplets10aand the droplet10bare changed in the same scan). TABLE 6First dropletsSecond dropletsLamination pitch [μm]84.7Number of discharging of droplets2Same scan or different scansDifferent scansSpecific gravity [g/cm3]1.161.16Surface energy [mN/m]3232Discharge amount [pL]216Discharge speed [m/s]57Kinetic energy [J]0.030.45Resolution (main scanning direction ×600 × 600300 × 300sub-scanning direction) [dpi2] Next, Table 7 below describes an example in which the head drive controller508sets the resolution of the droplets10aas the first droplets in the main scanning direction to be higher than the resolution of the droplets10bas the second droplets in a same scan, the discharge amount of the droplets10aas the first droplets to be smaller by one fourth than the discharge amount of the droplets10bas the second droplets (4 pL and 16 pL, respectively), and the discharge speed of the droplets10aas the first droplets to be about two thirds of the discharge speed of the droplets10bas the second droplets (5 m/s and 7 m/s, respectively) (in other words, the resolution and discharge amount of the droplets10aare reduced and the discharge speed of the droplets10aand the droplets10bare changed in the same scan). When the discharge amount of the droplets10aas the first droplets is decreased and the resolution of the droplets10ais increased, the penetration of the droplets10ain the powder surface direction increases with respect to the penetration depth in the lamination direction. On the other hand, it is necessary for the fabrication liquid10to sufficiently permeate in the lamination direction and permeate between the lamination layers to obtain a fabricated object. Therefore, setting the resolution of the droplets10aas the first droplets to be higher than the resolution of the droplets10bas the second droplets can sufficiently wet the powder surface with the fabrication liquid10before the droplets10bas the second droplets land on the powder surface. Thus, flying up of the powder can be restrained when the droplets10bas the second droplets lands on the powder surface. Further, setting the discharge amount of the droplets10bas the second droplets to be larger than the discharge amount of the droplets10aas the first droplets can make the resolution of the droplets10bas the second droplets to be lower than the resolution of the droplets10aas the first droplets, thus ensuring penetration of the fabrication liquid10in the laminating direction. TABLE 7The resolution of the droplets 10a as the first droplets ishigher than the resolution of the droplets 10b as thesecond droplet only in the main scanning direction.First dropletsSecond dropletsLamination pitch [μm]84.7Number of discharging of droplets2Same scan or different scansDifferent scansSpecific gravity [g/cm3]1.161.16Surface energy [mN/m]3232Discharge amount [pL]416Discharge speed [m/s]57Kinetic energy [J]0.060.45Resolution (main scanning direction ×600 × 300300 × 300sub-scanning direction) [dpi2] Next, Table 8 below describes an example in which droplets having different specific gravities are used as the droplets10aas the first droplets and the droplets10bas the second droplets. As an example, in the case of Table 8, droplets having a specific weight of 1.04 g/cm3were used as the droplets10aas the first droplets, and droplets having a specific weight of 1.16 g/cm3were used as the droplets10bas the second droplets. Table 8 describes an example in which the head drive controller508sets the discharge amount of the droplets10aas the first droplets to be reduced to half of the discharge amount of the droplets10bas the second droplets (8 pL and 16 pL, respectively) and the discharge speed of the droplets10aas the first droplets to be about two thirds of the discharge speed of the droplets10bas the second droplets (5 m/s and 7 m/s, respectively) in a same scan (in other words, different liquid materials were used in the same scan and the discharge amounts and the discharge speeds of the droplets10aand10bwere changed). TABLE 8Different liquid materials were used for the droplets 10a as the firstdroplets and the droplets 10a as the second droplets. The specificgravity of the droplets 10a as the first droplets is smaller than thespecific gravity of the droplets 10b as the second droplet.First dropletsSecond dropletsLamination pitch [μm]84.7Number of discharging of droplets2Same scan or different scansSame scanSpecific gravity [g/cm3]1.041.16Surface energy [mN/m]3232Discharge amount [pL]816Discharge speed [m/s]57Kinetic energy [J]0.100.45Resolution (main scanning direction ×300 × 300300 × 300sub-scanning direction) [dpi2] Next, Table 9 below describes an example in which droplets having different specific gravities were used as the droplets10aas the first droplets and the droplets10bas the second droplets. As an example, in the case of Table 9, droplets having a specific gravity of 1.04 g/cm3 were used as the droplets10aas the first droplets and droplets having a specific gravity of 1.16 g/cm3 were used as the droplets10bas the second droplets. Table 9 describes an example in which the surface energy of the droplets10aas the first droplets is smaller than the surface energy of the droplets10bas the second droplets, and the surface energy of the droplets10aas the first droplets is 26 mN/m and the surface energy of the droplets10bas the second droplets is 32 mN/m. Further, Table 9 describes an example in which the head drive controller508sets the discharge amount of the droplets10aas the first droplets to be reduced to half of the discharge amount of the droplets10bas the second droplets (8 pL and 16 pL, respectively) and the discharge speed of the droplets10aas the first droplets to be about two thirds of the discharge speed of the droplets10bas the second droplets (5 m/s and 7 m/s, respectively) in a same scan (in other words, different liquid materials were used in the same scan and the kinetic energies, the discharge amounts and the discharge speeds of the droplets10aand10bwere changed). TABLE 9Different liquid materials were used for the droplets 10a as the firstdroplets and the droplets 10b as the second droplets. The surfaceenergy of the droplets 10a as the first droplet is smaller than thesurface energy of the droplets 10a as the second droplets.First dropletsSecond dropletsLamination pitch [μm]84.7Number of discharging of droplets2Same scan or different scansSame scanSpecific gravity [g/cm3]1.041.16Surface energy [mN/m]2632Discharge amount [pL]816Discharge speed [m/s]57Kinetic energy [J]0.100.45Resolution (main scanning direction ×300 × 300300 × 300sub-scanning direction) [dpi2] In contrast to the Tables 1 to 9 as described above, Tables 10 and 11 describe experimental results of comparative examples. That is, Table 10 below describes an example in which the droplets10aas the first droplets and the droplets10bas the second droplets were discharged under the same conditions without changing the discharge amount, the discharge speed, and the like. Similarly, Table 11 below describes an example in which the droplets10aas the first droplets, the droplets10bas the second droplets, and the droplets10cas the third droplets were discharged under the same conditions without changing the discharge amount, the discharge speed, and the like. TABLE 10First dropletsSecond dropletsLamination pitch [μm]84.7Number of discharging of droplets2Same scan or different scansSame scanSpecific gravity [g/cm3]1.161.16Surface energy [mN/m]3232Discharge amount [pL]1212Discharge speed [m/s]77Kinetic energy [J]0.340.34Resolution (main scanning direction ×300 × 300300 × 300sub-scanning direction) [dpi2] TABLE 11FirstSecondThirddropletsdropletsdropletsLamination pitch [μm]84.7Number of discharging of droplets3Same scan or different scansSame scanSpecific gravity [g/cm3]1.161.161.16Surface energy [mN/m]323232Discharge amount [pL]888Discharge speed [m/s]777Kinetic energy [J]0.230.230.23Resolution (main scanning direction ×300 × 300300 × 300300 × 300sub-scanning direction) [dpi2] Table 12 below summarizes the density ratios of the fabricated objects, the presence or absence of the streak-like defect in the fabricated objects, and the kinetic energy of each turn of droplets in the experiments under the conditions described in each of the tables above. TABLE 12Presence ofstreak-likeKinetic energy [J]Densitydefect ofFirstSecondThirdratio [%]fabricated objectdropletsdropletsdropletsTABLE 152.9None0.120.45—TABLE 253.5None0.170.33—TABLE 353.6None0.170.34—TABLE 454.8None0.090.170.28TABLE 554.6None0.120.45—TABLE 654.2None0.030.45—TABLE 752.3None0.060.45—TABLE 853.5None0.100.45—TABLE 954.4None0.100.45—TABLE 1048.0Present0.340.34—TABLE 1149.1Present0.230.230.23 The density ratios of the fabricated objects described in Table 12 are ratios of the densities of the fabricated objects with respect to the densities of AlSi10Mg used as the powder by using the Archimedes principle. In addition, the presence or absence of the streak-like defect of the fabricated objects generated due to non-discharge or discharge bending of the droplets from the liquid discharge head52was determined by visual observation of the fabricated objects. As can be seen from Table 12, in the case of the examples of Table 10 and Table 11 as the comparative examples, the kinetic energy of all the droplets is the same, and the density of the fabricated objects is low with the density ratio being 48.0% or 49.1%. In addition, the flying powder adheres to the discharge nozzle, and streak-like defects are generated in the fabricated objects. On the other hand, in the examples of Tables 1 to 9 in which the kinetic energy of the droplets10aas the first droplets was reduced, the density ratio of the fabricated objects was significantly increased to 52.3% to 54.8%. In addition, the flying up of the powder was restrained and the streak-like defects in the fabricated objects were prevented from being generated. EFFECTS OF EMBODIMENTS As apparent from the above description, the three-dimensional fabricating apparatus601according to the above-described embodiments of the present disclosure is a three-dimensional fabricating apparatus of a fabricating liquid discharge method that discharges the fabrication liquid10to the laminated powder and solidifies the fabrication liquid10to fabricate the fabricated object, and sets the kinetic energy of the droplets10aas the first droplets of the fabrication liquid10to be smaller than the kinetic energy of the droplets10bas the second and subsequent droplets of the fabrication liquid10with respect to one pixel. As a result, the droplets10aas the first droplets of the fabrication liquid10lands on the powder surface with small kinetic energy. Thus, the flying up of the powder can be reduced. In addition, when the droplets10bas the second and subsequent droplets of the fabrication liquid10land on the powder surface, the powder surface is wet with the droplets10aas the first droplets of the fabrication liquid10. Thus, the powder is unlikely to move. For this reason, the flying up of the powder particles can be reduced even when the fabrication liquid10as the second and subsequent droplets land on the powder surface. Therefore, a disadvantage that the powder surface is roughened due to flying up of the powder particles can be prevented, and the low density of the fabricated objects can be prevented. In addition, the amount of the powder particles flying up from the powder surface can be reduced when the droplets land on the powder surface. Such a configuration can prevent the powder particles from flying up and adhering to the nozzle surface of the liquid discharge head moving above the powder surface. Thus, a disadvantage that discharge bending or discharge failure hampers normal image formation can be prevented. The above-described embodiments are presented as examples and are not intended to limit the scope of the present disclosure. The above-described embodiments can be implemented in other various forms, and various omissions, replacements, and changes can be made without departing from the scope of the present disclosure. In addition, the embodiments and modifications or variations thereof are included in the scope and the gist of the present disclosure. Each of the functions of the described embodiments may be implemented by one or more processing circuits or circuitry. Processing circuitry includes a programmed processor, as a processor includes circuitry. A processing circuit also includes devices such as an application specific integrated circuit (ASIC), digital signal processor (DSP), field programmable gate array (FPGA), and conventional circuit components arranged to perform the recited functions. | 47,337 |
11858210 | DESCRIPTION Embodiments will now be described with reference to the accompanying figures. The foregoing may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. All documents mentioned herein are hereby incorporated by reference in their entirety. References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Thus, the term “or” should generally be understood to mean “and/or” and so forth. Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein. The words “about,” “approximately,” or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Ranges of values and/or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the described embodiments. The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the embodiments. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the embodiments. In the following description, it is understood that terms such as “first,” “second,” “top,” “bottom,” “up,” “down,” and the like, are words of convenience and are not to be construed as limiting terms. As used herein, the term binder jetting shall be understood to refer to any manner and form of additive manufacturing including layer-by-layer spreading of a powder along a build volume and controlling distribution of one or more materials that may operate to bind at least a portion of the powder in each layer according to a respective predetermined two-dimensional pattern associated with the given layer. Binding, in this context, shall be understood to include joining at least a portion of the powder in a given layer to itself and to similarly joined powder in one or more adjacent layers of the powder to define a three-dimensional object in the build volume. That is, the three-dimensional object formed through such binding shall be understood to be a contiguous shape having greater adhesion to itself than to unbound particles of the powder in the build volume. In certain instances, the three-dimensional object may be processed in the build volume to facilitate removal of the three-dimensional object from the unbound particles in the build volume for additional processing to form a final part. Further, or instead, unless otherwise indicated or made clear from the context, the one or more materials that may operate to bind at least a portion of the powder may do so through any of various different direct or indirect mechanisms that may, but need not, occur before a subsequent layer is spread as part of the layer-by-layer process. By way of example, therefore, such mechanisms may include directly binding the powder in a given layer upon deposition of the one or more materials along the layer. This may also or instead include an application of a material or a combination of materials that locally reacts (e.g., precipitates) a binder or a component of a binder, or that otherwise operates to bind particles of the powder in a spatially controlled manner to facilitate fabrication of a three-dimensional object within the powder in the build volume. In the disclosure that follows, binder jetting processes are described with respect to components moving over a print box defining a build volume. As should be readily understood, however, this is a convention used for the sake of clarity and economy of explanation. Thus, unless otherwise specified or made clear from the context, it should be appreciated that any manner and form of relative movement of components may be used to carry out any one or more of the binder jetting processes described herein. Thus, for example, the print box may be, further or instead, movable with respect to one or more other components to achieve relative movement of components, as necessary to carry out any one or more of the binder jetting processes described herein. Also, in the context of the present disclosure, mobility of a powder shall be understood to refer to an aggregate ability of particles of the powder to move relative to one another along, within, or out of a given volume (e.g., an entire layer or a portion of a layer, as the context may dictate). Such mobility may be observed as a change in shape or density of at least a portion of a layer of particles of the powder in response to an external force exerted on the layer. Unless otherwise specified or made clear from the context, mobility is generally used in the present disclosure as a relative parameter in comparing two states of at least a portion of a layer of a powder. For example, a reduction in mobility of a layer of a powder shall be understood to refer to a state of a layer of a powder that, as compared to a state of the same layer of powder prior to treatment, has become less prone to movement in response to a given force. Powder with such reduced mobility may be said to be locked. More specifically, in the context of the binder jetting, such a reduction in mobility of a layer of a powder may correspond to a reduced likelihood of ejection of particles of the powder in response to impact of droplets of fluid delivered to the layer of the powder. An additional or alternative benefit of the condensation of vapor into the powder is that the cohesive force due to the presence of the liquid may draw the powder particles closer together and result in an increase in the density of the powder in the build volume, for example by causing the powder in a build volume to compress vertically, in the direction of gravitational force. This may have a beneficial effect of increasing density of the three-dimensional object in the build volume. With a higher density, the three-dimensional object may be less prone to slumping and distortion during subsequent processing, including during sintering to full density. The densification of the powder in the build volume due to the action of the condensed vapor may, further, or instead, have a benefit with respect to decreasing mobility of the powder. That is, under otherwise identical conditions, it is generally observed that powder with a higher packing density may be less mobile than powder with a lower packing density. It should be understood that this effect may be complementary and, in some cases, at least partially additive to the cohesive effect of the liquid which has been condensed from the vapor. In the context of the present disclosure, the term layer shall be understood to include a distribution of particles of powder defining a volume (e.g., a substantially rectangular cuboid) having length, width, and depth dimension. According to the convention used herein, the length and width of a given layer shall be understood to be defined along a plane parallel to movement of a spreader used to spread the powder along a build volume, and the depth of the given layer shall be understood to be defined by the dimension of the given layer in a direction perpendicular to the plane defining the length and width of the given layer. For the sake of clarity of explanation, it should be appreciated that the length, width, and depth of a layer may be referred to, respectively, as the x, y, z dimensions of the layer. Thus, for example, the x-y extent of a layer should be understood to refer to the area of the layer defined by the length and width of the layer. Unless otherwise specified or made clear from the context, the depth of a layer should be understood to be significantly smaller (e.g., at least an order of magnitude smaller and, in some cases, at least four orders of magnitude smaller) than the one or both of the width and length of the layer. As described in greater detail below, any one or more of the binder jetting processes described herein may be carried out by forming successive layers on top of one another such that a three-dimensional object is built up along the z-direction corresponding to the z-dimension of the successively formed layers. In each layer, one or more materials that may operate to bind the particles of the powder may be delivered along the x-y extent of the respective layer in a controlled two-dimensional pattern (e.g., based on a model of the three-dimensional object being formed). Unless otherwise specified or made clear from the context, the one or more materials along the controlled two-dimensional pattern may penetrate the depth of the respective layer such that the given layer may be bound to one or more preceding layers to form a three-dimensional object. In view of the foregoing, it should be appreciated that binding powder and reducing mobility of powder each refer to restricting movement of the powder during binder jetting processes, although these typically refer to different degrees of immobilization associated with different fabrication objectives. For example, binding powder should be generally understood to refer to a greater degree and/or extent of restriction in movement of the particles of the powder consistent with retaining a three-dimensional shape of a printed object, as compared to reducing mobility of the powder to mitigate particle movement during printing. Thus, binding will generally couple particles more securely than mobility reduction. However, this is not strictly required in all cases, and there may be circumstances (e.g., where a curable binder is applied but not yet cured and/or a mobility-reducing agent is applied but not yet evaporated) in which mobility reduction binds powder more securely than a binder. In any case, unbound powder with reduced mobility should be understood to be separable from bound powder defining the three-dimensional object in a manner that permits retrieval of the three-dimensional object from a build volume at an appropriate time during fabrication. Referring now to a temporal progression shown inFIGS.1A-1D, an additive manufacturing system100may be used to form a three-dimensional object102from particles103(e.g., metallic particles, ceramic particles, polymeric particles, or a combination thereof) of a powder104. The additive manufacturing system100may include a powder supply106, a print box108, a spreader110, an evaporator112, and a printhead114at least partially exposed to a controlled atmosphere of a build chamber115. In general, the evaporator112may improve a binder jetting process by addressing certain physical challenges associated with accurately delivering a binder to a powder in a layer-by-layer fabrication. For example, as described in greater detail below, the evaporator112may advantageously introduce vapor into a binder jetting process to reduce the likelihood of ejection of the particles103of the powder104(which may degrade hardware immediately or over time) while maintaining fidelity of an intended two-dimensional pattern of a binder or a component of a binder system delivered to the powder104from the printhead114. The overall result, therefore, is that the additive manufacturing system100including the evaporator112may facilitate forming the three-dimensional object102with a high degree of dimensional accuracy and, further or instead, may reduce downtime associated with hardware degradation. In use, as shown in the temporal progression inFIGS.1A-1D, the spreader110may be movable from the powder supply106to the print box108and along the print box108to spread a layer118of the powder104across a build volume116at least partially defined by the print box108. In some instances, a portion of the build volume116may extend above the print box108by one or more layers, depending on a standoff (i.e., vertical clearance) of the spreader110relative to the print box108. In such instances, each instance of the layer118may be spread above the portion of the build volume116defined by the print box108and, as the layer-by-layer fabrication process continues, at least some instances of the layer118may move into the portion of the build volume116defined by the print box108. Thus, in general, the build volume116shall be understood to be any volume defined by a plurality of instances of the layer118of the powder104stacked on top of one another and holding an overall shape, whether through angle of repose of the powder104, support from the print box108, or a combination thereof. Continuing with the temporal progression shown inFIGS.1A-1D, the evaporator112and the printhead114may be movable (e.g., in coordination with one another and, optionally, in coordination with movement of the spreader110) over the build volume116such that the evaporator112may direct a vapor phase of a first fluid120to the layer118of the powder104disposed along the top of the build volume116, and the printhead114may deliver a second fluid122(e.g., a binder or a component of a binder system) along a controlled two-dimensional pattern associated with the layer118of the powder104disposed along the top of the build volume116. The additive manufacturing system100may repeat one or more of these steps for each instance of the layer118in a plurality of instances of the layer118such that the second fluid122(and, in some instances, at least a portion of the first fluid120) operates to bind at least some of the powder104in the plurality of instances of the layer118to define the three-dimensional object102. In general, as compared to directing a liquid phase of the first fluid120toward the powder104under otherwise identical conditions, condensing the vapor phase of the first fluid120has been observed to be more effective at imparting cohesive strength to the powder104of the layer118with a reduced likelihood of bleeding of second fluid122. In particular, this difference between the liquid phase and the vapor phase has been observed in instances in which the first fluid120is water which, given its availability and ease of handling, may form a basis of a variety of useful implementations. Without wishing to be bound by theory, this observed difference in effectiveness between the liquid phase and the vapor phase of the first fluid120is believed to be attributable to more effective penetration of the vapor phase of the first fluid120into void space124defined between the particles103of the layer118. That is, delivery of a liquid phase of the first fluid120in the form of small droplets floating in a gas (a mixture commonly referred to as a mist) to the layer118tends to collect on top of the layer118such that a reduction in particle ejection is achievable only with large quantities of the first fluid120and such large quantities form pathways for the second fluid122to undergo unintentional, lateral spreading, also referred to herein as bleeding, beyond the controlled two-dimensional pattern associated with the second fluid122along the layer118. By comparison, however, the vapor phase of the first fluid120may condense onto and into the layer118creating suction that draws the first fluid120further into the layer118. This generally increases the likelihood that a liquid phase of the first fluid120may wet a larger number of necks126defined by contact between adjacent instances of the particles103. Because the liquid phase of the first fluid120holds the particles103together at the necks126(e.g., through capillary force), the improved penetration of the vapor phase of the first fluid120—and the associated increased likelihood of the presence of the liquid phase of the first fluid120at the necks126—has been observed to result in a significant reduction in mobility of the particles103while requiring only a small amount of the first fluid120. Without wishing to be bound by theory, it is believed that the Kelvin effect may prevent or reduce the likelihood of re-evaporation of the first fluid120in the high radius of curvature at the necks126, where the first fluid120acts on the particles103. The net result is that, while most of the first fluid120may re-evaporate quickly, the small amount of the first fluid120at the necks126may resist re-evaporation (and, in some cases, may never re-evaporate) such that the first fluid120at the necks may continue to reduce mobility of the particles103even as some of the first fluid120evaporates. Stated differently, the vapor phase of the first fluid120may advantageously reduce the likelihood of particle ejection while using an amount of the first fluid120that produces little or no bleeding of the controlled two-dimensional pattern of the second fluid122delivered to the layer118. Further, or instead, as compared to directing a liquid phase of the first fluid120to the layer118, the use of the vapor phase of the first fluid120may be less likely to roughen a top surface of the layer118along the top of the build volume116. For example, as compared to the liquid phase of the first fluid120, the vapor phase of the first fluid120may be less like to cause coalescence of loose instances of the particles103of the powder104to form small balls along the layer118. As one or more of the foregoing advantages are realized over a plurality of instances of the layer118, resulting improvements in dimensional accuracy of the three-dimensional object102may be achieved. In general, a reduction in mobility of the powder104of the layer118should not be understood to require any particular distribution of the first fluid120with respect to each neck126. That is, while wetting is shown inFIG.1Das occurring at each of the necks126, it should be appreciated that this an ideal distribution shown for the sake of clarity of illustration. Under certain conditions, some amount of the first fluid120may condense as small droplets on the surface of the particles103, away from the necks126. Further, or instead, the first fluid120may not reach all of the necks126formed by the particles103in the layer118. However, provided that the liquid phase of the first fluid120is along enough of the necks126formed by the particles103in the layer118, the mobility of the powder104may be reduced in the aggregate. The spreader110may generally span at least one dimension of the build volume116such that the spreader110may distribute a layer of the powder104on top of the build volume116in a single pass. As an example, the spreader110may include a roller rotatable about an axis perpendicular to an axis of movement of the spreader110across the print box108. The roller may be, for example, substantially cylindrical. In use, rotation of the roller about the axis perpendicular to the axis of movement of the spreader110may spread the powder104from the powder supply106to the print box108and form the layer118of the powder104along the build volume116. It should be appreciated, therefore, that a plurality of instances of the layer118of the powder104may be formed in the build volume116through repeated movement of the spreader110across the build volume116. The spreader110may be moved over the build volume116to form the layer118of the powder104with a substantially uniform depth over the width and length—the x-y extent—of the layer118, subject to dimensional variations attributable to typical manufacturing tolerances. This depth may be, for example, about 50 microns, although other dimensions are additionally or alternatively possible. For example, the depth of the layer118may be a function of any one or more of various different factors, including, for example, the size of the particles103, the size of the three-dimensional object102being formed, speed of fabrication, and depth of penetration of the second fluid122of the powder104on top of the build volume116. Further, or instead, the depth of the layer118may be substantially the same for each instance of the layer118in a plurality of instances of the layer118formed during fabrication of the three-dimensional object102, again subject to dimensional variations attributable to typical manufacturing tolerances. Thus, continuing with the example above, each instance of the layer118may be greater than about 50 microns and less than about 200 microns (e.g., about 65 microns). The printhead114may define at least one instance of an ejection orifice128directed toward the build volume116as the printhead114moves across the build volume116. For the sake of clarity of illustration and explanation a single instance of the ejection orifice128is shown and described. Typically, however, the printhead114may define hundreds of instances of the ejection orifice128directed toward the build volume116. As instances of the ejection orifice128become degraded over time, the performance of the printhead114may become compromised to a degree that impacts one or more of dimensional accuracy or strength of the three-dimensional object102. The use of the vapor phase of the first fluid120to reduce mobility of the particles103of the powder104, as described herein, may reduce the likelihood of certain degradations in performance of the printhead114associated with ejection of the particles103of the powder104, especially degradations in performance resulting from ejected instances of the particles103reaching and, in some cases, attaching to the bottom of the printhead114. Thus, for example, the vapor phase of the first fluid120may reduce the likelihood of clogging one or more instances of the ejection orifice128that may result from ejection of the particles103of the powder104. Further, or instead, the vapor phase of the first fluid120may reduce the likelihood of unintended changes to wetting characteristics along the bottom of the printhead114that may be caused by ejected instances of the particles103attaching to the bottom of the printhead114. The printhead114may include any one or more of various different types of activation mechanisms suitable for controlled delivery of the second fluid122. Thus, for example, the printhead114may be a piezoelectric printhead including one or more piezoelectric elements. Continuing with this example, each piezoelectric element may be associated with a respective instance of the at least one instance of the ejection orifice128and, in use, each piezoelectric element may be selectively actuated such that displacement of the piezoelectric element may expel the second fluid122from the respective one of the at least one instance of the ejection orifice128. Additionally, or alternatively, the printhead114be a thermal inkjet printhead including thermal elements that may be selectively heated to force expansion of the second fluid122through the at least one instance of the ejection orifice128and toward the build volume116. In certain implementations, the second fluid122may be a single liquid formulation ejected from the at least one instance of the ejection orifice128of the printhead114. In some implementations, however, the second fluid122may include a plurality of liquid formulations, and the printhead114may expel the plurality of liquid formulations from the at the least one ejection orifice128as necessary to achieve a desired distribution of the plurality of liquid formulations. For example, the printhead114may expel a plurality of solvents, a plurality of components of a binder system, or both from the at least one instance of the ejection orifice128. While the printhead114is described as a single printhead for the sake of clarity of explanation, it should be appreciated that the printhead114may, additionally or alternatively, include a plurality of printheads from which the second fluid122may be delivered toward the build volume116. In general, the printhead114may be controlled to jet the second fluid122toward the build volume116in a controlled (e.g., predetermined) two-dimensional pattern to the layer118, and this may be repeated for respective controlled two-dimensional patterns on a layer-by-layer basis to define the three-dimensional object102in the build volume116. In certain implementations, the printhead114may extend axially along substantially an entire dimension of the build volume116in a direction perpendicular to a direction of movement of the printhead114over the build volume116to carry out one-dimensional scanning. For example, in such implementations, a plurality of instances of the ejection orifice128of the printhead114may be arranged along the axial extent of the printhead114, and the second fluid122may be selectively jetted from these instances of the ejection orifice128along the axial extent to form a controlled two-dimensional pattern of the second fluid122along the layer118of the powder104as the printhead114moves in a single direction across the build volume116. Additionally, or alternatively, the printhead114may be movable in two dimensions above and parallel to an x-y extent of the layer118of the powder104along the build volume116to deliver a controlled two-dimensional pattern of the second fluid122along the layer118through two-dimensional scanning. Referring now toFIGS.1A-1D and2, the evaporator112may be securable to any one or more portions of the additive manufacturing system100to support the evaporator112above the build volume116. For example, the evaporator112may be coupled to one or more actuators controllable to move the evaporator112over the build volume116as part of any one or more of the binder jetting processes described herein. Further or instead, the evaporator112may be directly or indirectly coupled to one or more of the spreader110or the printhead114. Still further or instead, while the powder supply106may be stationary along a lateral portion of the build volume116in some instances, the powder supply106may alternatively be movable over the build volume116to dispense and meter the powder104in advance of movement of the spreader110over the build volume116, such as described in U.S. patent application Ser. No. 15/959,096, filed Apr. 20, 2018, the entire content of which is hereby incorporated herein by reference. In such implementations in which the powder supply106is movable over the build volume116, the evaporator112may additionally or alternatively be directly or indirectly coupled to the powder supply106. The evaporator112may include a housing201defining an inlet section202, and outlet section204, and a flow path206extending therebetween such that the inlet section202and the outlet section204are in fluid communication with one another via the flow path206. In general, it should be appreciated that any of various different approaches may be used to form the first fluid120into the vapor phase between the inlet section202and the outlet section204of the evaporator112. For example, such approaches may include changing one or more of temperature or pressure of the liquid phase of the first fluid120between the inlet section202and the outlet section204of the evaporator112to form the vapor phase of the first fluid120. For the sake of clarity of explanation, however, the example that follows describes the formation of the vapor phase of the first fluid120in the context of a particular technique known as sparging. While this technique may be useful for forming the vapor phase of the first fluid120at a temperature below the boiling point of the first fluid120, it should not be considered to be limiting, unless explicitly stated or made clear from the context. For example, as described in greater detail below, the vapor phase of the first fluid120may be formed through any one or more of various different techniques (e.g., techniques making use of atomization) suitable for forming the vapor phase of the first fluid120at a temperature at or above the boiling point of the first fluid120. The inlet section202and the outlet section204may be sized relative to one another to accommodate expansion associated with evaporating a liquid phase of the first fluid120in the evaporator112to form the vapor phase of the first fluid120issuable from the evaporator112. That is, the inlet section202may have a first open area sized for flow of the liquid phase of the first fluid120into the evaporator112, and the outlet section204may have a second open area sized for flow of the vapor phase of the first fluid120, alone or in combination with one or more gases, from the evaporator112and toward the layer118. In this context, the first open area of the inlet section202should be understood to refer to refer to a minimum flow restriction along the inlet section202and, similarly, the second open area of the outlet section204should be understood to refer to a minimum flow restriction along the outlet section204. To accommodate differences in density between the liquid phase of the first fluid120and the vapor phase of the first fluid120and/or one or more gases mixed with the vapor phase of the first fluid120, a ratio of the second open area of the outlet section204to the first open area of the inlet section202may be greater than about 10:1 and less than about 5,000:1. In certain instances, at least a portion of the flow path206between the inlet section202and the outlet section204may be nonlinear. Such nonlinearity may be useful, for example, for separating the liquid phase of the first fluid120from the vapor phase of the first fluid120within the evaporator112. More specifically, at least a portion of the flow path206may be nonlinear to act as a trap for the liquid phase of the first fluid120upstream of the outlet section204to reduce the likelihood of inadvertently delivering the liquid phase of the first fluid120to the layer118. In general, the outlet section204of the evaporator112may precede movement of the printhead114over the build volume116in at least one direction. Additionally, or alternatively, the spreader110may be movable over the build volume116and relative to the outlet section204of the evaporator112to precede movement of the outlet section204of the evaporator112over the build volume116in at least one direction. Thus, for example, the spreader110may spread the layer118of the powder104on top of the build volume116, the outlet section204may follow the spreader110over the build volume116to direct the vapor phase of the first fluid120onto the layer118of the powder104on top of the build volume116, and the printhead114may follow the outlet section204of the evaporator112over the build volume116to deliver the second fluid122(e.g., a binder or a component of a binder system) onto the layer118of the powder104on top of the build volume116. In this example, because the first fluid120is introduced into the layer118prior to delivery of the second fluid122to the layer118, it should be appreciated that the first fluid120may reduce mobility of the particles103of the powder104(e.g., by imparting increased cohesive strength to the layer118) and, thus, the particles103of the powder104may be less likely to be ejected from the layer as the second fluid122impacts the layer118. In certain implementations, as the outlet section204moves over the layer118, the outlet section204may have a substantially fixed standoff clearance (i.e., vertical separation distance) relative to the layer118. In this context, the substantially fixed nature of the standoff clearance should be understood to allow for small fluctuations in position (e.g., due to vibration) that may occur as components of the additive manufacturing system100move back and forth over the build volume116. In general, a lower bound of the standoff clearance may be a function of a minimum distance required to avoid contact between the outlet section204and the layer118(even as typical vibrations occur). Further, or instead, an upper bound of the standoff clearance may be a function of a maximum distance at which the vapor phase of the first fluid120may be delivered from the outlet section204to the layer118with little or no premature condensation above the layer118. In view of these competing considerations, the standoff clearance between the outlet section204and the layer118may be greater than about 0.5 mm and less than about 20 mm (e.g., less than about 5 mm). The outlet section204may be dimensioned relative to the build volume116based, for example, on the type of scanning used to deliver the vapor phase of the first fluid120in a direction from the evaporator112, toward the layer118on top of the build volume116. For example, the outlet section204may span an axial dimension of the build volume116perpendicular to a one-dimensional scanning movement of the outlet section204over the build volume116such that the entire x-y extend of the layer118may be traversed in a single, one-dimensional scan of the outlet section204over the build volume. Because such a one-dimensional scan can deliver the vapor phase of the first fluid120without overlapping regions along the layer118, one-dimensional scanning may facilitate achieving a substantially uniform distribution of the first fluid120to the layer118. With such a substantially uniform distribution of the first fluid120, the response of the layer118to impingement by the second fluid122may be consistent and repeatable, ultimately benefiting dimensional accuracy of the three-dimensional object102being formed. The outlet section204may include a slit or, another substantially elongate shape, from which the vapor phase of the first fluid120may be directed toward the layer118of the powder104. Continuing with this example, the length of the slit or other elongate shape may span at least one dimension of the build volume116in instances in which the vapor phase of the first fluid120is directed toward the layer118through one-dimensional scanning. Because the slit may be formed without obstructions, the flow of the vapor phase of the first fluid120may be substantially uniform along the outlet section204which, in turn, may impart benefits in uniformity of distribution of the first fluid120to the layer118. Additionally, or alternatively, other shapes of the outlet section204may be implemented. For example, the housing201may define a plurality of openings (e.g., a series of holes or small slits) along the outlet section204. That is, continuing with this example, the material of the housing201between the plurality of openings may form structural elements that may advantageously impart dimensional stability to the outlet section204. Further, or instead, while the outlet section204has been described as being movable in a one-dimensional scanning operation, it should be appreciated that the outlet section204may, alternatively or additionally, be movable along at least two dimensions along an x-y extent of the build volume116to deliver the vapor phase of the first fluid120to the layer118through two-dimensional scanning. More specifically, the outlet section204may be movable over the build volume116to direct the vapor phase of the first fluid120substantially along only the controlled two-dimensional pattern, in a given layer, associated with delivery of the second fluid122from the at least one instance of the ejection orifice128of the printhead119to the layer118. As compared to directing the vapor phase of the first fluid120to the entire x-y extent of the layer, selective delivery of the vapor phase of the first fluid120along the controlled two-dimensional pattern associated with the second fluid122may facilitate further reducing the likelihood of bleeding of the second fluid122. This may be useful, for example, for accurately forming small features in the three-dimensional object102. In certain implementations, the evaporator112may form a mixture of the vapor phase of the first fluid120with a carrier gas213ain combination with a distribution gas213bsuch that the mixture is directed toward the layer118of the powder104. As used herein, the carrier gas213aand the distribution gas213brefer to gases used with respect to different aspects of forming the mixture. That is, the carrier gas213amay be a gaseous medium in which the vapor phase of the first fluid120becomes saturated and, thus, the carrier gas213amay control an amount (e.g., a mass) of the vapor phase of the first fluid120in the mixture. Further, or instead, as used herein, the distribution gas213bmay be a gaseous medium movable through the evaporator112to mix with the vapor phase of the first fluid120saturated in the carrier gas213ato impart one or more desired flow characteristics (e.g., direction, velocity, or a combination thereof) to the mixture issuing from the outlet section204, toward the layer118. For the sake of describing certain aspects of forming and directing the vapor phase of the first fluid120through the evaporator112, the carrier gas213aand the distribution gas213bare described as being used in combination with one another in the example that follows. As described in greater detail below, however, the vapor phase of the first fluid120may additionally or alternatively through other techniques, some of which may be carried out without one or more of a carrier gas or a distribution gas. To facilitate decoupling the amount of the vapor phase of the first fluid120from the exit velocity through the outlet section204, the carrier gas213aand the distribution gas213bmay be independently controllable relative to one another. Further, or instead, to achieve suitable decoupling in certain instances, the carrier gas213aand the distribution gas213bmay be separately introduced into the evaporator112. In certain implementations, the carrier gas213aand the distribution gas213bmay be substantially inert with respect to one or more of the first fluid120, the particles103of the powder104, or one another. Further, or instead, the carrier gas213aand the distribution gas213bmay have the same composition. The evaporator112may include a first port210and a second port212. The first port210may define the inlet section202connectable in fluid communication with a liquid source140, via a first flow controller144, to receive a liquid form of the first fluid120from the liquid source140. The second port212may be connectable to a gas source142, via a second flow controller146, to receive the carrier gas213a. In certain implementations, the first flow controller144and the second flow controller146may include one or more of respective solenoid valves, linearly acting flow control valves, or other similar actuatable valves, such that flow through one or more of the first port210or the second port212may be selectively interrupted by closing the first flow controller144and the second flow controller146to interrupt formation of a mixture of the vapor phase of the first fluid120and the carrier gas213between formation of successive instances of the layer118. Such selective interruption in formation of the vapor phase of the first fluid120may, in turn, reduce unintended variation in environmental conditions above the build volume116. In some implementations, the mixture of the carrier gas213and the vapor phase of the first fluid120may be formed by sparging—that is, dissolving the first fluid120in the carrier gas213. Thus, for example, the evaporator112may include a sparger214disposed along the reservoir208. The reservoir208may be in fluid communication with the first port210, and the sparger214may be in fluid communication with the second port212. In use, the liquid phase of the first fluid120may be introduced into the reservoir208to a level sufficient to submerge at least a portion of the sparger214in the reservoir208. The carrier gas213(e.g., air or nitrogen) may be introduced into the evaporator112via the second port212and bubbled, via the sparger214, through a liquid phase of the first fluid120in the reservoir208. As described in greater detail below, the amount of the first fluid120formed through sparging may be indirectly controlled based on directly controlling one or more of the temperature of the liquid form of the first fluid120in the reservoir208or a flow rate of the carrier gas213athrough the reservoir208. At the gas/liquid interface between bubbles216of the carrier gas213aand the liquid form of the first fluid120in the reservoir208, the vapor phase of the first fluid120may be introduced into the carrier gas213a. Accordingly, the fluid exiting the reservoir208—for example, above the reservoir208—may include the vapor phase of the first fluid120saturated in the carrier gas213a. The volume percentage of the vapor phase of the first fluid120in the mixture with the carrier gas213amay be controlled by controlling, for example, temperature of the first fluid120in the reservoir208. As a more specific example, the liquid phase of the first fluid120may be controlled to a predetermined temperature below the boiling point of the first fluid120and corresponding to a saturation temperature of a predetermined volumetric percentage of the vapor phase of the first fluid120in the carrier gas213a. In instances in which the first fluid120is water and the carrier gas213ais air, this saturation temperature may be greater than about 50° C. and less than about 90° C., corresponding to water content of greater than about 12 percent and less than about 70 percent. Thus, more generally, the evaporator112may form the vapor phase of the first fluid120below a boiling point of the first fluid120, which may have safety advantages based at least on reduced heating requirements. As described in greater detail below, however, certain implementations of evaporators described herein may heat the first fluid120above a boiling point of the first fluid120to realize certain other advantages in delivering the vapor phase of the first fluid120to the layer118. With the volume percentage of the vapor phase of the first fluid120controlled based on the temperature of the liquid form of the first fluid120in the reservoir208, the amount of the vapor phase of the first fluid120may be varied by varying the flow rate of the carrier gas213athrough the reservoir208. That is, at a fixed temperature of the liquid form of the first fluid120in the reservoir208, increasing the flow rate of the carrier gas213aproduces a greater amount of the vapor phase of the first fluid120along a portion of the flow path206above the reservoir208. Similarly, at the fixed temperature of the liquid form of the first fluid120in the reservoir208, decreasing the flow rate of the carrier gas213aproduces less of the vapor phase of the first fluid120above the reservoir208. The sparger214may define a plurality of orifices215, such as may be defined by a porous structure (e.g., a porous metal) useful for forming a large number of the bubbles216of the carrier gas213aas the carrier gas213amoves through the sparger214. The bubbles216formed by movement of the carrier gas213athrough the orifices215of the sparger214may be useful for enhancing introduction of the vapor phase of the first fluid120into the carrier gas213amoving through the reservoir208. That is, the bubbles216formed by the sparger214may be small such that there is a large contact area between the carrier gas213and the liquid phase of the first fluid120. Such a large contact area may increase the likelihood that the bubbles216become saturated with the vapor phase of the first fluid120before the bubbles216reach the top of the reservoir208. In general, under otherwise identical conditions, smaller bubbles may be useful for reducing the time and/or height of the liquid phase of the first fluid120required to saturate the vapor phase of the first fluid120into the bubbles216of the carrier gas213amoving through the liquid phase of the first fluid120in the reservoir208. In certain implementations, the evaporator112may include a first heater222in thermal communication with the reservoir208. The first heater222may be, for example, a cartridge heater extending into the reservoir208. In use, the first heater222may be at least partially submerged in the liquid form of the first fluid120. Additionally, or alternatively, the first heater222may be controllable to maintain the liquid phase of the first fluid120in the reservoir208at a predetermined target temperature, which may be useful for maintaining a target volumetric percentage of the vapor phase of the first fluid120in the mixture exiting the reservoir208. For example, the heater222may maintain the predetermined temperature according to an open loop control approach or through closed loop control (e.g., based on an indication of temperature from the first heater222itself and/or from a separately positioned temperature sensor (not shown)). The evaporator112may, in some instances, include a level sensor224disposed in the reservoir208to sense a level of the liquid phase of the first fluid120in the reservoir208. For example, the level sensor224may provide feedback to a controller, such as any one or more of the controllers described herein. More specifically, based at least in part on a signal from the level sensor224the flow rate of the liquid phase of the first fluid120delivered to the reservoir208, via the first port210, may be adjusted. In some instances, the level sensor224may deliver a binary signal which, when the level of the first fluid120in the reservoir208is low, is used to open the first flow controller144leading to the first port210, and when the level is high is used to close the first flow controller144. In some implementations, the evaporator112may include a second heater226in thermal communication with the flow path206to heat the mixture of the carrier gas213aand the vapor phase of the first fluid120moving along the flow path206from the reservoir208. In general, the second heater226may be positioned along any one or more portions of the flow path206to reduce the likelihood of condensation of the vapor phase of the first fluid120along the flow path206, between the reservoir208and the outlet section204. More specifically, the second heater226may be positioned along any one or more portions of the flow path206to maintain the flow path206at or above the temperature of the liquid form of the first fluid120in the reservoir208. For example, the second heater226may maintain the flow path206at or above the predetermined temperature according to an open loop control approach or through closed loop control (e.g., based on an indication of temperature from the second heater226itself and/or from a separately positioned temperature sensor (not shown)). As should be readily appreciated, any of various different arrangements of the second heater226may be used to maintain such an elevated temperature along the flow path206. Thus, for example, the second heater226may extend continuously along the flow path206, between the reservoir208and the outlet section204. As another example, the second heater226may include spatially distributed sections along the flow path206. Further, or instead, the second heater226may be any of various different types of heaters that may be controlled to a target temperature above the temperature of the liquid phase of the first fluid120in the reservoir. Thus, for example, the second heater226may be a pad heater that may be mounted directly to any one or more portions of the housing201. In certain instances, the housing201may define one or more auxiliary inlets207through which the distribution gas213bmay be introduced. As an example, the auxiliary inlets207may be positioned to introduce the distribution gas213bto a portion of the flow path206above the reservoir208such that the flow of the distribution gas213bmay generally direct the mixture of the vapor phase of the first fluid120and the carrier gas213afrom the reservoir208toward the outlet section204. This direction of the distribution gas213bmay be useful, for example, for reducing the likelihood of undesirable recirculation of flow above the reservoir208. In instances in which the distribution gas213band the carrier gas213ahave the same composition, the distribution gas213bmay be received at the auxiliary inlets207via fluid communication with the gas source142. In such implementations, the second flow controller146may, also or instead, control the flow of the distribution gas213bthrough the auxiliary inlets207. It should be appreciated, however, that the distribution gas213bmay be received from a separate source and, further or instead, the flow of the carrier gas213aand the distribution gas213binto the evaporator112may be controlled by any manner and form of flow controllers. In certain implementations, the evaporator112may include a vapor probe228positioned to measure concentration of the vapor phase of the first fluid120issuing from the evaporator112. For example, the vapor probe228may be near the outlet section204of the evaporator112and, optionally, may be movable along with the outlet section204of the evaporator112as the outlet section204of the evaporator112moves relative to the build volume116. In some instances, the vapor probe228may be sensitive to prolonged use under conditions associated with the binder jetting processes described herein. Accordingly, the vapor probe228may be releasably securable to the evaporator112. For example, the vapor probe228may be used as part of an initial set-up of the additive manufacturing system100to determine a volumetric concentration of the vapor phase of the first fluid120under conditions of a binder jetting process to be carried out for forming the three-dimensional object102. Following the initial set-up of the additive manufacturing system100, the vapor probe228may be removed from the evaporator112to reduce the likelihood of damage or degraded performance of the vapor probe228. Additionally, or alternatively, the vapor probe228may be reattached to the evaporator112periodically to verify operation of the evaporator112. The selection of the vapor probe228may be based on the composition of the first fluid120. For example, in instances in which the first fluid120is water, the vapor probe228may include a humidity probe, such as a probe including a polymer having a changing resistance or dielectric constant in the presence of water. For more general implementations and/or implementations in which the first fluid120is a substance other than water, the vapor probe228may include a chilled mirror cooled until condensation is detected as scatter of a laser deflected off of the chilled mirror. Referring again toFIGS.1A-1C, the additive manufacturing system100may further include a controller130in electrical communication with the powder supply106, the print box108, the spreader110, the printhead114, and the evaporator112. The controller130may include one or more processors131operable to control one or more of the powder supply106, the print box108, the spreader110, the printhead114, and combinations thereof. The one or more processors131of the controller130may execute instructions to control z-axis movement of one or more of the powder supply106and the print box108relative to one another as the three-dimensional object102is being formed. For example, the one or more processors131of the controller130may execute instructions to move the powder supply106in a z-axis direction toward the spreader110to direct the powder104toward the spreader110as each layer of the three-dimensional object102is formed and to move the print box108in a z-axis direction away from the spreader110to accept each new layer of the powder104along the top of the build volume116as the spreader110moves across the build volume116. In general, the controlled movement of the print box108relative to the powder supply106is based on a thickness of a corresponding layer being formed in the build volume116. Additionally, or alternatively, the one or more processors131of the controller130may execute instructions to control movement of the spreader110from the powder supply106to the print box108to move successive layers of the powder104across the build volume116. For example, the one or more processors131of the controller130may control speed of movement of the spreader110across the build volume116. As a further or alternative example, the controller130may control one or more features of the spreader110useful for packing the top layer of the powder104as the spreader110moves across the build volume116. Returning to the specific example of the spreader110being rotatable, the one or more processors131of the controller130may control rotation (e.g., speed, direction, or both) of the spreader110. The one or more processors131of the controller130may, further or instead, control the printhead114. For example, the one or more processors131of the controller130may control movement (e.g., speed, direction, timing, and combinations thereof) of the printhead114across the build volume116. Further, or instead, with at least one instance of the ejection orifice128disposed over the build volume116, the one or more processors131may control the delivery of the second fluid122from the printhead114toward the layer118of the powder104along the top of the build volume116. More generally, the one or more processors131may control the printhead114to deliver the second fluid122toward the layer118along a controlled two-dimensional pattern associated with the layer118. The controlled two-dimensional pattern may vary from layer-to-layer, as necessary, according to the shape of the three-dimensional object102being defined layer-by-layer in the build volume116. The additive manufacturing system100may further, or instead, include a non-transitory, computer readable storage medium132in communication with the controller130and having stored thereon a three-dimensional model134and instructions for causing the one or more processors131to carry out any one or more of the methods described herein. In general, as sequential instances of the layer118are introduced to the build volume116and the second fluid122and the vapor phase of the first fluid120are delivered to each instance of the layer118in a plurality of sequential instances of the layer118of the powder104, the three-dimensional object102is defined according to the three-dimensional model134stored in the non-transitory, computer readable storage medium132. In certain implementations, the controller130may retrieve the three-dimensional model134in response to user input, and generate machine-ready instructions for execution by the additive manufacturing system100to fabricate the three-dimensional object102. FIG.3is a flowchart of an exemplary method of managing powder mobility in binder jet additive manufacturing using a vapor phase of a fluid. Unless otherwise specified or made clear from the context, the exemplary method300may be implemented using any one or more of the various different additive manufacturing systems, and components thereof, described herein. Thus, for example, the exemplary method300may be implemented as computer-readable instructions stored on the computer readable storage medium132(FIGS.1A-1C) and executable by the one or more processors131(FIGS.1A-1C) of the controller130(FIGS.1A-1C) to operate the additive manufacturing system100(FIGS.1A-1C). As shown in step302, the exemplary method300may include spreading a layer of a powder across a build volume at least partially defined by a print box. In general, the powder may have a mobility for particles of the powder within the print box as the layer of the powder is spread across the build volume. That is, to facilitate substantially uniform spreading of the powder, the particles of the powder may be relatively movable with respect to one another as the powder is initially put down and spread across the build volume. As described in greater detail below, once the powder has been spread in the form of the layer, the mobility of the powder may be advantageously reduced (e.g., such that the particles of the powder in the layer have increased cohesive strength) to reduce the likelihood of ejecta formation in response to impact force of a fluid, such as a binder or a component of a binder system, on the powder. The powder may include any one or more of the powders described herein and, thus, may include one or more of metallic particles, ceramic particles, and polymeric particles. In instances in which the powder includes metallic particles, the metallic particles may include any one or more of various different metallic components useful for forming a finished part. As one of many examples, the metallic particles may include stainless steel particles, which may be particularly suitable for implementations in which the first fluid includes water. Further, or instead, the metallic particles may include one or more of carbon steel or tool steel types. Continuing with this example, to reduce the likelihood of corrosion of these metallic particles, the atmosphere in and around the build volume may be controlled to be oxygen-free (e.g., by using an inert gas, such as nitrogen). Continuing still further with this example, the first fluid may be selected to reduce the likelihood of corrosion of these metallic particles and, thus, for example, may include any one or more of deoxygenated water, one or more organic solvents, or one or more fluorocarbon liquids. It should be noted that many organic solvents have lower surface energies than water, which may be advantageous for achieving better wetting of particles on the powder but may result in lower cohesive forces between particles of the powder. As yet another example, the powder may include metallic particles that are alloyable with one another to form, for example, a metal having more desirable properties, such as greater strength and/or improved resistance to corrosion, as compared to one or both of the constituent components of the alloy. The particles of the powder may have a predetermined size distribution, specified at least according to an average particle size (e.g., greater than about 0.5 microns and less than about 50 microns). In general, the predetermined size distribution may be based on considerations related to the depth of the layer being formed, flowability of the powder, subsequent processing (e.g., sintering), cost, or a combination thereof. Further, or instead, the predetermined size distribution may facilitate spreading the powder to achieve a suitable volume fraction of void space defined by the particles in the layer. For example, the volume fraction of void space in each layer may be greater than about 0.25 and less than about 0.75 in the layer. Within this range, the powder may be sufficiently penetrable by the first fluid while also being sufficiently packed such that capillary force of the liquid phase of the first fluid on the particles produces an appreciable reduction in the likelihood of particle ejection. As shown in step304, the exemplary method300may include directing a vapor phase of a first fluid to the layer of the powder. In general, directing the vapor phase of the first fluid may include forming the vapor phase of the first fluid in an evaporator (e.g., as the evaporator moves over the layer) and issuing the vapor phase of the first fluid from the evaporator toward the layer. Although formation and issuance of the vapor may be separately controlled in some instances, such separate control is not necessary in all implementations. Further, whether separately controlled or not, formation and issuance of the vapor may occur substantially simultaneously (e.g., with a delay of less than about 2 seconds). Directing the vapor phase of the first fluid to the layer of the powder may include forming the vapor phase of the first fluid according to any one or more of the various different techniques described herein, unless a contrary intent is indicated or made clear from the context. Thus, for example, the vapor phase of the first fluid may be directed to the layer in combination with a carrier gas different from the first fluid (e.g., air, nitrogen, argon, or a combination thereof), as described above with respect to sparging. Additionally, or alternatively, the vapor phase of the first fluid may be directed to the layer by atomizing the first fluid and directing the atomized first fluid toward a hot surface to form the vapor phase, as described in greater detail below. In general, the vapor phase of the first fluid may be directed to the layer of the powder according to any manner and form of issuing the vapor from an evaporator described herein. Thus, for example, the vapor phase of the first fluid may be issued from an outlet section defined by the evaporator as the outlet section is over the layer. As a more specific example, the evaporator and the layer may move relative to one another as the vapor phase of the first fluid issues from the outlet section to facilitate distributing the vapor phase of the first fluid along the x-y extent of the layer. The relative movement between the evaporator and the layer may be achieved through any one or more combinations of movement of the evaporator and/or the layer relative to one another. Thus, by way of example and not limitation, the vapor phase of the first fluid may issue from the outlet section of the evaporator moving over the layer as the layer remains stationary or moves. As the vapor phase of the first fluid is directed to the layer, at least a portion of the vapor phase of the first fluid may persist until contact with the layer of the powder is achieved. That is, directing the vapor phase of the first fluid to the layer of the powder may, at least temporarily, alter an environment immediately above the layer of the powder and, in particular, increase a volumetric concentration of the vapor in the environment immediately above the layer of the powder. Thus, taking an example in which the first fluid is water, the environment immediately above the layer of the powder may have an initial humidity associated with an environment (e.g., in a build chamber) above the layer. Continuing with this example, directing the vapor phase of the first fluid to the layer of the powder may increase the humidity in the environment immediately above the layer of the powder as compared to the humidity in the same region prior to the introduction of the vapor phase of the first fluid. Further or instead, the increase in the volumetric concentration of the vapor may be achieved globally along the x-y extent of the layer or locally along portions of the x-y extent of the layer. For example, an outlet section of the evaporator may be a shroud sized to deliver the vapor phase of the first fluid along the entire x-y extent of the layer at the same time, without any scanning by the evaporator. That is, as a more specific example, the outlet section of the evaporator may be sized to be substantially the same size as the x-y extent of the layer such that the vapor phase of the first fluid issuing from the outlet section of the evaporator is directed to the entire x-y extent of the layer contemporaneously. As compared to one-dimensional or two-dimensional scanning methods, delivering the vapor phase of the first fluid to the entire x-y extent of the layer at the same time may offer advantages with respect to uniformity of the first fluid along the x-y extent of the layer. In certain implementations, the vapor phase of the first fluid may be directed to the layer in a laminar flow. As used in this context, such a laminar flow includes flow of the vapor phase of the first fluid substantially devoid of eddies that may interfere with penetration of the vapor phase of the first fluid into the layer, where the vapor phase may condense to a liquid phase to decrease mobility of the particles of the powder in the layer. Further, or instead, as compared to highly turbulent flow, directing the vapor phase of the first fluid to the layer in a laminar flow may reduce the likelihood that the incidence of the vapor phase of the first fluid on the layer may itself create ejecta. The first fluid may be, for example, any one or more of various different fluids that may be safely handled and generally compatible with other materials (e.g., the powder and a binder or component of a binder system) associated with the binder jetting process. For example, the first fluid may be non-flammable and vaporized over a temperature range compatible with the components of a system (e.g., the additive manufacturing system100inFIGS.1A-1C) used to carry out the exemplary method300. Additionally, or alternatively, the first fluid may be substantially inert at least with respect to the particles of the powder and/or a binder or a component of a binder system. For example, the first fluid may be introduced to the powder and removed from the powder without changing the chemical composition of the powder beyond a predetermined material specification. As an example of such an inert system, at least a portion of the powder may be non-oxidizing with respect to the first fluid (e.g., the first fluid may include water, and the powder may include stainless steel particles). Additionally, or alternatively, the first fluid may be substantially completely removable from the three-dimensional object via one or more of heating and drying the three-dimensional object (e.g., as part of post-processing described in greater detail below). Accordingly, examples of the first fluid include, but are not limited to, one or more of the following: water; acetone; toluene; methyl ethyl ketone; ethanol; isopropyl alcohol; and n-butyl acetate. Further, or instead, the first fluid may include one or more fluorocarbons. While the first fluid may be substantially inert with respect to other materials used in binder jetting in certain instances, it should be appreciated that other combinations of materials may be used. That is, in certain instances, the first fluid may be chemically reactive with one or more other materials used in binder jetting. For example, in some cases, directing the vapor phase of the first fluid to particles of the powder may result in the use of only a small amount of the first fluid. In turn, the small amount of the first fluid may result in only a limited amount of chemical reaction taking place between the first fluid and other binder jetting materials. In many instances, such limited amounts of chemical reaction may be acceptable without impacting overall quality of the three-dimensional object being formed. As a specific example, in instances in which the first fluid is water, the first fluid may be compatible with one or more materials that would otherwise be corroded by water. Continuing with this example, because the one or more materials are exposed to a limited quantity of water and it is likely that this small amount of water evaporates as the build continues, there is a limited time in which the one or more materials are exposed to the water. The result, therefore, is a limited amount of corrosion. In certain instances, this limited amount of corrosion may not materially impact achieving target composition in a final part. For example, even if there is a limited amount of corrosion—as in the case of carbon steel powder—this corrosion may be reversed by reduction of the oxide to meal during a sintering operation. While limited chemical reactions may be characteristic of certain combination of materials, more substantial chemical reactions may be additionally or alternatively used to combine materials. As an example, the first fluid may advantageously react with a second fluid along the layer, as described in greater detail below. While the first fluid may be compatible with other materials associated with the binder jetting process and with components of the additive manufacturing system used to carry out the process, it may nevertheless be useful to limit the amount of the vapor phase of the first fluid that moves beyond the build volume during layer-by-layer formation of the three-dimensional object. For example, between spreading successive layers of the plurality of layers, a flow of the vapor phase of the first fluid from the evaporator toward the layer may be interrupted such that the presence of the vapor phase of the first fluid beyond the x-y extent of the layer is limited. Such a limitation may, for example, reduce the amount of the first fluid required to carry out a particular binder jetting process. Further, or instead, interrupting the flow of the vapor phase of the first fluid in this way may reduce the likelihood of unintended liquid condensation in areas beyond the x-y extend of the layer. As shown in step306, the exemplary method300may include condensing the first fluid from the vapor phase to a liquid phase to reduce mobility of the particles of the powder. The condensation of the vapor of the first fluid on the layer of the powder may occur, for example, in the presence of a temperature differential between the vapor phase of the first fluid and at least a portion of the layer of the powder. That is, as the relatively hot vapor phase of the first fluid comes into contact with a relatively cool portion of the layer, the vapor phase of the first fluid may condense to the liquid phase. For the sake of clarity of explanation of certain principles, condensation of the vapor phase of the first fluid is generally described herein with respect to condensation in the overall layer. However, it should be understood that, as conditions vary over a layer, the degree of condensation may vary accordingly over the layer. Thus, unless otherwise indicated or made clear from the context, reference to condensation in the layer should be understood to refer to condensation in any given portion of the layer. As an example, in instances in which the vapor phase of the first fluid is below the boiling point of the first fluid, the layer may be initially at a temperature below a saturation temperature of the vapor phase in a gaseous environment immediately above the respective portion of the layer. As the vapor phase of the first fluid contacts the layer, the vapor phase of the first fluid may condense as it is cooled below the saturation temperature. The saturation temperature of the vapor phase of the first fluid in a gaseous environment may be referred to herein as the “dew point.” As used in this context, the dew point shall be understood to characterize condensation in water-air systems, as well as condensation in any other systems described herein. Additionally, or alternatively, as described in greater detail below, the vapor phase of the first fluid may be above the boiling point of the first fluid in certain instances, and contact between the vapor phase of the first fluid and the layer cools the vapor phase of the first fluid to a temperature below the boiling temperature such that the first fluid condenses to a liquid phase. As may be appreciated from the foregoing examples, the condensation that occurs through the temperature differential between the layer and the vapor phase of the first fluid may be a substantially open loop process in some cases. That is, certain parameters of the temperature differential may be initially set and the change in the temperature differential may act to control condensation without separate feedback or intervention during fabrication of a given three-dimensional object. More specifically, parameters associated with the vapor phase at the upper end of the temperature differential may be set and monitored based at least in part on safety considerations. Additionally, or alternatively, the initial temperature of the layer of the powder at the lower end of the temperature differential may be controlled (e.g., through the use of heat—such as infrared heat—directed at the powder, directing a cool gas over the layer, or a combination thereof) to a target temperature to facilitate consistent condensation of the vapor throughout the layer-by-layer fabrication process. In some implementations, however, the environment of the powder prior to spreading may be stable (e.g., about 25° C.) throughout fabrication such that consistency in condensation—both in terms of spatial distribution along a single layer and layer-to-layer distribution—is achievable without separate control of the initial temperature of the powder in the layer. While condensing the vapor phase of the first fluid may be carried out using open loop control in some instances, certain parameters associated with condensation of the vapor phase of the first fluid are measurable and, thus, may be suitable for implementation as aspects of closed loop control strategies. As an example, measuring a temperature rise of a powder in a build volume may be a useful as a proxy for determining at least a relative amount of condensation of the vapor phase of the first fluid in a given layer. That is, under otherwise nominally identical conditions, a larger temperature rise of the powder in the build volume may be indicative of a higher volume of the first fluid being condensed in a given layer. Thus, under certain control strategies, the temperature rise of the powder in the build volume may be controlled such that layer to layer variation in temperature rise of the powder in the build volume is within a target range. For example, the temperature rise of the powder in the build volume may be used as a feedback parameter to control temperature of the vapor phase of the first fluid being directed toward the layer. In implementations in which the desired amount of the first fluid condensed in powder of the build volume is relatively small, the associated temperature rise of the powder in the build volume may be correspondingly small. As an example, if the amount of the first fluid condensed accounts for approximately 1% of the void space of stainless steel powder in the build volume, the temperature rise of the powder in the build volume due to condensation of the vapor phase of the first fluid may be as little as 5° C. This observation may form the basis of a useful control approach in which the temperature control requirements associated with the powder in the build volume are relaxed, or even eliminated. That is, under conditions corresponding to only a small temperature rise of the powder in the build volume, the process of condensing the vapor phase of the first fluid may be robust without closed loop control. The condensing vapor phase may penetrate void space defined between the particles of the powder to deliver the first fluid to necks formed by the particles, as described above with respect toFIGS.1A and1B. With adequate penetration into the void space, condensing the first fluid from the vapor phase to the liquid phase along each layer may increase cohesive force holding the particles of the powder together in the respective layer, as compared to cohesive forces holding the particles of the powder together in the respective layer prior to condensation of the first fluid along the respective layer. In particular, it has been observed that such an increase in cohesive force may be achieved with only a small amount of the liquid phase of the first fluid in void spaces defined by the particles (e.g., the liquid phase of the first fluid in greater than about 0.1 percent of the void space and less than about 10 percent of the void space). As discussed above, this is significant at least because it facilitates reducing mobility of the particles of the powder (e.g., to reduce the likelihood of ejection of the particles) without significantly increasing the likelihood of bleeding of a binder or a component of a binder system. As shown in step308, the exemplary method300may include delivering a second fluid to the layer along a controlled two-dimensional pattern associated with a portion of the three-dimensional object to be formed within the layer. In general, at least the second fluid (and, in some cases, at least a portion of the first fluid in the layer) may operate to bind at least some of the powder in the layer. Thus, for example, the second fluid may include a binder or at least one component of a binder system useful for holding the particles of the powder together, such as any binder or component of a binder system known in the art. As a more specific example, to facilitate delivery of the second fluid, the second fluid may include a liquid medium (e.g., a solvent), and at least one component of the binder system dispersed (e.g., dissolved) in the liquid medium. Additionally, or alternatively, the second fluid may include one or more materials (e.g., polymeric materials) curable in the build volume prior to removing the three-dimensional object from the build volume. In certain implementations, the step306of condensing the vapor phase of the first fluid on the layer may precede the step308of delivering the second fluid to the layer such that the second fluid is delivered onto the layer including the condensed vapor. For example, the second fluid may be delivered (e.g., jetted) to the layer from a printhead trailing movement of the evaporator over the build volume as the vapor phase of the first fluid is directed toward the layer on top of the build volume. As described above, this order of application of the first fluid and the second fluid may be particularly useful, as the reduction in mobility imparted to the layer by the liquid phase of the first fluid in the layer may reduce the likelihood that impact of the second fluid on the layer may inadvertently eject particles of the powder. In turn, such a reduction in ejected particles may reduce the likelihood of clogging or otherwise degrading the printhead used to deliver the second fluid. Because clogging of the printhead may impact accuracy of jetting the second fluid along a controlled two-dimensional pattern in a given layer, the reduction in clogging achievable through the presence of the liquid phase of the first fluid in the layer may improve the quality (e.g., dimensional accuracy) of the three-dimensional object being formed and, in turn, may improve the quality of the final part formed from the three-dimensional object. In general, the first fluid may be condensed from the vapor phase to the liquid phase at least within the controlled two-dimensional pattern associated with delivery of the second fluid along the given layer. Thus, for example, the first fluid may be condensed from the vapor phase to the liquid phase along substantially the entire x-y extent of the layer while the two-dimensional pattern of the second fluid spans less than the entirety of the x-y extent of the layer. In view of such overlapping, the first fluid and the second fluid may advantageously be compatible with one another in the layer and, in some cases, may cooperate with one another in the layer in any of a variety of ways useful for improving the binder jetting process. As an example, the liquid phase of the first fluid may be soluble in the second fluid to facilitate delivering the second fluid to necks formed by the particles. That is, given that the first fluid may be at the necks prior to delivery of the second fluid, solubility of the first fluid and the second fluid may be useful for facilitating movement of the second fluid to the necks. In some instances, the first fluid may be useful in reducing the likelihood of beading of the second fluid along the top of the layer. That is, in some instances, the second fluid may be delivered to a layer, where surface tension of the second fluid may cause the second fluid to draw toward itself. As the second fluid in the layer is drawn toward itself in this way, beads may form on top of the layer. These beads are a mixture of the second fluid and particles of the powder and can be relatively large compared to the depth of the layer (e.g., 200 micron beads may form on a layer having a 50 micron depth) such that the presence of these beads may significantly interfere with formation of one or more subsequent layers. Ultimately, this may degrade the dimensional accuracy or other properties (e.g., strength, density) of the three-dimensional object being formed. In certain instances, the first fluid may reduce mobility of the particles of the powder such that surface tension of the second fluid may be less likely to draw the particles of the powder into the formation of beads. In addition, or in the alternative, the first fluid may modify one or more characteristics of the second fluid to reduce the likelihood of bead formation. As an example, the first fluid may have a larger surface tension than the second fluid and, where the first fluid and the second fluid overlap along the layer, the larger surface tension of the first fluid may resist beading. In some instances, at least one component of the first fluid may be the same as at least one component of the second fluid. As a particular example, the first fluid and the second fluid may each be water-based fluids and, thus, may have similar handling requirements (e.g. storage temperatures) and/or may respond similarly to post-processing conditions. Thus, in general, as compared to requirements for handling disparate materials, such commonality of components may reduce complexity of carrying out the exemplary method300. In certain instances, at least one component of the first fluid in the liquid phase may be the same as at least one component of the second fluid. As shown in step310, the exemplary method300may, optionally, include delivering a third fluid along at least a portion of the controlled two-dimensional pattern of the second fluid in the layer. The third fluid may be jetted, for example, from any one or more of the printheads described herein (e.g., printhead114inFIGS.1A-1C). Thus, for example, the third fluid may be delivered from a separate instance of the printhead used to deliver the second fluid. Further, or instead, the third fluid may be delivered from the same printhead used to deliver the second fluid, such as in cases in which the printhead is a multi-material printhead. The third fluid may be, for example, a suspension including an anti-sintering agent. As used herein, an anti-sintering agent shall be understood to include a material that is less sinterable than at least a portion of the particles of the powder. By way of example, the anti-sintering agent may be used to introduce certain structural characteristics into the final part. Such structural characteristics may include an area of weakness useful for separating portions of the final part from one another. As shown in step312, the exemplary method300may include repeating any one or more of the steps of the exemplary method300for each layer of a plurality of layers such that at least the second fluid (and, in some cases, at least a portion of the first fluid) operates to bind at least some of the powder in the plurality of layers to define a three-dimensional object in the build volume. In certain implementations, each step may be repeated for each layer of a plurality of layers forming the three-dimensional object. In some implementations, certain steps may be performed selectively in the plurality of layers forming the three-dimensional object. As an example, the steps of directing the vapor phase of the first fluid and condensing the vapor phase of the first fluid may be skipped for certain layers. As a more specific example, these steps may be skipped at regular intervals (e.g., one layer in every 100 layers) during fabrication of the three-dimensional object. Further, or instead, more than one layer may be skipped at a time. More generally, any intermittent use of directing the vapor phase of the first fluid and condensing the vapor phase of the first fluid should be understood to fall within the scope of the present disclosure. Further, or instead, the step of delivering the second fluid to the layer may be skipped for certain layers to form separation between multiple three-dimensional objects in instances in which multiple three-dimensional objects are formed as part of a single build. Having described the exemplary method300, attention is now turned to a specific example set forth for the purpose of further explanation only. Nothing in this example shall be construed as a limitation on the overall scope of this disclosure. In this example, the x-y extent of the build volume is 330 mm×330 mm, and the powder is gas-atomized 17-4 PH stainless steel powder with a particle size distribution characterized by a D10 of 6 microns, a D50 of 13 microns, and a D90 of 22 microns. Each layer spread across the build volume has a nominal thickness of 65 microns. When spread, the packing density of the powder in the layer is 58 percent. Thus, the void space constitutes 42 percent of the volume of the as-spread layer. The first fluid is water, and the second fluid is a polymer dissolved in a water-based material. The evaporator forms a vapor phase of the first fluid based on atomization, as described in greater detail below. The traverse rate of the evaporator over the build volume is 0.5 m/s. During the traverse, the flow rate of water into the evaporator is 5 cc/minute. The distribution gas flowing into the evaporator is nitrogen flowing at 25 liters/minute. Upon evaporation, the water expands by almost a factor of about 2000 and, thus, the volumetric flow rate of the water vapor is approximately 10 liters/minute. This water vapor mixes with the nitrogen flowing at 25 liters/minute and issues from the outlet of the evaporator through a slot having a width of 2 mm. In this example, if all of the water issuing from the outlet of the evaporator condenses within a newly spread layer, the condensed water will fill approximately 1.9 percent of the void space. Given that some of the water vapor may flow over the build volume and condense elsewhere, the condensed water in the newly spread layer will be greater than 0 and less than about 1.9 percent under these conditions. Thus, as may be appreciated from this example, a reduction in mobility of the powder in a given layer may be achieved with only a small amount of fluid in the void space defined by particles of the powder forming the layer. Referring now toFIGS.1A-1D and4, an additive manufacturing plant400may include the additive manufacturing system100, a conveyor404, and a post-processing station406. The print box108containing the three-dimensional object102may be moved along the conveyor404and into the post-processing station406. The conveyor404may be, for example, a belt conveyor movable in a direction from the additive manufacturing system100toward the post-processing station. Additionally, or alternatively, the conveyor404may include a cart on which the print box108is mounted and, in certain instances, the print box108may be moved from the additive manufacturing system100to the post-processing station406through movement of the cart (e.g., through the use of actuators to move the cart along rails or by an operator pushing the cart). The post-processing station406may include an oven407. In use, the print box108may be moved into the oven407, and heat may be directed into the build volume116. For example, the heat directed into the build volume116may evaporate at least some of the liquid phase of the first fluid120from the build volume116. To achieve practical drying times, it should be appreciated that a small amount of the liquid phase of the first fluid120may remain in the build volume116following a drying cycle. In this context, a small amount of the liquid phase of the first fluid120should be understood to be an amount that does not interfere with subsequent steps carried out in the post-processing station. In certain instances, the three-dimensional object102may be heated in the oven407to a temperature sufficient to cure at least the second fluid122defining the three-dimensional object102. Such curing of the second fluid122may further bind the particles103of the powder104to impart further rigidity to the three-dimensional object102in the build volume116. Once this additional rigidity is achieved in the three-dimensional object102, the unbound portion of the powder104may be separated from the three-dimensional object102through any one or more of various depowdering steps. In general, the heating cycle of the oven407may be a function of the composition of the first fluid120and the second fluid122. That is, in some cases, the oven407may be heated to a temperature suitable for removing the first fluid120, and then heated to a higher temperature suitable for curing the second fluid122. Alternatively, the first fluid120may be removed from the three-dimensional object102through heating in an environment suitable for curing the second fluid122. In the post-processing station406, the three-dimensional object102may be removed from the print box108. The powder104remaining in the print box108upon removal of the three-dimensional object102may be, for example, recycled for use in subsequent fabrication of additional parts. Additionally, or alternatively, in the post-processing station406, the three-dimensional object102may be cleaned (e.g., through the use of pressurized air) of excess amounts of the powder104. The three-dimensional object102may undergo one or more debinding processes in the post-processing station406to remove all or a portion of the binder system from the three-dimensional object102. In general, it shall be understood that the nature of the one or more debinding processes may include any one or more debinding processes known in the art and is a function of the constituent components of the binder system. Thus, as appropriate for a given binder system, the one or more debinding processes may include a thermal debinding process, a supercritical fluid debinding process, a catalytic debinding process, a solvent debinding process, and combinations thereof. For example, a plurality of debinding processes may be staged to remove components of the binder system from the three-dimensional object102separately. In certain instances, the post-processing station406may include a furnace408. The three-dimensional object102may undergo sintering in the furnace408such that the particles103of the powder104combine with one another through one or more of solid state or liquid state sintering processes to form a finished part. Additionally, or alternatively, one or more debinding processes may be performed in the furnace408as the three-dimensional object102undergoes sintering. Further or instead, one or more debinding processes may be performed outside of the furnace408or in a different instance of the furnace408in which sintering takes place. While certain implementations have been described, other implementations are additionally or alternatively possible. For example, while the vapor has been described as being formed through the use of sparging and, more generally, through techniques associated with forming a vapor phase of the first fluid below a boiling point of the first fluid, other techniques for forming the vapor phase of the first fluid are additionally or alternatively possible. For example, referring now toFIGS.1A-1D and5A, an evaporator500may form a vapor phase of the first fluid120based on atomizing the first fluid120to form small droplets and heating the small droplets in the in the evaporator500to a temperature at or above the boiling point of the first fluid120, as described in greater detail below. As compared to forming a vapor phase of the first fluid120through sparging, forming the vapor phase of the first fluid120through a combination of atomization and heating may reduce the need to carry a reservoir of fluid across the build volume116and, more generally, may be implemented in a smaller size envelope. Unless otherwise specified or made clear from the context, the evaporator500may be used in the additive manufacturing system100to form the vapor phase of the first fluid120and, thus, may be used to carry out various different aspects of the exemplary method300(FIG.3). The evaporator500may include an atomizer502, a heater503, and a housing504. The housing504may define an inlet section506and an outlet section508in fluid communication with one another along a flow path510defined therebetween. As described in greater detail below, the housing504may support the atomizer502and the heater503such that the atomizer502and the heater503may cooperate with one another to form a mixture of a vapor phase of the first fluid120in a distribution gas along the flow path510. In use, the mixture of the of the vapor phase of the first fluid120and the distribution gas may issue from the outlet section508of the housing as the evaporator500moves over the layer118of the powder104. The atomizer502may include an inlet port512and an exit nozzle514in fluid communication with one another. In general, the atomizer502may receive a liquid phase of the first fluid120at the inlet port512from the liquid source140. More specifically, the atomizer502may be in fluid communication with the liquid source140via the first flow controller144. As indicated above, the first flow controller144may include a solenoid valve or other similar actuatable valve that may interrupt flow from the liquid source140. Additionally, or alternatively, the first flow controller144may be actuatable to meter the flow of the liquid phase of the first fluid120into the inlet port512according to any one or more of various different liquid metering techniques. Thus, for example, the first flow controller144may, further or instead, include a metering pump. In use, the atomizer502may receive the metered flow of the liquid phase of the first fluid120and may form the liquid phase of the first fluid120into droplets516at the exit nozzle514through any one or more of various different known techniques for atomizing liquid. For example, the atomizer502may atomize the first fluid through one or more of ultrasonic atomization, hydraulic atomization, or gas atomization, including through nebulization. The atomizer502may be supported, for example, along the inlet section506of the housing504with the inlet port512of the atomizer502generally accessible from outside of the flow path510to facilitate connection of the atomizer502in fluid communication with the liquid source140via the first flow controller144. With the inlet port512so supported along the inlet section506of the housing504, at least a portion of the exit nozzle514of the atomizer502may be disposed along the flow path510. Thus, in use, the droplets516produced by the atomizer502may be expelled from the exit nozzle514and into the flow path510. For example, the droplets516may be directed into the flow path510in a direction generally toward the outlet section508of the housing504. Further, or instead, the exit nozzle514of the atomizer502may be mounted to the inlet section506of the housing504such that a spray pattern of the droplets516expelled from the exit nozzle514is directed to one or more heated surfaces of the housing504prior to exiting the outlet section508. For example, to reduce the likelihood that the droplets516expelled from the exit nozzle514do not impinge on any hot surfaces of the housing504, the flow path510may include one or more non-linear sections. More specifically, such non-linear sections may define a tortuous path in a direction from the inlet section506to the outlet section508. In certain instances, the inlet section506of the housing504may include one or more gas inlets518for receiving a distribution gas520. The distribution gas520may be any one or more of the various different distribution gases described herein and, unless otherwise indicated or made clear from the context, may be the same as the distribution gas213b(FIG.2). In general, the one or more gas inlets518may be connectable, such as through the use of a manifold or other similar arrangement, in fluid communication with a pressurized source of the distribution gas520. As an example, the one or more gas inlets518may be connectable in fluid communication with the gas source142via the second flow controller146, which may control flow of the distribution gas520into the housing504. As the distribution gas520moves into the evaporator500through the gas inlets518, the distribution gas520may mix with the droplets516. In particular, the droplets516may be sufficiently small (e.g., having an average size of greater about 5 microns and less than about 100 microns) to form a suspension of the droplets516in the distribution gas520. Such a suspension of the droplets516in the distribution gas520, commonly referred to as a mist, may be useful for reducing the likelihood of unintended aggregation of the droplets516along the flow path510. In turn, such a reduction in the likelihood of unintended aggregation may be useful for maintaining consistent conditions in the vapor phase of the first fluid120issuing from the outlet section508of the housing504during use. The heater503may be in thermal communication with the flow path510to heat the mixture of the droplets516and the distribution gas520as the mixture moves along the flow path510. More specifically, the heater503may heat at least a portion of the housing504along the flow path510to heat the mixture to a temperature at or above the boiling temperature of the first fluid120. Through such heating, the droplets516carried by the distribution gas520may vaporize such that the mixture becomes a gaseous mixture prior to issuing from the outlet section508of the housing504. The heater503may be any one or more of various different types of heaters controllable to a target temperature at or above the boiling temperature of the first fluid120(e.g., through open loop control or through closed loop control based on an indication of temperature from the heater503itself and/or from a separately positioned temperature sensor (not shown)). Thus, for example, the heater503may include one or more pad resistance heaters. The heater503may be in thermal communication with the flow path510via, for example, one or more walls of the housing504(e.g., mounted on the outside of the housing504) such that the heater503is not directly exposed to the mixture of fluids moving through the flow path510. In general, such isolation of the heater503from direct exposure to the mixture of fluids may reduce the potential for degradation of the heater503over time. In instances in which heat from the heater503is conducted through the housing504, the housing may be formed of a material having a high thermal conductivity (e.g., one or more metals) and sufficient thickness such that temperature along the flow path510is substantially uniform to promote, in turn, reliable and consistent vaporization of the first fluid120along the flow path510. In general, the outlet section508may be shaped and arranged to facilitate a substantially uniform distribution of the vapor phase of the first fluid120along an x-y extent of the layer118. Thus, for example, the outlet section508may span at least one dimension of the build volume116(and thus the layer118) as the evaporator500is moved over the build volume116. Further, or instead, the outlet section508may be substantially perpendicular to the layer118of the powder as the evaporator moves over the build volume116. In certain implementations, the outlet section508of the housing504may, further or instead, be in the shape of a converging nozzle in a direction defined from the inlet section506to the outlet section508of the housing504to reduce the likelihood of inducing eddy currents as the vapor phase of the first fluid120issues from the outlet section508. The outlet section508through which the vapor phase of the first fluid120is issued from the evaporator500may have a significantly greater open area than an open area of the inlet port512through which the liquid phase of the first fluid120is introduced into the evaporator500. This difference in open area is at least partially attributable to differences in density between the liquid phase of the first fluid120and vapor phase of the first fluid120. Thus, for example, the inlet port512may have a first open area, the outlet section508may have a second open area, and the ratio of the second open area to the first open area may be greater than about 10:1 and less than about 5,000:1 (e.g., about 1,000:1). In certain implementations, the evaporator500may include a gate522movable to interrupt flow issuing from the outlet section508of the housing504. In particular, the gate522may be in an open position to permit issuance of the vapor phase of the first fluid120toward the layer118as the evaporator500is above the build volume116. Further, or instead, the gate522may be moved to a closed position to block the flow of the vapor phase of the first fluid120toward the layer118as the evaporator500is moved to a position lateral to the build volume116. That is, the gate522may be actuated to close between formation of successive layers to reduce the likelihood of inadvertently delivering the vapor phase of the first fluid120to areas away from the layer118. In addition to being a useful safety measure, such control over the vapor phase of the first fluid120may be useful for managing atmospheric control in the build chamber115. In certain implementations, opening and closing the gate522may coincide with shutting off the flow of the distribution gas520and the first fluid120into the flow path510. The gate522may be generally oriented to open and close without interfering with the layer118. For example, the gate522may be movable in a direction parallel to the x-y extent of the layer118such that the gate522may be movable within the standoff clearance between the outlet section508and the top of the layer118. Additionally, or alternatively, the gate522may be positioned within the housing504, along the flow path510. In certain instances, the residence time of the first fluid120along the flow path206may be based on the time required for the evaporator500to traverse the layer118. For example, it may be useful to generate and dispense the vapor phase of the first fluid120during the time it takes for the evaporator500to traverse the layer118. Doing so may reduce the likelihood that significant residual amounts of the first fluid120and/or the distribution gas520remain in the evaporator500in the brief shut-off periods between formation of successive layers. In turn, the gaseous mixture of the vapor phase of the first fluid120and the distribution gas520may be substantially uniform from layer to layer. While evaporator500has been described as using the distribution gas520to form a mixture with the first fluid120, it should be appreciated that the vapor phase of the first fluid120may be produced without the use of the distribution gas520. For example, operation of the evaporator500without the distribution gas520may include introducing the first fluid120into the flow path510defined by the housing504(e.g., with or without atomization) and heating the first fluid120along the flow path510to a temperature at or above the boiling temperature of the first fluid120to form the vapor phase. Without a distribution gas in the flow path510, expansion of the vapor phase of the first fluid120may drive the vapor phase of the first fluid120toward the outlet section508. Thus, as compared to implementations in which a distribution gas is used, the outlet section508may be smaller to achieve a suitable exit velocity of the vapor phase of the first fluid120issuing from the outlet section508. Elimination of the distribution gas520may have the advantage of reducing complexity of hardware. Further, or instead, elimination of the distribution gas520may facilitate delivering the vapor phase of the first fluid120toward the layer at lower velocities than may be achievable with the use of the distribution gas520. Without wishing to bound by theory, through elimination or substantial reduction of the distribution gas520, most of the fluid directed from the outlet section508to the layer118is the vapor phase of the first fluid120. Again without wishing to be bound by theory, as the vapor phase of the first fluid120contacts the powder104, the vapor phase of the first fluid120may condense and enter the void space124of the powder, thus making room for an additional amount of the vapor phase of the first fluid120to contact the powder104to condense and enter the void space124of the powder. Accordingly, it is believed that reduction or elimination of the distribution gas520may result in more of the vapor phase of the first fluid120condensing on and in the powder104, with less of the vapor phase of the first fluid120spilling off of the x-y extent of the layer118and being lost to the environment of the build chamber115. While the use of a single atomized spray has been described with respect to vaporization, it should be appreciated that a plurality of atomized sprays may be used to facilitate, among other things, producing a large amount of a vapor phase of a fluid. For example, referring now toFIGS.1A-1D and5B, an evaporator550may include a rail551supporting a first exit nozzle552a, a second exit nozzle552b, a third exit nozzle552c, and a fourth exit nozzle552d(collectively referred to as the plurality of exit nozzles552a-d). While the plurality of exit nozzles552a-dis shown as including four exit nozzles, it should be readily appreciated that any number of exit nozzles may be supported on the rail551. Further, unless otherwise specified or made clear from the context, components of the evaporator550should be understood to be analogous to similar components of the evaporator500(FIG.5A). For the sake of economic description, these similar components are not described separately, except to note differences or to highlight certain aspects. The evaporator550may also include a heater553and a housing554, with the housing554defining an inlet section556and an outlet section558in fluid communication with one another along a flow path560defined therebetween. The housing554may define an inlet port562in fluid communication with the rail551such that a liquid form of the first fluid120(e.g., received from the liquid source140via the first flow controller144) may flow along the rail551to the plurality of exit nozzles552a-d. At the plurality of exit nozzles552a-d, droplets566may be formed through any one or more of the various different atomization techniques described herein. The heater553may be disposed along the housing554and, in general, should be understood to be analogous to the heater503(FIG.5A). Thus, in use, the heater553may heat the housing554to a temperature above the boiling point of the first fluid120. That is, as the droplets566from the plurality of exit nozzles552a-dimpinge on one or more surfaces of the housing554, the droplets566may vaporize to form the vapor phase of the first fluid120. In certain implementations, the housing554may define one or more gas inlets568through which a distribution gas570may be introduced into the flow path560(e.g., from the gas source142via the second flow controller146) to create certain flow characteristics in the flow path560, as described with respect to any one or more of the distribution gases described herein. In some implementations, the distribution gas570may be omitted, such that the flow of the vapor phase of the first fluid120may issue from the outlet section558through expansion of the first fluid120as the first fluid120vaporizes. While methods for managing powder mobility have been described with respect to a first fluid and a second fluid that do not substantially chemically react with one another in the build volume, other combinations of the first fluid and the second fluid are additionally or alternatively possible. For example, the first fluid and the second fluid may chemically react with one another to facilitate one or more of localizing the second fluid along a controlled two-dimensional pattern, forming binder or a component of a binder system, or some combination thereof. FIG.6is a flow chart of an exemplary method600of a binder jet additive manufacturing method including in situ (i.e., within build volume) chemical reaction of a first fluid directed in a vapor phase toward a layer with a second fluid delivered to the layer. Unless otherwise specified or made clear from the context, the exemplary method600may be implemented using any one or more of the various different additive manufacturing systems, and components thereof, described herein. Thus, for example, the exemplary method600may be implemented as computer-readable instructions stored on the computer readable storage medium132(FIGS.1A-1C) and executable by the one or more processors131(FIGS.1A-1C) of the controller130(FIGS.1A-1C) to operate the additive manufacturing system100(FIGS.1A-1C). As shown in step602, the exemplary method600may include spreading a layer of a powder across a build volume at least partially defined by a print box. In general, spreading the layer in step602shall be understood to be analogous to step302described above with respect to the exemplary method300(FIG.3). Thus, for example, spreading the layer in step602shall be understood to include spreading any one or more of the various different types of powders described herein to form a substantially uniform layer of the powder across the top of the build volume. As shown in step604, the exemplary method600may include directing a first fluid in a vapor phase toward the layer of the powder. In general, directing the first fluid in the vapor phase in step604shall be understood to be analogous to step304described above with respect to the exemplary method300(FIG.3). Thus, for example, directing the first fluid in the vapor phase in step604shall be understood to include introducing the vapor phase of the first fluid to a layer of the powder that is cooler than the vapor phase of the first fluid. This temperature differential between the vapor phase of the first fluid and the layer of the powder may drive penetration of the vapor phase of the first fluid into the layer as the vapor phase of the first fluid condenses. That is, unless otherwise specified or made clear from the context, directing the first fluid in the vapor phase in step604shall be understood to result in a distribution of a substantial portion of the liquid phase of the first fluid along necks defined by particles of the powder (as described above with respect toFIG.1D). As shown in step606, the exemplary method600may include delivering a second fluid along the layer in a controlled two-dimensional pattern associated with the layer. In general, at least one component of the second fluid delivered to the layer may chemically react with the first fluid along the controlled two-dimensional pattern associated with the layer. As an example, the first fluid may increase one or more of a degree of crosslinking or a degree of polymerization of the at least one component of the second fluid (e.g., one or more of cyanoacrylate, silane, a silane-grafted polymer, or a moisture curable polyurethane) along the controlled two-dimensional pattern associated with the layer. As an additional or alternative example, the first fluid may include one or more components that change a pH level of the at least one component of the second fluid along the controlled two-dimensional pattern associated with the layer. In particular, the first fluid may include one or more of nitric acid, hydrogen chloride, ammonia, or carbon dioxide, as these materials are commonly available and have well-understood handling requirements. Continuing with this example, one or more of these materials may be dissolved in a solvent, such as water. More generally, however, while certain examples of chemical reactions are described below, the chemical reaction of the at least one component of the second fluid with the first fluid should be understood to include any change in the molecular or ionic structure of one or both of the first fluid or the second fluid along the controlled two-dimensional pattern. Further, or instead, the chemical reaction between the first fluid and the at least one component of the second fluid may be at least initiated, and in some cases may be completed, before a subsequent layer is formed on top of the layer. The second fluid may include, for example, a liquid medium in which at least one component of the second fluid is dispersed. The liquid medium may be, for example, different from the first fluid to facilitate maintaining the at least one component of the second fluid in a stable form until the at least one component of the second fluid is chemically reacted with the first fluid in the layer. As an example, the first fluid may be water, the at least one component of the second fluid may be chemically reactable with the first fluid, and the liquid medium of the second fluid may be anhydrous (e.g., an anhydrous solvent in which the at least one component of the second fluid is dissolved) such that the at least one component of the second fluid remains stable in the carrier liquid. As a specific example, the at least one component of the second fluid may be a cyanoacrylate and the anhydrous solvent may be one or more ketones (e.g., acetone, butanone, cyclohexanone) or one or more esters (e.g., ethyl acetate or butyl acetate). As yet another specific example, the at least one component of the second fluid may be a silane or a silane-grafted polymer, and the anhydrous solvent may be methanol or ethanol. As still another specific example, the at least one component of the second fluid may be polyurethane and the anhydrous solvent may be any one or more of various different urethane-grade solvents, such as Eastman™ Butyl Acetate, available from Eastman Chemical Company of Kingsport, Tennessee. In some implementations, the chemical reaction of the first fluid and the second fluid may increase localization of the second fluid along the respective layer as compared to localization of the second fluid along the given layer prior to chemical reaction of the first fluid and the at least one component of the second fluid. Such localization may, for example, make the second fluid less likely to flow in the layer, thus reducing the likelihood that the second fluid will bleed to distort the controlled two-dimensional pattern. In general, such a change in the flow characteristics of the second fluid may correspond to a change in viscosity of the second fluid, such as may be achieved through chemical reaction of the first fluid and the at least one component of the second fluid to form a gel or a sol. As a more specific example, the at least one component of the second fluid may include colloidal silica, and the first fluid may change the pH level of the colloidal silica to form a silica gel. In instances in which the at least one component of the second fluid includes an alkaline stabilized colloidal silica, the first fluid may have an acidic character. In instances in which the at least one component of the second fluid is an acid stabilized colloidal silica, the first fluid may have a basic character. In certain implementations, the chemical reaction of the first fluid and the at least one component of the second fluid may form at least one component of a binder along the controlled two-dimensional pattern associated with the layer. As an example, chemical reaction of the first fluid and the at least one component of the second fluid may be used to form polyacrylic acid in situ in the layer. For example, the at least one component of the second fluid may include pre-crosslinked unneutralized polyacrylic acid. Continuing with this example, the chemical reaction of the first fluid and the at least one component of the second fluid may increase the pH level of the pre-crosslinked unneutralized polyacrylic acid. In general, such in situ formation of at least one component of the binder may be particularly advantageous in instances in which the at least one component of the binder is challenging to deliver. That is, in some cases, the properties that make a material particularly well suited for binding particles may correspond to a tendency of that same material to clog hardware. Thus, in some cases, the in situ formation of the at least one component of the binder from the first fluid and the second may reduce the likelihood of clogging hardware. Additionally, or alternatively, the chemical reaction of the first fluid and the at least one component of the second fluid may form an anti-sintering agent along the controlled two-dimensional pattern associated with the layer. For example, the anti-sintering agent may be formed in an area along which preferential fracturing may be desired (e.g., to separate multiple instances of a part being fabricated at the same time). While the anti-sintering agent may be formed through any one or more of various different chemical reactions of the first fluid and the at least one component of the second fluid, the chemical reaction of the first fluid and the at least one component of the second fluid may form the anti-sintering agent through flocculation (e.g., due to a pH change in a stable suspension of the anti-sintering agent) in some implementations. As an example, the at least one component of the second fluid may include a pH stabilized suspension of TiO2particles that may be caused to flocculate by the first fluid. Further, or instead, the chemical reaction of the first fluid and the at least one component of the second fluid may form the anti-sintering agent through precipitation. As an example, the first fluid may include a base (e.g., ammonia) having a pH level above 7, and the at least one component of the second fluid may include acid solubilized aluminum hydroxide. In this example, the chemical reaction of the base and the acid solubilized aluminum hydroxide may precipitate aluminum hydroxide. In some implementations, the composition of the first fluid may change between the liquid phase in which it is delivered to the evaporator and the liquid phase after condensation in the layer. As an example, consider the case in which it is desirable for the condensed liquid phase of the first fluid in the layer to be water-based but slightly basic. As a more specific example, it may be desirable for the condensed liquid phase of the first fluid in the layer to include water with some amount of ammonia dissolved in it. However, in instances in which the evaporator functions by atomizing the first fluid and impinging the resulting droplets on surfaces above the boiling point of the first fluid, providing the first fluid with some amount of ammonia dissolved therein is likely to result in the ammonia coming out of solution upon evaporation and turning into ammonia gas. Some, but perhaps not all, of this ammonia gas may then re-dissolve in the condensed liquid within the layer. The result, therefore, is that the composition of the liquid phase of the first fluid within the layer may differ from the composition of the liquid phase of the first fluid provided to the evaporator. Alternatively, or in addition, the composition of the liquid phase of the first fluid condensed in the layer may be influenced by the nature and composition of the distribution gas. Continuing with the example of ammonia above, the amount of ammonia dissolved in water in the layer may be increased by using a distribution gas having a partial concentration of ammonia. Thus, stated differently, the distribution gas may be used to increase the ammonia concentration in the first fluid condensed in the layer to achieve a concentration suitable, for example, for carrying out a chemical reaction including the second fluid. As an additional or alternative example, a combination of the first fluid and the distribution gas may be used to form slightly acidic water. That is, pure water may be provided to the evaporator as the first fluid and the distribution may include carbon dioxide (e.g., carbon dioxide alone or in a mixture with an inert gas). As this mixture is directed to the layer, the water may condense in the layer and the carbon dioxide may dissolve into this condensed water to create carbonic acid and lower pH of the condensed water. In some implementations, the vapor phase of the first fluid may be directed to the layer before the second fluid is delivered to the layer to form the controlled two-dimensional pattern in the layer. In such instances, the first fluid may be concentrated at necks formed by particles of the powder of the layer (e.g., as described with respect toFIG.1D), thus reducing mobility of the particles of the powder of the layer. Continuing with this example, the chemical reaction between the first fluid and the second fluid may take place at least at areas of contact between the particles. For example, chemical reaction of the first fluid and the second fluid in the vicinity of the necks of the particles may form a third material at the necks. This third material may, for example, impart improved cohesive strength at the necks of the particles. As shown in step608, the exemplary method600may include, for a plurality of layers, repeating the steps of spreading a respective layer of the powder, directing the first fluid in the in the vapor phase to the respective layer, and delivering the second fluid along the respective layer such that at least the second fluid (and, in some cases, at least some of the first fluid) operates to bind a portion of the powder in the plurality of layers to form a three-dimensional object in the build206 While the vapor phase of a fluid has been described as being delivered to a layer from an evaporator moving over the layer, it should be appreciated that the vapor phase of a fluid may, further or instead, be introduced into the layer through controlling an environment in a build chamber (e.g., the build chamber115inFIGS.1A-1C). As compared to the use of an evaporator, controlling the environment of the build chamber may require moving fewer components across the build volume. Further, or instead, as compared to delivering the vapor phase of the first fluid from an evaporator, controlling the environment of the build chamber to introduce vapor into the layer may facilitate achieving more uniform condensation of the first fluid across the layer. FIG.7is a flowchart of an exemplary method700for managing powder mobility in binder jet additive manufacturing based on controlling an environment of a build chamber. That is, by controlling the environment of the build chamber relative to a temperature of the layer, a vapor phase of the first fluid may condense along the layer as a suitably low temperature is established in the layer. Unless otherwise specified or made clear from the context, the exemplary method700may be implemented using any one or more of the various different additive manufacturing systems, and components thereof, described herein. Thus, for example, the exemplary method700may be implemented as computer-readable instructions stored on the computer readable storage medium132(FIGS.1A-1C) and executable by the one or more processors131(FIGS.1A-1C) of the controller130(FIGS.1A-1C) to operate the additive manufacturing system100(FIGS.1A-1C). As shown in step702, the exemplary method700may include forming a layer of the powder across a build volume at least partially defined by a print box, the layer of the powder exposed to an environment defined by a build chamber. In general, forming the layer of the powder in step702shall be understood to be analogous to step302described above with respect to the exemplary method300(FIG.3). Thus, for example, forming the layer in step702shall be understood to include spreading any one or more of the various different types of powders described herein to form a substantially uniform layer of the powder across the top of the build volume. In general, it may be useful to manage formation of the layer of the powder to reduce the likelihood that the first fluid in the environment above the layer may condense as the layer is being formed. Such premature condensation of the first fluid may, for example, interfere with uniformity of the layer and, over the course of a plurality of layers, may significantly distort the three-dimensional object being formed. Thus, in some instances, forming the layer may include spreading the powder at a temperature above the dew point of the first fluid in the vapor phase in the mixture with the carrier gas such that the first fluid does not prematurely condense as the powder is being spread to form the layer. For example, heat (e.g., from infrared heat source) may be directed at the powder as the spreader moves the powder across the layer. Additionally, or alternatively, the powder supply may be heated to a temperature above the dew point of the first fluid in the carrier gas in the build chamber. In certain implementations, forming the layer may further or instead include forming a non-condensing region locally in front of the spreader as the spreader moves across the build volume to form the layer. Such a non-condensing region may be formed, for example, through one or more of drying or introduction of a gas (e.g., blowing) that does not contain the first fluid in a concentration sufficient to condense. As shown in step704, the exemplary method700may include maintaining the environment in the build chamber at a predetermined relative saturation of a first fluid in a vapor phase in a mixture with a carrier gas. For example, the predetermined relative saturation of the first fluid in the vapor phase of the mixture with the carrier gas may be greater than about10percent and less than about 90 percent. Further, or instead, given that the first fluid introduced into the layer is drawn from the environment in the build chamber, maintaining the predetermined relative saturation of the first fluid in the vapor phase in the mixture with the carrier gas in the build chamber may include introducing the first fluid in the vapor phase into the build chamber at a volumetric flow rate greater than or substantially equal to a volumetric rate of condensation of the first fluid from the vapor phase to the liquid phase along the layer of the powder. Additionally, or alternatively, maintaining the predetermined relative saturation of the first fluid in the vapor phase in the mixture with the carrier gas may include continuously moving the mixture through the build chamber such that the environmental parameters in the build chamber may remain substantially constant even as the first fluid condenses onto the layer. In certain implementations, a volume of the first fluid in the vapor phase in the environment in the build chamber may be greater than the volume of void space defined by the powder in the layer such that penetration of the first fluid into the void space is generally not limited by the amount of the first fluid available in the environment. As shown in step706, the exemplary method700may include establishing, in the layer, a temperature below a dew point of the first fluid in the vapor phase in the mixture with the carrier gas such that at least some of the vapor phase of the first fluid in contact with the powder in the layer condenses to a liquid phase along the layer of the powder. That is, returning to the example in which the powder is heated as it is spread to form the layer, the layer of the powder may be cooled from a temperature above the dew point to a temperature below the dew point such that the first fluid in contact with the first layer may condense. Although some degree of cooling may occur through natural convection between the layer of the powder and the environment in the build chamber, forced convective cooling (e.g., by blowing a cooled gas, such as the carrier gas, over the layer) may be useful for cooling the layer to a predetermined temperature below the dew point to facilitate achieving repeatability of the condensation process on a layer-to-layer basis. Further, or instead, forced convective cooling may be useful for achieving cooling on a time scale that may be suitably implemented in a layer-by-layer process. As shown in step708, the exemplary method700may include delivering a second fluid to the layer along a respective controlled two-dimensional pattern associated with the layer according to a computerized model of a three-dimensional object. The second fluid may be any one or more of the second fluids described herein and, thus, may be a binder or a component of a binder system. In certain implementations, condensation of the first fluid from the vapor phase to the liquid phase in the layer may precede delivering the second fluid to the layer along the controlled two-dimensional pattern to reduce the likelihood of mechanical ejection of particles of the powder upon impact by the second fluid along the controlled two-dimensional pattern. In certain instances, it may be useful to control the temperature of the second fluid in coordination with the temperature of the layer and the dew point temperature. For example, to avoid creating an inadvertent temperature differential that drives further condensation of the first fluid from the environment of the build chamber, the second fluid may be delivered to the layer at a temperature substantially equal to or greater than the temperature of the layer such that the second fluid does not cool the layer. As shown in step710, the exemplary method700may include repeating steps702,704,706, and708for a plurality of layers such that at least the second fluid (and, in some cases, at least a portion of the first fluid) operates to bind at least a portion of the particles of the layer of the powder to define a three-dimensional object in a build volume. In some implementations, each of the steps may be performed in each of the plurality of layers forming the three-dimensional object. In some implementations, however, certain steps may be performed selectively in the plurality of layers forming the three-dimensional object. For example, in some cases, the temperature of a given layer may be maintained above the dew point of the first fluid such that condensation does not occur in the given layer. While phase change of the first fluid has been described in terms of condensation from a vapor phase to a liquid phase, it should be appreciated that other phase changes may be useful in reducing mobility of particles in a binder jetting process. As an example, referring againFIG.3, condensing the first fluid in the exemplary method300may further include freezing the first fluid along the layer of the powder to form a solid phase along the respective layer. As compared to the reduction in mobility imparted to the particles by the liquid phase of the first fluid, the solid phase may offer further reduction in mobility. In general, freezing the first fluid along the layer of the powder may include exposing the layer of the powder to a material below the freezing point of the first fluid. Examples of cold materials that may be useful for freezing the first fluid along the layer include one or more of refrigerated air or liquid nitrogen. Given that the persistence of the solid phase beyond formation of a given layer may be undesirable, the second fluid delivered to the layer in the controlled two-dimensional pattern may be at a temperature sufficient to melt the solid phase to the liquid phase along at least the controlled two-dimensional pattern. The second fluid may further or instead cause melting of the solid phase through chemical reaction. As yet another example of the use of other types of phase changes,FIG.8is a flowchart of an exemplary method for managing powder mobility in binder jet additive manufacturing using vapor deposition. As shown in step802, the exemplary method800may include spreading a layer of a powder across a build volume at least partially defined by a print box. In general, spreading the layer in step802shall be understood to be analogous to step302described above with respect to the exemplary method300(FIG.3). Thus, for example, spreading the layer in step802shall be understood to include spreading any one or more of the various different types of powders described herein to form a substantially uniform layer of the powder across the top of the build volume. As shown in step804, the exemplary method800may include directing a first material in a vapor phase to the layer, the first material undergoing deposition from the vapor phase to form a solid along the layer (e.g., along an entire x-y extent of the layer). As used in this context, deposition should be understood to refer to a phase transition in which the vapor phase of the first material transforms into a solid phase without passing through a liquid phase. As compared to depositing a liquid phase and freezing the liquid phase, deposition of the first material may be useful, for example, for achieving substantial reduction in mobility of the powder relatively quickly (e.g., without the additional delay associated with freezing a liquid phase). In general, directing the first material in the vapor phase to the layer may include moving the first material in the vapor phase (e.g., with or without mixing in one or more of a carrier gas or a distribution gas) to the layer of the powder. In instances in which a carrier gas or a distribution gas is used to deliver the first material, the first material may be substantially inert with respect to the carrier gas or the distribution gas, as the case may be. Further, or instead, the first material may be substantially inert with respect to the one or more of the carrier gas or the distribution gas, as a given implementation may dictate. In certain implementations, the first material may be a material that is in the solid form at or near room temperature conditions (e.g., naphthalene or iodine). In such instances, the solid phase of the first material may be realized along the layer without additional cooling. As should be readily appreciated, this may offer certain advantages with respect to complexity of implementation. As shown in step806, the exemplary method800may include delivering a second material to the layer along a controlled two-dimensional pattern associated with the layer. In general, delivering the second material to the layer in step806shall be understood to be analogous to step308described above with respect to the exemplary method300(FIG.3). Thus, for example, delivering the second material to the layer in step806may include jetting or otherwise delivering the second material from a printhead moving over the layer. In certain implementations, deposition of the first material from the vapor phase to the solid along the layer may precede delivery of the second material to the layer. That is, with the solid along the layer, the impact of the second material incident on the layer may be less likely to eject particles of the powder. It may be generally desirable to maintain the second material in a liquid phase in the layer to facilitate, for example, penetration of the second material in the layer. Thus, in some instances, it may be useful to control the temperature of the layer to a temperature between a first temperature associated with freezing of the first material and a second temperature associated with freezing of the second material. More specifically, the second temperature may be lower than the first temperature such that the second material may be delivered in a liquid phase in a layer that includes the solid formed from the first material. As a more specific example, the first material may include water, and the second material may include alcohol. Continuing with this example, the layer may be cooled to a temperature of about −5° C. (e.g., using refrigerated air in an environment above the layer). As the first material including water contacts the layer, the deposition of the water may form frost on the layer. This frost may reduce mobility of the particles in the layer as the second material including alcohol is delivered in a liquid phase to the layer and penetrates the layer. As shown in step808, the exemplary method800may include repeating one or more of the steps802,804, and806for a plurality of layers such that at least the second material (and, in some cases, at least a portion of the solid formed from the first material) operates to bind at least some of the powder in the plurality of layers to form a three-dimensional object in the build volume defined by the print box. In certain implementations, each of the steps may be performed in each layer to form the three-dimensional object. In some implementations, however, certain steps may be performed selectively in the plurality of layers forming the three-dimensional object. As an example, the step of directing the vapor phase of the first material may be skipped for certain layers in the plurality of layers. As shown in step810, the exemplary method800may further or instead include heating the three-dimensional object to an elevated temperature. As the three-dimensional object is heated to this elevated temperature, the solid formed from the first material may sublimate from the three-dimensional object. For example, as the first material sublimates from the three-dimensional object, the second material may remain in the three-dimensional object. Further, or instead, in instances in which the second material includes at least one component of a binder system, heating the three-dimensional object to the elevated temperature may increase one or more of a degree of polymerization or a degree of crosslinking of the at least one component of the binder system such that the three-dimensional object may become more dimensionally stable. The above systems, devices, methods, processes, and the like may be realized in hardware, software, or any combination of these suitable for a particular application. The hardware may include a general-purpose computer and/or dedicated computing device. This includes realization in one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors or other programmable devices or processing circuitry, along with internal and/or external memory. This may also, or instead, include one or more application specific integrated circuits, programmable gate arrays, programmable array logic components, or any other device or devices that may be configured to process electronic signals. It will further be appreciated that a realization of the processes or devices described above may include computer-executable code created using a structured programming language such as C, an object oriented programming language such as C++, or any other high-level or low-level programming language (including assembly languages, hardware description languages, and database programming languages and technologies) that may be stored, compiled or interpreted to run on one of the above devices, as well as heterogeneous combinations of processors, processor architectures, or combinations of different hardware and software. In another aspect, the methods may be embodied in systems that perform the steps thereof, and may be distributed across devices in a number of ways. At the same time, processing may be distributed across devices such as the various systems described above, or all of the functionality may be integrated into a dedicated, standalone device or other hardware. In another aspect, means for performing the steps associated with the processes described above may include any of the hardware and/or software described above. All such permutations and combinations are intended to fall within the scope of the present disclosure. Embodiments disclosed herein may include computer program products comprising computer-executable code or computer-usable code that, when executing on one or more computing devices, performs any and/or all of the steps thereof. The code may be stored in a non-transitory fashion in a computer memory, which may be a memory from which the program executes (such as random access memory associated with a processor), or a storage device such as a disk drive, flash memory or any other optical, electromagnetic, magnetic, infrared or other device or combination of devices. In another aspect, any of the systems and methods described above may be embodied in any suitable transmission or propagation medium carrying computer-executable code and/or any inputs or outputs from same. The method steps of the implementations described herein are intended to include any suitable method of causing such method steps to be performed, consistent with the patentability of the following claims, unless a different meaning is expressly provided or otherwise clear from the context. So, for example performing the step of X includes any suitable method for causing another party such as a remote user, a remote processing resource (e.g., a server or cloud computer) or a machine to perform the step of X. Similarly, performing steps X, Y and Z may include any method of directing or controlling any combination of such other individuals or resources to perform steps X, Y and Z to obtain the benefit of such steps. Thus, method steps of the implementations described herein are intended to include any suitable method of causing one or more other parties or entities to perform the steps, consistent with the patentability of the following claims, unless a different meaning is expressly provided or otherwise clear from the context. Such parties or entities need not be under the direction or control of any other party or entity, and need not be located within a particular jurisdiction. It should further be appreciated that the methods above are provided by way of example. Absent an explicit indication to the contrary, the disclosed steps may be modified, supplemented, omitted, and/or re-ordered without departing from the scope of this disclosure. It will be appreciated that the methods and systems described above are set forth by way of example and not of limitation. Numerous variations, additions, omissions, and other modifications will be apparent to one of ordinary skill in the art. In addition, the order or presentation of method steps in the description and drawings above is not intended to require this order of performing the recited steps unless a particular order is expressly required or otherwise clear from the context. Thus, while particular embodiments have been shown and described, it will be apparent to those skilled in the art that various changes and modifications in form and details may be made therein without departing from the spirit and scope of this disclosure and are intended to form a part of the invention as defined by the following claims, which are to be interpreted in the broadest sense allowable by law. | 143,593 |
11858211 | DETAILED DESCRIPTION Described herein are systems for material deposition, for example, such systems as facilitate the deposition of material at a single point on a surface from several sources in rapid succession, as deposit material from a container and seal the container after deposition as part of a material printing application, and/or as seal a container holding material for deposition as part of a 3D printing application. In a first example, a system that facilitates the deposition of material at a single point on a surface from several sources in rapid succession is described. In one embodiment, containers, such as syringes, containing material are arranged in a conical shape or other shape with all their tips pointing toward a single point of deposition. A piston mounted on a rotating arm is moved by a motor to the desired container. The piston presses down on the container holder. The holder slides toward the point of deposition, bringing the tip of the container into proximity with the point of deposition. Pressurized gas or other means is used to force material through the container. After deposition, the piston is released, and a spring returns the container holder to its original position. The entire container array is mounted on a horizontal stage allowing movement in one direction or along an axis. Alternatively, rather than having to first select a desired container to dispense material, rotate the piston to the selected container, and then move the container and piston arrangement so that the tip of the container is proximate the point of deposition, each container may be fitted with a piston-like arrangement so that a respective container need only be moved to the deposition position and its respective piston (or other dispensing actuator) engaged in order to deposit material. Such an arrangement may provide for more rapid dispensing of material than one which requires rotation of the piston. Referring toFIGS.1-3, a system100that facilitates the deposition of material in accordance with embodiments of the invention is illustrated. In one embodiment syringes112containing material are arranged in a cone shape, with their tips114pointing at one common point in space. Alternatively, the syringes or other containers112can be arranged with part of their barrels116in a closed loop of any shape with their tips114pointing at a common single point in space. Springs or other biasing mechanisms keep the syringes or other containers112lifted a fixed distance above the deposition surface (not shown). In the illustrated embodiment, to deposit material from a given syringe or other container112the container is first brought into proximity with the deposition surface (wherein lies the point toward which all the tips of the containers point). A piston118is mounted on a rotating arm120. A motor122rotates arm120so that the piston118is brought in line with the desired container112. The piston118is actuated so that it presses down on the container mount124. In another embodiment of the invention, each container has its own piston and there is no rotating arm. The container112slides along two sliders126, which ensure that the container does not rotate about its axis. The piston118then brings the deposition tip114into proximity with the deposition surface. A pressurized gas or other means is then used to force material from the container112onto the deposition surface. In this way the system can deposit material from many (six in this illustrated example, but more or fewer in other embodiments) containers in rapid succession, because all of the containers (e.g., their point of dispensing) are close to their final location, and all that is needed is to rotate the piston into position and to actuate it, which is accomplished quickly with currently conventional pistons and motors. The system is equipped with a limit switch128to perform homing. The rotating arm120has a slot130cut into it. The slot130is located such that when the piston118is in its home position, the slot130passes through the limit switch128. In this way the arm120can be rotated to a precise home position. The system is designed such that it can operate without all the containers being loaded onto the system. By using holders of different sizes, the system100can accommodate containers112of different sizes (e.g., at the same time), although this may require by leaving some container spots empty. As mentioned above, an alternative arrangement eliminates the need to rotate arm120so that the piston118is brought in line with the desired container112. Instead, each container112is fitted with its own dispensing mechanism (e.g., a piston like piston118) so that when the container is brought into proximity with the deposition surface its respective dispensing mechanism can be immediately activated to dispense material. Or, the dispensing mechanism (e.g., a piston or other device) may be centrally located and bringing the container into proximity with the deposition surface would include positioning the container so that it is acted upon by the centrally located dispensing mechanism. Thus, the plurality of containers112may each include a respective piston118or other dispensing mechanism and may be arranged about the common point of deposition with their respective material dispensing ends114oriented towards that common point of deposition. Each container may be included within a respective mount124and translatable so as to actuatable by its respective piston or, alternatively by another dispensing mechanism, when in a deposition position at which each respective container dispenses material, and further translatable under influence of a biasing mechanism to return to an original position at which each respective container does not dispense material. Referring toFIG.4, the array of containers112may be mounted on a horizontal stage132, which is translatable (under the control of a motor) along two rails134a,134bon a frame136. This allows control over where the material is deposited in one dimension and can facilitate, for example, optimal spreading of material on a deposition surface. This horizontal stage132also gives the system the ability to remove the containers112from the deposition area. This facilitates maintenance tasks, cleaning containers, replacing containers, or other tasks. It also gives the system the ability to remove the containers from the working area to avoid contamination. Thus, a system to deposit material from many containers (e.g., syringes) in rapid succession by orienting the openings of the containers toward a single point of deposition and rapidly moving the containers towards that point before deposition has been described. In some embodiments, close packing of the containers in a cone or other shape with their deposition ends pointing towards the common (single) point of deposition minimizes the footprint of the system and minimizes time between deposition from each container. The containers are arranged so as to each move in the vertical direction (or, more generally, along a linear axis) on two sliders which prevents axial rotation of the containers. In further embodiments of the invention, a system to move many containers of material for deposition along a single axis to control the point of deposition is provided. The present invention affords the ability to use containers of various sizes by using appropriately sized holders which can be removed and replaced and leaving some container slots empty, as necessary. A limit switch and slot cut into part of the rotating arm enables the arm to accurately return to its home position. Now turning to further examples of systems for material deposition, a system that deposits material from a container and seals the container after deposition as part of a material printing application is described. Referring toFIGS.5-9, a system10and method for sealing a syringe (or other container) containing material for deposition, e.g., in a 2D or 3D printing application are illustrated. A rod18is inserted inside the syringe26. A flexible cap24is attached to one end of the rod. This cap creates a seal with the material exit30. When the rod18is forced in the direction of the exit30, an airtight seal is formed, and no material can leak out of the exit. A guide22can be attached to the rod18, ensuring that the rod18is properly aligned with the exit30. A gasket/O-ring16is attached to the other end of the rod18. The gasket/O-ring16is mounted inside a cylindrical tube36, forming a piston. The piston is actuated using pressurized gas. Vacuum can be used to aid operation of the piston. Gas enters via a connection14mounted in the syringe cap. The gas enters a channel32under the piston, forcing it away from the exit30, and opening the exit. Grooves20in the syringe cap allow gas to enter the body of the syringe34where the material is held. The pressurized gas in the body of the syringe forces material through the exit30. A relief hole12allows air to exit and enter freely according to the position of the piston. A vacuum can also be applied sequentially after the pressurized gas via the same port. The vacuum aids the spring28in returning the piston and sealing the exit30. The vacuum can also be used to perform de-gassing on the material in the syringe. When material is not being deposited, spring28forces the piston down, creating an airtight seal at the exit30. This seal is maintained even if the syringe is disconnected from the gas/vacuum line. This allows removal of the syringe from this system without material leaking from the exit. By controlling the strength and timing of the application of pressurized gas and vacuum, as well as the inner diameter of the needle38, the deposition of material can be controlled. Still a further example of a system for material deposition, in particular a system that seals a container holding material for deposition as part of a 3D printing application, is discussed with reference toFIGS.10-20. In this example, a system40includes a syringe barrel adapter46fitted onto a syringe48containing the material to be deposited. A one-way air valve52is mounted inside the adapter46. A gas hose42is attached to the end of the adapter46via a threaded connector44and is connected to a tank of pressurized air or other gas. This pressurized gas is used to force the material out of the tip of the syringe48when desired. For the gas to flow into the syringe and pressurize it, the one-way valve52must be opened. This is accomplished by a small bar50which is part of the threaded connector44. As the connector44is screwed onto the barrel adapter46, the bar50presses on the one-way valve52forcing it open. The gas flows through the one-way valve52into the syringe48but is prevented from flowing back into the hose. Periodically it may be necessary to remove the syringe from the system in which it is mounted and disconnect it from the pressurized gas hose. This is accomplished by simply unscrewing the hose42from the syringe barrel adapter46. As the bar50is removed from pressing on the one-way valve52, the valve closes. The syringe48remains sealed, avoiding leaking and contamination of the material inside the syringe. In another embodiment of the invention, the syringe is sealed with a flexible rubber seal instead of a one-way valve. The seal56is mounted inside the barrel adapter46which is inserted inside the syringe48. A thin slit55in the top of the seal56can be opened to allow gas to pass through. The gas hose (not shown in these views) is connected to the barrel adapter46via a threaded connector44. Mounted inside the threaded connector44is a cylinder53with a conical hole54. When the hose is connected to the barrel adapter46and syringe48, the conical hole54in the cylinder53presses on the edges of the top of the rubber seal56, deforming the top of the seal and forcing it open (seeFIGS.15A(closed) and15B (open)). The top of the seal56has protruding sections57only on two sides. This ensures that when the face of the conical hole54meets the top of the seal56, they will only coincide in line with the slit55at the top of the seal56. This force along the length of the seal56will cause it to open. The threaded connection44is then screwed onto the barrel adapter46. When the seal56is open, gas can flow through and be used to force material out of the tip of the syringe48. When the hose is disconnected and the cylinder53with the conical hole54is removed, the rubber seal56returns to its undeformed shape and seals automatically. In a further embodiment of the invention (seeFIGS.16-18) a spring58forces a metal ball60against an aperture68sealing the syringe48. The aperture68is sealed by a flexible rubber gasket62. The spring58rests inside a tube64which is mounted in the barrel adapter46. The tube64is narrow enough to prevent buckling, and horizontal motion of the ball60as the spring58is compressed. The tube64is also wide enough to ensure the passage of gas when the valve is open. This valve is connected to the gas hose by a threaded connector44. Inside this connector44is mounted a metal sleeve66with a pin67suspended inside. The sleeve66has spaces for gas to pass from the hose to the valve/syringe, and the pin67is centered in line with the ball60. When the hose is pressed onto the syringe the pin67presses on the ball60compressing the spring (seeFIG.18). This opens the valve allowing gas to flow through. In another embodiment of the invention (seeFIG.19-20) the one-way valve is replaced with a flexible rubber disc70attached to a spring58. The spring58forces the disc70against a hole in a tube72mounted inside the barrel adapter46. The disc70is mounted on the end of a rod74which rests inside the spring58, preventing the spring from buckling and the disc from deflecting away from the hole. Like the ball valve, there is a sleeve76with a pin77mounted inside a threaded connection44which is attached to the end of the gas hose. When the hose is connected the pin77presses down on the disc70(seeFIG.20), opening the seal, and allowing gas to pass into the syringe. Thus, a sealing system for a container of a materials deposition system used in a 3D printing process allows a seal to close automatically when the container is disconnected from a gas hose or vacuum. In one embodiment, a one-way valve is inserted within a syringe barrel adapter that attaches to the syringe, the syringe serving as the materials container. In another embodiment, the one-way valve is replaced with a rubber seal that remains closed unless forced open by pressure from a conical hole inside a cylindrical part. A further embodiment replaces the one-way valve with a metal ball on a spring, which presses against an aperture sealing the syringe until forced open by the action of connecting the syringe to a gas hose. Another embodiment operates in a similar way, replacing the ball with a rubber seal. In each embodiment, the materials container is sealed off from the environment preventing contamination of a material in the container from the outside. The invention allows for simple replacement of the container because the container itself is sealed. The connection to the air hose or vacuum does not have to be overly tight and can therefore be detached easily. Collectively, embodiments of the invention include: Embodiment 1 A system, having a plurality of containers configured in an array to dispense material, in which the containers each have a material dispensing end, and the containers are organized within the system so that each dispensing end of each container is oriented towards a common, single deposition point. A piston is mounted on an arm, and the arm is rotatable to align the piston with mounts of each of the containers. The mounts of the containers are each translatable under actuation by the piston to a deposition position, at which the containers dispense material, and are further translatable under the influence of a biasing mechanism to return to an original position at which the containers do not dispense material. The array of containers is mounted on a stage translatable along an axis. Embodiment 2 A system as in embodiment 1, wherein the plurality of containers are arranged in a cone shape, with their material dispensing ends each oriented towards the common, single deposition point. Embodiment 3 A system as in any of the foregoing embodiments, wherein the mounts of the containers are translatable under actuation by the piston along respective pairs of sliders. Embodiment 4 A system as in any of the foregoing embodiments, wherein the containers are syringes. Embodiment 5 A system as in any of the foregoing embodiments, wherein the syringes are arranged in a cone shape, with their material dispensing ends each oriented towards the common, single deposition point. Embodiment 6 A system as in any of the foregoing embodiments, wherein the mounts of the syringes are translatable under actuation by the piston along respective pairs of sliders. Embodiment 7 A system as in any of the foregoing embodiments, wherein the arm has a slot therein and the system further includes a limit switch, the slot in the arm located such that when the piston is in a home position, the slot passes through the limit switch. Embodiment 8 A system as in any of the foregoing embodiments, wherein each of the containers is received in a respective one of a plurality of holders, the holders being sized to accommodate containers of different sizes. Embodiment 9 A method, in which material from a plurality of containers of a system is deposited towards a common, single deposition point. Each container is a member of an array and has a material dispensing end and the plurality of containers is organized within the system so that each dispensing end of each container is oriented towards the common, single deposition point. The depositing from each respective container of the plurality of containers includes: rotating a piston so as to be aligned with a mount of the respective container, actuating the piston against the mount of the respective container so as to translate the respective container to a deposition position, dispensing the material from the respective container using a pressurized gas, and translating the respective container to an original position by a biasing mechanism. Embodiment 10 A system as in embodiment 9, wherein the array of containers is mounted on a stage translatable along an axis and the method of deposition includes translating the stage to move the containers towards the deposition point before material deposition commences. Embodiment 11 A system as in either of embodiments 9 or 10, wherein actuating the piston against the mount of the respective container so as to translate the respective container to a deposition position includes translating the respective container along a pair of sliders to the deposition position. Embodiment 12 A system for sealing a syringe or other container containing material for deposition includes a rod inside the syringe; a flexible cap attached to a first end of the rod, the flexible cap creating a seal with a material exit of the syringe when the rod is displaced within the syringe along an axis thereof towards the material exit; a guide positioned within the syringe and configured so as to ensure that the rod is aligned with the material exit; and a syringe cap including a gasket attached to a second end of the rod opposite the flexible cap, the gasket being mounted inside a cylindrical tube within the syringe cap forming a piston actuatable using pressurized gas introducible into the syringe via a connection mounted in the syringe cap and directable via a channel under the piston to force the piston away from the material exit, thereby to open the material exit. The syringe cap includes grooves configured to allow gas to enter a body of the syringe and force material therein contained through the material exit. Embodiment 13 A system as in embodiment 12, wherein the syringe further includes a relief hole to allow air to exit and enter freely according to a position of the piston. Embodiment 14 A system as in embodiment 12 or 13, wherein the syringe further includes a spring to bias the piston such that the rod and flexible cap seal the material exit in the absence of a pressurized gas introduced via the connection mounted in the syringe cap. Embodiment 15 A system for sealing a syringe or other container containing material for deposition includes a container and adapter. The adapter is configured to fit over a first end of the container. A second end of the container is adapted as a material exit of the container. The adapter is fitted with a seal configured to close automatically when the adapter is disconnected from a gas supply. Embodiment 16 A system as in embodiment 15, wherein the seal includes a one-way valve. Embodiment 17 A system as in embodiment 15 or 16, wherein the seal includes a rubber seal mounted inside the adapter and is adapted to remain closed unless forced open by a portion of the adapter impinging on the seal. Embodiment 18 A system as in any of embodiments 15-17, wherein the adapter is configured with a cylinder having a conical hole adapted to impinge upon a pair of edges of the seal, thereby forcing open a slit in a top of the seal. Embodiment 19 A system as in embodiment 15, wherein the seal includes a metal ball on a spring, the spring biasing the ball against an aperture unless forced open by a pressurized gas from the gas supply. Embodiment 20 A system as in embodiment 15, wherein the seal consists of a rubber seal. Embodiment 21 A system as in embodiment 15, wherein the seal is a one-way air valve fitted in the adapter and the adapter is threaded to receive an air hose and includes a bar positioned to press upon the one-way air valve, forcing it open when a pressurized gas is introduced into the adapter via the air hose. Embodiment 22 A system as in embodiment 21, wherein the bar includes holes to allow air to pass therethrough. Embodiment 23 A system as in embodiment 15, wherein the seal is a flexible rubber valve mounted inside the adapter and has a thin slit in its top. An interior space of the adapter is configured to impinge upon the top of the seal, forcing the slit to open in the presence of a pressurized gas from a tube connected to the adapter. Embodiment 24 A system as in embodiment 15, wherein the seal is a flexible rubber valve and the adaptor is configured to receive an air hose. Embodiment 25 A system as in embodiment 15, wherein the seal is a metal ball on a spring. In the absence of a gas from the gas supply, the spring biases the ball against a rubber gasket sealing a hole within the adapter. The adapter includes a pin arranged to displace the ball and gasket from the hole in the presence of the gas from the gas supply. Embodiment 26 A system as in embodiment 15, wherein the seal is a rubber disc. In an absence of a gas from a gas supply, the disc is biased against an aperture in the adapter by a spring. The adapter includes a pin arranged to displace the disc from the aperture in the presence of the gas from the gas supply. Embodiment 27 A system including a plurality of containers for dispensing one or more materials. The containers each have a respective material dispensing end and a respective dispensing mechanism, and are arranged with one another about a common point of deposition with their respective material dispensing ends oriented towards the common point of deposition. Each of the containers is included within a respective mount and is translatable between an original position at which a respective container does not dispense material and a deposition position at which the respective container dispenses material when actuated by its respective dispensing mechanism. Embodiment 28 The system as in embodiment 27, wherein each of the plurality of containers is mounted on a common stage translatable along an axis. Embodiment 29 The system as in either of embodiments 27 or 28, wherein the plurality of containers are arranged in a cone shape, with their material dispensing ends each oriented towards the common point of deposition. Embodiment 30 The system as in any of embodiments 27-29, wherein the containers are syringes. | 24,405 |
11858212 | DETAILED DESCRIPTION The present disclosure is directed to a novel additive manufacturing (i.e., 3D printing) method and apparatus. In accordance with one exemplary feature, a method and apparatus consistent with the present disclosure provides the ability to build a layer-by-layer deposited structure without requiring a platform or a support medium chamber. In accordance with another exemplary feature a method and apparatus consistent with the present disclosure may be used to control the printing (deposition) direction in 3D directions like the 6-axis printing or 7-axis printing or higher degrees of 3D printing without the need for a mold (either temporary scaffold of support material or a durable mold tool). In accordance with another exemplary feature, a method and apparatus consistent with the present disclosure maybe used to increase the stacking-direction strength compared to traditional AM processes. All current AM processes are layer-by-layer deposition despite the use of powder, liquid, ink, melted materials, etc. The layer-by-layer addition process introduces defects, e.g., voids, residual stress, etc. These types of defects are likely to appear in all current AM processes despite that the deposition direction is x, y, or z. In accordance with another exemplary feature, a method and apparatus consistent with the present disclosure may be used to print various materials such as continuous fiber reinforced composites, discontinuous fiber reinforced composites, as well as materials without fiber reinforcement. In contrast, the current AM processes (like the FDM) have the disadvantage of only being able to print short discontinuous fiber reinforced composites or/and materials without fiber reinforcement due to the manufacturing issues as previously mentioned. A Novel Free-Form Curved-Structure (FFCS) Printing Head FIG.2is an illustration of an exemplary embodiment of the 3D printing head: a free-form curved-structure (FFCS) printing head. It is for illustration and explanatory purposes only but is not intended for limitation. The elements numbered in theFIG.2are: Element1: printing head. Element1-1: mechanism to receive and process the incoming feedstocks including, but not limited to, polymer filament, fiber tow, micro-particles, nanoparticles, ink, or any combination thereof. Element2: filament output port; which is part of the printing head1. A printing head1can have one or more than one of filament output ports. Element3: localized field emitter; which is part of the printing head1. A printing head1can have one or more than one of localize field emitters. Element4: localized pressing unit; which is part of the printing head1. A printing head1can have one or more than one of localize pressing units. Element5: localized pressing pad; which is associated with the localized pressing unit4. A localized pressing unit4can have one or more than one of localize pressing pads. Element6: localized pressing surface; which is associated with the localized pressing pad5. A localized pressing pad can have one or more than one of localize pressing surfaces. For example, but not to limit the possible configurations, the pressing pad5can contain different sub areas that can have different shapes and can have channels between the sub areas. The pressing pad5may also contain some moving parts including, but not limited to, ball rollers or cylinder rollers to reduce the friction. Element7: field emitted by the localized field emitter3. Element8: backing article; which is responsive to the field7and can work together with field7to generate field-induced force on the backing article8. At least one backing article can be used to associate with a field7. Element9: new filament, which is extruded from the filament output port2; the new filament9is used to form the latest layer of deposition of the 3D part. Element10: tensioner. Element1: cutter to cut the new filament9. Element12: printing head position control mechanism such as a robot arm to control the position (coordinates & angles) of the printing head1. Element13: existing deposition layer(s) of a 3D part. For example, but not limited to, an existing deposition layer can be established by layer-by-layer deposition of the new filament9layers. Element14: relative position controller to control the relative position of The localized pressing unit4with respect to the printing head1. Element15: assistant rollers of the printing head1. The operational concept of the novel printing head1can be explained with the help of usingFIG.2, whereinFIG.2is for explanation purposes only but does not limit the scope and details of the disclosure. As illustrated inFIG.2, the illustrated exemplary printing head1includes at least one filament output port2, at least one connected localized field emitters3, and at least one connected localized pressing unit4. For the purposes of this application, the term “connected” means these elements are used, moved, and controlled coordinately. The connections between them can be direct attachment or indirectly associated with additional coordinated control mechanisms (such as but not limited to gear box, hydraulic cylinders, belt, actuators, or servos). In addition, the connection relation can be fixed or adjustable. It also has a mechanism1-1to receive and process the incoming feedstocks. Feedstocks suitable for use in the present disclosure include, but are not limited to polymer filaments, fiber tows, micro-particles, nanoparticles, inks, or any combination thereof. In the illustrated exemplary construction, the localized pressing unit4has at least one localized pressing pad5. The localized pressing pad5has at least one localized pressing surface6. A localized pressing surface6is defined as an effective contact surface of a localized pressing pad5with an object that is pressed against the localized pressing pad5. For explanation purpose only, if an object is pressed against a localized pressing pad5that includes four flat sub-pads, there are four localized pressing surfaces. If a cylinder roller is used as the localized pressing pad5to press a relatively flat object, the localized pressing surface6is the small contact area between the cylinder roller and the relatively flat object. Note that for 3D printing practice, the localized pressing surface6is significantly smaller than the part to be printed by the printing head1. Note the smaller the size of the localized pressing surface6, the higher resolution of the printing head1has. By way of example only, and not limitation, the area of a localized pressing surface6may be less than 1/16thof the surface area of the part to be printed. The localized field emitter3can emit at least one fields7approximately normal (i.e., perpendicular) to the localized pressing surface6. The field7emitted by the localized field emitter3induces the localized force to pull one or more than one piece of backing articles8relatively toward the localized pressing surface6. Note that an opposite field can also push the backing articles8relatively away from the localized pressing surface6. Backing articles8suitable for use in the present disclosure include, but are not limited to, small steel balls, a continuous piece or multiple pieces of flexible rubber or polymer articles containing iron particles that are responsive to a magnetic field (a type of field7) emitted by the localized field emitter3and are pulled towards the localized pressing surface6, In the present disclosure, the position and shape of the localized pressing surface6are precisely controlled so as to play the role as a localized shaping tool surface to travel along the precise path that each new filament9is designed to be placed. This is done to precisely control the curvature of the new filament9being pressed under the localized pressing unit4. As the new filament9just extruded from the filament output port2is quite flexible and can be shaped (i.e., unsolidified) (e.g., the FDM filament is melted when just extruded), precisely controlling the shape and position of the localized pressing surface6(or the assembly of multiple coordinated localized pressing surfaces6) can be very effective in precisely controlling the desired surface shape (facing the localized pressing surface6) and the position of the new filament9for fulfilling its role in the 3D printed part. It should be noted that the process-induced residual stress build-up or designed pre-loaded stress requirements may change the filament location and shape when the 3D part printing is completed or is used in the designed service. Accordingly, in a preferred practice, the location and shape design of the new filament placement during the disposition process should compensate such expected changes. Further, in a preferred embodiment, proper numerical simulations (such as finite element analysis) may be used to estimate such changes and factor the predicted changes into the part design. Also, as shown inFIG.2, the field7emitted by the localized field emitter3is remotely interacting with the backing article8. Hence, one can control the field7to adjust the field-induced force on the backing article8thereby effectively controlling the compression force exerted on the localized pressing surface6that is serving as the role of a localized shaping tool surface. This can define the local shape, location, and material compaction of a subject (such as but not limited to the new filament9) being compressed against it. In another exemplary system, one can turn off the field7to disengage the backing article8and the localized pressing surface6. In another embodiment of the present disclosure, one can switch the direction of the field7to repel the backing article8away from the pressing surface6. Examples of fields suitable for use in the present disclosure include, but are not limited to, a magnetic field, an electrostatic field, fluid pressure (such as vacuum pressure if there are appropriate channels to conduct the pressure induced force to the backing article8), or any combination thereof. Note that by using multiple fields one can gain more control capability or transitioning/switching to different applicable fields in the event one field's effectiveness drops during the part printing process. By changing the field strength, one can control the localized material compaction and expansion of any subject inserted between the localized pressing surface6and the backing article8. Localized compaction control can help to control the desired local material properties, reduce the void contents, and also control the residual stresses or even preload the deformation of shape memory materials (such as shape memory polymers or shape memory alloys) while they are placed between the localized pressing surface6and the backing article8. If there are fibers (e.g., carbon fibers) loaded in the new filament9, with appropriate matrix removal mechanism associated with either the new filament9(like resin bleeding channels pre-manufactured in some FRP prepregs) or the localized pressing pad5or additional accessories to work with the printing head1, one can control the field. Thereby controlling the compaction and removing the excessive matrix of the filament9through the matrix removal mechanism. This produces a high fiber volume fraction in the new filament9. Examples of the matrix removal mechanism suitable for use in the present disclosure include, but are not limited to, resin flow channels or resin bleeding fabric connected to a low pressure container to collect the excessive resin matrix squeezed out from the new filament9by the localized pressing pad5. Besides the material compaction control (and also the expansion control of expandable materials) in the normal direction of the localized pressing surface6, it is also possible to control the tension/compression of a new filament9along the filament direction. A tensioner10shown inFIG.2can control the resistance against the new filament9while being pulled from the filament output port2towards the localized pressing surface6. Thus, the tension of the new filament9can also be controlled by the tensioner10while being compressed under the localized pressing surface6. In addition, one can use two or more (i.e., multiple) sets of localized pressing surfaces6and backing articles8as clamps. By relatively moving and controlling the multiple clamps in a coordinated manner one can change the preloaded stress and deform the material layer between the clamps. This opens additional degrees of freedom to engineer the material properties locally. On another note, if the material layer contains at least one shape memory material such as shape memory alloy or shape memory polymer, such a material layer can be programmed locally by this pre-tension or pre-deformation approach during the printing process. By programming the shape memory material, a 4D part can also be printed by the printing head1. The compaction can also help reduce the inter-filament void due to filament-stacking, which is a common defect in traditional FDM process. A cutter11can be equipped to the printer head1to cut the new filament9as necessary. Cutters11suitable for use in the present disclosure include, but are not limited to blades, lasers, or ultrasound cutters. In the illustrated exemplary construction, the printing head1is attached to a printing head position control mechanism12such as a robot arm or a robot; note that the “position” of the printing head1refers to the “location” and “alignment” of the printing head1. For explanation purposes only, in a 3D space, the location of an object can be presented as (x,y,z) coordinates and the alignment can be denoted as the two angles of an arbitrary line of the object against an x,y,z axis coordinate system, e.g., a spherical coordinate system uses two angles to define a vector's alignment (direction). During the layer-by-layer deposition, by adding more of the new filaments9, there will one or more existing deposition layers13as well as an additional new filament9which can be placed on top of the existing deposition layers13. When the printing head1passes by, a new filament9can be extruded out from the filament output port2and be applied atop the existing deposition layer(s)13. The material compaction control and the filament tension control can be applied to compress and bond the new filament9to the existing deposition layer(s)13under desired stresses and desired fiber volume fraction, if applicable. The field7can be used to control the compaction and the tensioner10can be used to apply the tension to the new filament9. Multiple clamps formed by multiple sets of localized pressing surfaces6and backing articles8can also help to control the position, shape, and deformation of the existing deposition layers13while the new filament9is compressed and bonded to the existing layers13by a set of pressing surface6and backing article8. In accordance with another exemplary system, the existing deposition layer(s)13can also be created by other deposition methods or preferred manufacturing methods other than 3D printing as an insert to be incorporated as a part of the 3D printed part. This practice allows other materials and functional objects with preferred manufacturing methods (due to cost, quality, functionality, etc.) to also be used in the 3D part printing by the printing head1. A suitable example of such a scenario is the incorporation of functional modules, such as a wireless sensor module or an actuator module, into the 3D part. Many functional modules are typically preferred to be assembled & tested ex vivo to before being incorporated into the 3D printed part. Sometimes, the wireless sensor module can also help the printing process by sensing the parameters during 3D printing process. In many situations, the sensor module can also be used after the printing process during the part's life cycle. Suitable examples of parameters which can be detected by the sensor module include, but are not limited to, stress, strain, electrical properties (like dielectric constant and conductivity), thermal properties (e.g., the use of a tiny hot wire method to measure the thermal conductivity or specific heat), mechanical properties (e.g., roughness and hardness), coordinates (i.e., location) and/or angles (e.g., using GPS, accelerometers, direction sensor, etc.), pressure, temperature, humidity, chemical contents, acoustic characteristics (e.g., sonic index of refraction or reflectivity), density, radiopacity, and sensor identity number (to distinguish it from other sensor modules in the printed part). Suitable examples of parameters or excitation of the actuator modules generated that will affect the function of the 3D printed part include, but are not limited to, stress, force, strain, heat, sound, electrical wave, and magnetic wave. In one exemplary arrangement, it is preferred to control the relative position of a localized pressing unit4with respect to the printing head1. In this arrangement, there is a relative position controller14to control the relative position of the localized pressing unit4with respect to the printing head1. To further enhance the printing resolutions, the localized pressing surface6may have different shapes. In one exemplary system consistent with the present disclosure, the printing head1can replace different shapes of localized pressing surfaces6. In another exemplary system, the localized printing unit4can adjust the shape of the localized printing surface6. For explanation purpose but not for limitation, the localized printing surface can change from a flat surface to a curved surface, such as concave, convex, or saddle surface, to create more details for the printed part. The change can be effected by replacing different printing pads or using actuator-deformed flexible membranes to form the localized printing surface. In accordance with another exemplary arrangement, multiple localized pressing units4can be used in the printing head1. In accordance with another exemplary arrangement, multiple localized pressing pads5can be used in the printing head1. In accordance with another exemplary arrangement, multiple localized pressing pads5can be used in a localized pressing unit4. In accordance with another exemplary arrangement, a localized pressing pad5can have multiple localized pressing surfaces6. In accordance with another exemplary arrangement, a localized pressing pad5can have one or more rotating elements such as cylinder rollers or ball rollers. In accordance with one exemplary system consistent with the present disclosure, the backing article8can be attached to the 3D printed part103and is a part of the 3D printed part103. In another exemplary system consistent with the present disclosure, the backing article8can be a detached from the 3D printed part103. In another exemplary system consistent with the present disclosure the backing article8is pre-manufactured before the printing process. In another exemplary system consistent with the present disclosure, the backing article8is manufactured during the printing process. In another exemplary system consistent with the present disclosure, the backing article8can be included in the new filament9. In another exemplary system consistent with the present disclosure, the backing article8can be included in the existing deposition layer13. In another exemplary system consistent with the present disclosure, the backing article8is not included in the new filament9. In another exemplary system consistent with the present disclosure, the backing article8is not included in the existing deposition layer13. By way of example only, and not limitation, examples of backing articles suitable for use consistent with the present disclosure include, but are not limited to, small pieces of soft rubber pads filled with steel particles to be supplied as pre-manufactured accessories for the printing head. These small rubber pads can be detached from the 3D printed part103and retrieved once the printing process is finished. Such small pieces rubber pads can be re-useable and will not necessarily be a part of the 3D printed part103after the 3D printing process. In one exemplary system consistent with the present disclosure, steel fibers or particles may be filled in a certain type of polymer matrix to or from the new filament9thereby establishing a new filament which has the dual roles of the new filament9and the backing article8while just extruded out from the filament output port2. Later on, a second new filament9can be deposited atop the first filament, and the first filament now has the dual roles of the existing deposition layer13and the backing article8. In this exemplary construction, the backing articles8become a part of the 3D printed part103(if the first filament layer is not removed). In accordance with another exemplary system, the first filament layer containing steel fibers or particles is removed so long as such removal of the polymer matrix can be achieved without damaging the roles other portions of the 3D printed part. For example water soluble polymer can be used as the polymer matrix of the first steel-filled filament and subsequently dissolved with water after the printing process. In accordance with this exemplary system, different type of polymers in other filaments can be used such that these polymers are not washed away by the water. In accordance with another exemplary system, the polymer matrix of the first filament is pH sensitive or can be decomposed after being exposed to a certain environment. Those skilled in the art will be aware of other water soluble tooling materials which can also be used for this purpose. The removal of the first filament can be accomplished during the 3D printing process, after the 3D printing process, or during the service of the 3D printed part, e.g., if the first steel-filled filament was left with the 3D part, one can use its magnetic field responsive attribute to help the 3D printed part103to be adhesive-bonded with other parts either during assembling process or healing the crack of the bond-line (as an induction heating layer). In accordance with another exemplary system consistent with the present disclosure, the magnetic responsive attribute can be used to generate clamping force by applied magnetic field. For example, where the printing head1is used to print a repair on top of damaged 3D printed part103and the damaged part has this magnetic responsive layer (i.e., the backing layer8) in it, then the printing head1can be used to compact and bond new filaments on top of the damaged area to repair the damaged part. In this case, the damaged area may need to be cleaned first before the repair process. In accordance with another exemplary system consistent with the present disclosure, the new filament for the repair process is the same type of filament as the original filament in the part103. In accordance with another exemplary system consistent with the present disclosure, the new filament for the repair process is different types of filament than the original filament in the part103. For example, if the original filament is carbon fiber reinforced epoxy, one can remove the damaged layer and print the same carbon fiber reinforced epoxy for repair. On the other hand, if the damage of the carbon fiber reinforced epoxy layer is minimal such as shallow surface layer crack (such as delamination or splitting) in part03, one can print and press a resin film filament on the damage area and force the repairing resin to flow into and fill the crack for repairing the part103. In accordance with another exemplary system consistent with the present disclosure, the first filament, containing steel fibers or particles, is not left in the 3D printed part. For instance, if the steel fibers or particles somehow interfere with the best optimized function of the 3D printed part. For example, steel will increase the weight of the part and may rust during the service. In addition, stainless steel is expansive and may not fit the cost-effectiveness depending on market analysis. If the backing article8is not included in the new filament9nor the existing deposition layer13, a backing article delivery mechanism can be included in the printing system to place the backing article8near the printing head1and to be captured by the field7. By way of example only, and not limitation, backing article delivery mechanisms suitable for use in the present disclosure include, but are not limited to, an assistant robot or arm thereof to deliver the backing article8near to the printing head1, a launcher to launch the backing article8to the near target area, a sprayer (or blower) to spray (or blow) small backing articles near the target area, or a very strong field7to attract the backing article8from a longer distance, or any combination thereof. For example, one can increase the strength of field7to pick up the backing article8from a nearby tray. Another example is to have an assistant robot (or robot arm) also emit the same field as field7to deliver a backing article8near the printing head1and gradually increase the field strength from printing head1to take away the backing article8. In accordance with another exemplary system consistent with the present disclosure, the process is reversed to allow the printing head1to give the backing article8to the assistant robot (or robot arm). The printing head1can also address the thermal management and solidification controls of the filament and printed materials. Such controls can be achieved by temperature, heat, UV light, ultrasound, and laser. In accordance with one exemplary system consistent with the present disclosure, the printing head1is equipped with at least one cooling component, e.g., a water cooling channel or thermos-electric cooler. In accordance with another exemplary system consistent with the present disclosure, the printing head1may be equipped with at least one energy source for heating. Examples of suitable energy sources include, but are not limited to, an electrical heating element, a UV lamp, an ultrasound source heating, an induction heating element, a microwave heating element, or a laser source. Note that if the new filament9contains electrically conductive materials, the induction heating could be very effective for uniform and fast heating of the new filament9despite the thickness of the new filament9. In accordance with one exemplary system, induction heating is used to heat a thick new filament9wherein the new filament9is electrically conductive. In another exemplary system consistent with the present disclosure, the printing head1has the capability to apply preheating or precooling on the existing deposition layer(s)13to accomplish the best binding results between the new filament9and existing deposition layer(s)13. In another exemplary system consistent with the present disclosure, the capability of preheating or precooling on the existing deposition layer(s)13is used to reduce the process induced residual stress such as thermal stress, stress due to polymer shrinkage, stress due to phase-change induced shrinkage, etc. In one exemplary system consistent with the present disclosure, the backing article8is different than the existing deposition layer13. However, in another exemplary system consistent with the present disclosure, the backing article8can also be the existing deposition layer13. Thus, the field directly induces the force on the existing deposition layer13. For example, the suction of vacuum (pressure field) can be used to pull a solid and non-permeable existing deposition layer13toward the localized pressing surface6and compress and deposit new filament9on the solid and non-permeable existing deposition layer13. Or, if the deposited layer13contains a significant amount of iron content, a magnetic field can be directly applied to achieve the same results. A weak field-induced force may not be able to provide optimal material compaction control and clamping force. Thus, the field-induced force needs to be strong enough to create significant material compaction control and clamping force to achieve the essential capabilities of this disclosure as described hereinabove. In one exemplary system consistent with the present disclosure, the field emitted by the localized field emitter3is penetrating through a localized pressing surface6. In another exemplary system consistent with the present disclosure, the field7emitted by the localized field emitter3is not penetrating through the localized pressing surface6. In another exemplary system consistent with the present disclosure, the field7emitted by the localized field emitter3is applied in the surrounding area and not penetrating through the localized pressing surface6. In the event the existing deposition layers13is permeable (to a fluid such as air), the field7, the (vacuum) pressure field and the backing article8can be made of a non-porous membrane material. However, it is envisioned that magnetic field and iron containing backing article may be more effective than the pressure field based approach. A combination of using the pressure field together with the magnetic field may be desirable to create a more capable control on the backing article8. It may be desirable to 3D print hollow objects. In accordance with one exemplary system consistent with the present disclosure, the backing article8can be enclosed in a cavity between a new filament9and existing deposition layers13. This would create an open hollow gap between the printed deposition of the new filament9and the existing deposition layer13thereby enabling a 3D-printing hollow envelope/cavity. The backing article(s)8enclosed in the cavity can be left inside the 3D printed object or be removed after the part being printed. For example, if one uses small stainless steel balls as the backing articles8, and use the backing articles to print a hollow 3D part, one can retrieve the balls through a small opening through the hollow 3D printed part. The localized pressing pad5and the localized pressing units4can also incorporate many additional features. The localized pressing pad5can have a porous character or several vacuum channels to help to draw vacuum or remove excessive resin matrix or air (or volatile gases). The localized pressing unit4can also have sensors to detect physical or chemical properties of the new filament9and the existing deposition layer(s)13and the bonding interface between them. Properties suitable for use in the present disclosure includes, but are not limited to, material hardness, void, temperature, degree of cure of the polymer matrix, thickness, fiber volume fraction, modulus, and rheological behaviors. Sensors suitable for use in the present disclosure include, but are not limited to, ultrasound sensor, acoustic emission sensor, thermocouple, dielectric sensor, material hardness sensor, and a small microscope lens/camera. The printing head1can also incorporate sensors. For example, the printing head1can incorporate a thermography camera for monitoring the temperature close to the printing area and assisting the heating and cooling management (including pre-heating and pre-cooling). The printing head1can also incorporate a sensor capable of determining its position in the space in which it is printing the part. For example, a vision sensor can allow the printing head1detect its relative position to avoid hitting (or interfering with) the surroundings inside a confined working space where it is assigned to print the new 3D printed part. One of the key features of the present disclosure is there is no need for a platform or support medium chamber. This is significant because it allows for the capability of printing 3D parts onsite rather than first printing the 3D part offsite and subsequently shipping the part to the site. Accordingly, the onsite 3D printing capability of the present disclosure will be very helpful for such practical scenarios. In addition, if the 3D printed part needs to be modified according to the conditions of the site, the onsite printing capability can achieve so easily. In accordance with one exemplary system consistent with the present disclosure, the printing head1adds the mechanisms to interact with a 3D printed part103through one or more functional modules embedded or deposited into the part, e.g., the addition of a sensor or/and actuator module or small particle or fiber capable of responding to a signal or field emitted by the printing head1. The particles or fibers may be placed in any pattern that is amenable to rapid identification, such as a bar code, QR code, linear code, etc. One example is to obtain the temperature inside the part (as opposed to the surface temperature) measured by the module during the printing process. Another example is to utilize an identification reading mechanism to retrieve the identification numbers of some modules, the modules being placed at strategic locations and designed to assist in locating key locations of the part during the 3D printing process and/or later-on assembly and/or secondly-processing (like cutting, trimming, etc.). Any other parameters collected from the module can be used for assisting the manufacturing process and can be registered under the unique module identification number. If each 3D printed part103has the modules with unique module identification numbers, one can record the complete manufacturing history of the 3D printing part103and use the data as a reference for quality control, service, and repair. In another exemplary system consistent with the present disclosure, the aforesaid mechanism (for the printing head1to interact with the 3D printed part103through one or more functional modules) can be used as security protection. First, without getting these modules for matching the printing files, others will not be able to successfully print the 3D part (even if they have the printing file) without first getting the authentic modules from the 3D part design IP owner if the interaction mechanisms between the printing head1and the 3D printed part103is a necessary steps during the 3D printing and later assembly, service, or repair. Second, if a hacker maliciously changes the design file of the 3D printing, the chances of matching all key modules and the history of recorded associated with the module identification numbers within desired manufacturing tolerance is still very low and, in any event, can be readily detected by the manufacturing system. For example, if a hacker altered the printing head1moving path so that the filament deposition path is altered so it is moving from module A to module C instead of an originally designed path of moving from module A to module B, then the temperature history registered by modules A, B, C under hacker-altered printing path will be obviously different from the temperature history registered by modules A, B, C under original design with significantly different heating sequence/timing. If one also include more physical parameters in the history such as dielectric properties, ultrasound responses, etc., it will be even easier to detect if the path is being maliciously altered. If one deploys ten (10) such functional modules, it will be extremely difficult to maliciously alter the printing path and still see these faulty parts being printed without being discovered by the system. For example, if a carbon fiber composite part is printed, its original ply sequence (i.e., fiber direction of each ply) is generally carefully designed to achieve certain criteria in elastic responses (vibration, fatigue, ply-associated failure modes, etc.) with respect to certain loading environment. Additionally, for example, if a hacker altered the inner layers' fiber directions and kept visible surface layers' fiber directions unaltered (for a typical composite of 3 mm thick airplane skin which about 30 layers or more fiber layers) it will be extremely difficult to detect by any test without fracturing and testing the part sections by sections. This, more than likely, would be more expansive and time consuming than building a new part. The security enabled by this embodiment of the present disclosure would be very helpful in stopping a hacker's malicious attacks in altering the printing file and printing without authorization. An exemplary embodiment of a method of verifying the intellectual property compliance in a 3D printed workpiece comprises printing an ID module in the workpiece during the printing of the workpiece using a 3D printer. The ID module is then read to obtain an ID code, which is transmitted to an authentication server. An authentication signal is then received from the authentication server indicating positive or negative authentication. Depending on when the ID module is read the method can be used for various types of intellectual property verification. For example, the ID module may be read during the printing process as a means of ensuring that the design for the workpiece is not a pirated copy. Once the ID module has been printed, it is read, and the ID code is verified with the authentication server to ensure that the design file is used by an authorized user. If the authorization signal is positive, printing can continue. If it is negative (meaning that the design file was pirated), printing halts. Additional responses to a negative authorization signal may be used, such as overwriting the pirated design file to destroy it, sending a piracy notice to a third party, causing the printing head to destroy the portions of the workpiece that have already been printed, or overwriting the firmware of the 3D printer. A positive authentication signal can trigger additional actions. For example, the licensee associated with the ID code can be identified, and a royalty charge can be accrued to the licensee's account for printing the workpiece. As another example, a record could be made of an authorized workpiece that can be consulted by parties in the chain of custody of the workpiece (e.g., buyers who wish to authenticate the goods). The method can also be used to conduct automated quality control (QC), to check for unexplained design deviations in the workpiece. In such methods, the structure and dimensions of the workpiece can be checked by determining the locations of one or more modules and reporting the locations to a QC server, which ensures that the workpiece has been correctly manufactured. For example, in some embodiments of the method the first ID module is printed at a first location in the workpiece, and a second ID module is printed at a second location in the workpiece. The locations of the first and second ID modules are then detected by the printer or another local device, and the locations are transmitted to the QC server. The QC server then compares the locations of the first and second modules in the workpiece to their intended locations in the design of the workpiece, and sends a QC confirmation signal. This approach can be used to account for defects in the workpiece arising from multiple causes, such as defects in the printer hardware, defects in the printer software, bad copies of the design file, and even malicious tampering with the printer software or the design file. Generally some deviation will be acceptable, within certain tolerance ranges. In some embodiments of the method the QC confirmation signal communicates whether the relative locations of the first and second ID modules are within a tolerance range of the design specification for the relative locations of the first and second ID modules. The method can also be used by a party that who acquires the workpiece in the flow of commerce to verify that the workpiece is not an unauthorized imitation (“counterfeit”). In such versions of the method the ID module is read by the party that acquires the workpiece, and the ID code is sent to an authentication server. The authentication server checks the ID code for indications of counterfeiting. Such indications could include that the ID code has already been reported for a different workpiece, lack of any record that the ID code was ever used for an ID module in a licensed workpiece, and a record of the ID code being associated with a counterfeit workpiece. If one or more indications of counterfeiting are found, a counterfeiting signal may be sent back to the acquiring party. In any embodiment of the method involving communications between the printer and a remove server (e.g., the authentication server and the QC server), security measures can be put in place to authenticate the sender and/or receiver or to encrypt the communications. For example, either or both parties can send a secure certificate that authenticates the identity of the sender. Furthermore, any signal may be encrypted using a private key of the sender, and wherein the signal can be decrypted using a public key of the sender. In a specific embodiment consistent with the present disclosure, for adding more relative motion control of the printing head1on the 3D printed part, one or more assistant roller(s)15may be added onto the printing head1. In one exemplary system, the assistant rollers15are connected to the printing head1. In another exemplary system, the assistant rollers15are connected to localized pressing unit4, if appropriate. The assistant roller(s)15can be moved to push against the 3D printed part103on the existing deposition layer13or/and on the new filament9to assist in reducing and controlling the pressure on the localized pressing surface6. Another major use of the assistant rollers15is to control the precise thickness of the new filament9, by controlling the precise gap (i.e., distance) between the localized pressing surface6and the existing deposition layer13. When necessary, the assistant rollers15can also assist in lifting the localized pressing pad5away from the surface of the 3D printed part103. In one embodiment of the present disclosure, at least one assistant roller(s)5is driven by one or more than one motors. Thus, the assistant rollers15can control the additional push or drag force to the print head1moving on the surface of the 3D printed part. Such push or drag control by the assistant rollers15can also assist the tensioner10and printing head position control mechanism12to control the tension applied to the new filament9. The assistant rollers5are preferred to be motorized. The printing head1can handle one single new filament9or more than one new filament9. The printing head1can have a single new filament output port2or more than one filament output port2. It can use one type of new filament9or more than one type of filament9. A Novel Printing Method and System Enabled by the Printing Head The printing head1takes a different 3D method in comparison to traditional 3D printing methods and allows for the direct printing of filaments (in general) into a 3D part without relying on a platform or a support medium chamber (which is required in other additive manufacturing methods). In one exemplary practice consistent with the present disclosure, a novel free-form curved-structure (FFCS) printing method is described herein below.FIG.3AandFIG.3B) are used for explanation purposes only and in no way are intended to limit the present invention. FIGS.3A and3Billustrate how to use the printing head to print a curved-shaped part. Element1: printing head1; inFIGS.3A and3B, it is also assumed with all its functions described previously disclosure. Element8: backing article, which is responsive to the field7and can work together with field7to generate field-induced force on the backing article. Element12: printing head position control mechanism such as a robot arm to control the position (coordinates & angles) of the printing head1. Element101: anchor units, which are used to secure the 3D printed part103being printed during the 3D printing process. Element101-1: anchor position control mechanism to control the position of the anchor unit101. It can be a robot arm, a truss secured to ground or the surrounding environment, etc. Element101-2: coupling pad to help the anchor unit to hold the printed part. It can be used to provide effective clamping force to clamp the 3D part103between the anchor unit101and itself. Element103: 3D printed part; it can be a portion of the part under printing when is still during the 3D printing process. Element105: the moving direction of the printing head1. Element107: controller for controlling the printing head1and the printing head position control mechanism12. To print a 3D part103, one or more printing heads1first supply a section of new filament9with one end that is secured by the anchor unit101as shown inFIG.3A. The anchor unit101has the anchor position control mechanism101-1to precisely control its position. A coupling pad101-2can be used to help the anchor unit101to effectively clamp the solidified new filament9. The print head1is works by emitting the field7from a localized field emitter3to control at least one backing articles8to working with at least one localized pressing unit4to control the position (i.e., coordinates and angles) and compaction of the new filament9and shape it and solidify it as the features described hereinabove so that the new filament9once leaving the printing head1is solidified with desired shape and compaction. Note one can also control the tension of the new filament9as described hereinabove. By moving the printing head1and spinning out and solidifying more new filament9gradually along the designed path in 3D space under the shape and compaction control by the localized pressing unit4and field emitter3of the printing head1, one can produce more layers of deposition of the 3D part103. By repeating the procedure with a gradually evolved printing path to deposit more new filaments9, one can grow the 3D printed part103and deposit more new filaments9to the top of the existing deposition layers13as shown inFIG.3B. Multiple sets of anchor units101can be used to better support the 3D printed part103when appropriate as shown inFIG.3B. When the 3D printed part103's size becomes too large for a single anchor unit101to hold, multiple sets of anchoring systems are very helpful and cost-effective compared with a single set of strong and expansive anchoring system. In accordance with one exemplary practice, the anchor unit101can use a localized field (such as a magnetic field) to attract the coupling pad101-2, to thus provide strong clamping capability. In accordance with another exemplary practice, the anchor unit101can move its anchoring position at the 3D printing part103by releasing (or reducing) the clamping force in order to move the anchor unit101to a different relative position of the 3D printed part103and resume its strong clamping force to secure the 3D printed part103. In accordance with another exemplary practice, a printing head1can also be used as the anchor system to secure the 3D printed part101. By appropriately controlling the printing head1to move along each designed new filament9placement path and compress the existing deposition layers13against the extruded new filament9as described, along with the support from the anchor units101, a 3D part103can be printed without using any mold or support medium chamber. In accordance with one exemplary practice, the 3D printing system has one printing head1. In accordance with another exemplary practice, multiple printing heads1can work together for the 3D printing. For example, one can have x number of printing heads1to be controlled by x number of robot arms (x can be 1, 2, 3 . . . etc.) to work together under the commands of a controller107or the coordinated commends of multiple controllers107. Each printing head1can play the role for depositing new filaments9, serving as an anchor unit101, interacting with the embedded functional modules (such as a wireless sensor module or an actuator module), sensing the manufacturing parameters of the 3D printed part, sensing the surrounding environment (such as through aforementioned vision sensor and thermography camera), sending information to the controller107, or any combination thereof. In accordance with another exemplary practice, the controller107can analyze the design of the part to be printed and generate optimized commends to operate either single printing head1or multiple printing heads1for printing the 3D part. If the backing article8is not included in the new filament9nor the existing deposition layer13, a backing article delivery mechanism, which helps to place the backing article8near the printing head1can be included in the printing assembly to let the backing article8be captured by the field7, Suitable examples of backing article delivery mechanisms include, but are not limited to, assistant robot, e.g., drone, (or robot arm) to deliver the backing article8near to the printing head1, a launcher to launch the backing article8to the near target area, a sprayer (or blower) to spray (or blow) small backing articles near the target area, a very strong field7to attract the backing article8from longer distance, and any combination of the aforementioned approaches. In one exemplary practice, the anchor unit101can use a localized field (such as a magnetic field) to attract the coupling pad101-2, wherein the coupling pad01-2can be delivered by as method same as the backing article delivery mechanism. In some situations, some materials could be heavy and soft thus the solidified filament and layers couldn't support themselves when the thickness of the part is thin and at least one of the other dimensions (i.e., length and width) are long. In other words, it is sometimes possible that a certain portion of the 3D printed part103could be saggy and not stiff enough to hold its relative position. This can be mitigated by using more anchor units101to reduce the span between two anchored locations. If design modification is allowed, it will be better to print in a way that the stiffness of printed portion (typically increasing the thickness will make the portion stiffer) grows strong enough before moving to increase the length and width. On the other hand, one important feature of the printing head1is that it already has an implied solution for handling this concern. As previously mentioned, the printing head1can use an identification reading mechanism to retrieve the identification numbers of some modules which are placed at strategic locations and designed to help to locate important locations of the part during the 3D printing process (or/and later-on assembly or/and secondly-processing, e.g. cutting, trimming, etc.). Since one can relate the modules identification numbers with the corresponding correct positions in the part design file, one can still print new filament9on top of the saggy existing deposition layer13by following the designed path near the modules and use the backing article8to return the saggy existing deposition layers13back to the correct position to be bonded with the new filament9. In accordance with one exemplary practice, results can be further enhanced by adding multiple printing heads1or multiple movable anchor units101to perform the local stretch and position control of the material of the saggy (or soft) 3D part103near the designed place of the new filament9to be deposited on. The purpose is to form a piecewise precisely positioned and well expanded plane from the saggy 3D part for the printing head1to work on. Each printing head1can also be equipped with multiple localized pressing units4that can move relatively. The multiple localized pressing units4can also provide similar contribution as using multiple printing heads1or multiple movable anchor units101. In addition, the motorized assistant rollers15can also help to precisely move a saggy part under the localized pressing unit4. As such, the printing head1method can enable the printing of a 3D part made in any portion of soft materials in the absence of the any mold nor support medium chamber. In accordance with another exemplary practice, a controller107is used to process the designed 3D printing procedure of the part103and control the printing head position control mechanism12and the printing head1(which includes the filament output port2, the field emitter5, and the localized pressing unit4) to successfully print the 3D part103. In one exemplary practice, the controller107is used to control at least one set of anchor units101and anchor position control mechanisms101-1. In another exemplary practice, the controller107analyzes the data sensed by the printing head1and compares the data with the original design for necessary adjustment in its next step control commands. By way of example only, the data sensed by the printing head1may include the identification numbers of at least one functional module embedded in the 3D printed part103. In accordance with another exemplary practice, the controller107records the data sensed by the printing head1into the processing history data of the 3D printed part103. In accordance with another exemplary practice, the processing history data of the 3D printed part103includes the parameters corresponding to at least one functional module. In addition to printing new 3D parts, this method is also applicable for repairing damaged parts, given the backing articles8or equivalent (that can create the effective field-induced force to compress and bond the new filament9to the damage part) is presented at the damaged area of the part. For example, if the backing article8is included in the existing deposition layer13of the damaged part, one can use the printing head1to print new filaments9on the damaged part to repair or retrofit the damaged part; wherein the backing article8and the printing head1work together to compress and bond the new filament9to the damaged part on the damaged area. Note that prior cleaning and surface treatment (such as surface sanding or debris removal) may be needed before the 3D printing-repair. On the other hand, if the backing article8is not included in the existing deposition layer13of the damaged part, in order to achieve the same effect of compression and bonding as aforementioned, one can supply at least one backing articles8with the damaged part to work together with the printing head1to print new filaments9on the damaged part to repair or retrofit the damaged part. In accordance with one exemplary practice, this method can be used for manufacturing new parts. In another exemplary practice, this method can be used to repair damaged parts. Of course, variations and modifications of the foregoing are within the scope of the present disclosure. The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. Preferred embodiments of this invention are described herein, including the best mode known to the inventor for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expect skilled artisans to employ such variations as appropriate, and the inventor intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. | 57,014 |
11858213 | DETAILED DESCRIPTION The following detailed description of various embodiments herein makes reference to the accompanying drawings, which show various embodiments by way of illustration. While these various embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments may be realized and that changes may be made without departing from the scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected, or the like may include permanent, removable, temporary, partial, full or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. It should also be understood that unless specifically stated otherwise, references to “a,” “an” or “the” may include one or more than one and that reference to an item in the singular may also include the item in the plural. Further, all ranges may include upper and lower values and all ranges and ratio limits disclosed herein may be combined. As will be described more fully below with reference to the drawings, a vibration-assisted SL system or apparatus and process is disclosed, in accordance with various embodiments. By way of one non-limiting embodiment, the system comprises a top-down mask-image-projection based stereolithography (MIP-SL) system. In contrast with more traditional top-down SL systems or processes, in which a resin surface is constrained by a fixed transparent glass, the vibration-assisted SL system includes a coated transparent glass mounted on two aluminum bars that are configured to vibrate in response to a vibratory source. In one non-limiting embodiment, for example, the vibratory source may comprise a membrane in the paper cone of an audio speaker, such as, for example, an MB42X audio speaker, sold under the brand name Micca®. Instead of using a direct-pull method to separate the build surface from the constrained surface (i.e., the transparent glass) following exposure to an irradiating light source and curing of a layer of resin, the vibration-assisted SL process facilitates vibration of the transparent glass to break a vacuum or other adhesive environment existing between the build surface and the transparent glass, thereby facilitating separation of the transparent glass from the build surface. For clarity, the term build surface used in this disclosure generally refers to the uppermost or the lowermost surface of the build part following curing of a layer. However, where distinction is helpful, the build surface of the build part prior to having a layer of resin cured thereon may be referred to as a pre-cure build surface, while the build surface following curing of a layer of resin upon the pre-cure build surface may be referred to as a post-cure build surface. Referring now toFIG.1A, together with the insets illustrated atFIGS.1B and1C, a vibration-assisted SL system100is illustrated. In accordance with various embodiments, the vibration-assisted SL system100includes a frame102configured to position an electromagnetic energy source104, such as, for example, an ultraviolet light projector106, a distance away from (e.g., a distance above) a resin tank108. In various embodiments, the resin tank108is configured to surround a build platform110and a constrained surface112which, in various embodiments, may comprise a transparent glass114having an upper surface and a lower surface, the upper surface being generally oriented toward the ultraviolet light projector106and the lower surface being generally oriented downward toward a resin109contained within the resin tank108. An artificial boundary117may, in various embodiments, be disposed within the resin tank108to prevent the resin109from flowing onto the upper surface of the transparent glass114. In various embodiments, the artificial boundary117may comprise a wall116in the shape of a square or a circle configured to surround the transparent glass114or at least a portion of the upper surface thereof. Still referring toFIGS.1A-1C, the vibration-assisted SL system100may also include a vibratory source120which, in various embodiments, may comprise an audio speaker122having a membrane124in the form of a paper cone126. As described above, in one non-limiting embodiment, the vibratory source120may comprise the MB42X audio speaker, sold under the brand name Micca®, which includes the membrane124in the form of the paper cone126. In various embodiments, vibratory motion from the vibratory source120is transmitted to the constrained surface112(or to the transparent glass114) via a linkage system128coupled to the constrained surface112. In one non-limiting embodiment, the linkage system128includes a first end130connected to the vibratory source120and a second end132connected to the constrained surface112(or to the transparent glass114). In various embodiments, the linkage system128includes a pressure sensor164mounted to a stationary base166. A bias element168, such as, for example, a coil spring169, connects the pressure sensor164to a second end165of a second member142. Additional details of the linkage system128and various of the other components or sub-systems of the vibration-assisted SL system100are provided below. Referring now toFIGS.2A and2B, and the inset atFIG.2C, a schematic view of a vibration-assisted SL system200, similar to the vibration-assisted SL system100described above with reference toFIGS.1A-1C, is provided. The vibration-assisted SL system200includes an electromagnetic energy source204, such as, for example, an ultraviolet light projector206, positioned a distance away from (e.g., a distance above) a resin tank208. In various embodiments, the resin tank208is configured to surround a build platform210and a constrained surface212which, in various embodiments, may comprise a transparent glass214having an upper surface213and a lower surface215, the upper surface213being generally oriented toward the ultraviolet light projector206and the lower surface215being generally oriented toward or submerged within a resin209contained within the resin tank208. An artificial boundary217may, in various embodiments, be disposed within the resin tank208to prevent the resin209from flowing onto the upper surface213of the transparent glass214or at least a portion thereof. In various embodiments, the artificial boundary217may comprise a wall216in the shape of a square or a circle configured to surround at least a portion of the upper surface213of the transparent glass214. A build part201(or a part or a workpiece) undergoing fabrication is also illustrated positioned on the build platform210and under the constrained surface212or the transparent glass214. During operation, in one non-limiting embodiment (including the embodiment described below with reference toFIGS.3A-3D), the ultraviolet light projector206is configured to irradiate electromagnetic energy having a wavelength of approximately four-hundred five nanometers (405 nm), at a power consumption level of approximately seven Watts (7 Watts) and with a resolution of 1280×800 pixels. In yet a further non-limiting embodiment (including the embodiment described below with reference toFIGS.3A-3D), the resin209comprises MakerJuice G+, available from MakerJuice Labs. Still referring toFIGS.2A-2C, the vibration-assisted SL system200may also include a vibratory source220configured to vibrate in a generally up and down or vertical direction (e.g., in the Z-direction). In various embodiments, the vibratory source220may comprise an audio speaker222having a membrane224in the form of a paper cone226, such as, for example, the audio speaker122described above with reference toFIGS.1A and1B. In various embodiments, vibratory motion from the vibratory source220is transmitted to the constrained surface212(or to the transparent glass214) via a linkage system228that couples the vibratory source220to the constrained surface212. In one non-limiting embodiment, the linkage system228includes a first end230connected to the vibratory source220and a second end232connected to the constrained surface212(or to the transparent glass214). While the disclosure with reference toFIGS.1A-1CandFIGS.2A-2Cdescribes the vibratory source220as being coupled to the constrained surface212or the transparent glass214via the linkage system228, it will be appreciated that the vibratory source220(e.g., in the form or a piezoelectric actuator or a vibratory motor or the like) may be directly connected to the constrained surface212or to the transparent glass214(or to the resin tank208) without use of a linkage system. For example, in various embodiments, a vibratory source, such as a piezo actuator may be attached directly above or below the constrained surface212, with no linkage coupling the two components. In further detail, as illustrated inFIG.2A, the linkage system228includes a first member240connected to a second member242. In various embodiments, the first member240is disposed in a substantially horizontal orientation and the second member242is disposed in a substantially vertical orientation. The second member includes a first end244connected to the first member240at a location intermediate a first end246and a second end248of the first member240. In various embodiments, the linkage system228further includes a third member250having a first end252connected to the first end246of the first member240and a second end254connected to the vibratory source220. Similarly, a fourth member256includes a first end258connected to the second end248of the first member240and a second end262connected to a first side260of the constrained surface212. In various embodiments, the third member250and the fourth member256are oriented in a substantially vertical orientation, being both substantially parallel to the second member242and substantially perpendicular to the first member240. In various embodiments, the linkage system228includes a pressure sensor264mounted to a stationary base266. A bias element268, such as, for example, a coil spring269, connects the pressure sensor264to a second end265of the second member242. The bias element268(e.g., the coil spring269) is configured to store energy when the linkage system228vibrates in response to a vibratory input signal delivered by the vibratory source220. In various embodiments, the bias element268will compress or extend in response to motion of the second member242but will not influence a maximum value of a force applied to the pressure sensor. The bias element268may also be configured to filter vibratory noise within the linkage system228similar to operation of a capacitor in an electrical circuit. As illustrated inFIGS.2A and2B, the vibration-assisted SL system200may also include additional linkage systems, similar to the linkage system228described above. Thus, in various embodiments, for example, the vibration-assisted SL system200may include a first linkage system231, having the various components described above with reference to the linkage system228, and a second linkage system233, being a mirror image of the first linkage system231and being connected to a second side261of the constrained surface212. The first linkage system231will vibrate in response to a first vibratory source221(e.g., the vibratory source220) and transmit the vibrational energy to the first side260of the constrained surface212, while the second linkage system233will vibrate in response to a second vibratory source223and transmit the vibrational energy to the second side261of the constrained surface212. During operation, in one non-limiting embodiment (including the embodiment described below with reference toFIGS.3A-3D), a sine wave is used as the vibratory input signal, having a frequency of 60 Hz. As illustrated inFIGS.2B and2C, during operation, an uppermost build layer270of the resin209will be solidified following exposure of electromagnetic energy (e.g., ultraviolet light) through a mask image or via a pattern-controllable irradiating light source. A vacuum (or otherwise adhesive) environment is formed between a build surface203of the build part201and the lower surface215of the transparent glass214. As the build platform210is lowered to separate the build surface203and the constrained surface212or the lower surface215of the transparent glass214, a separation force, fseparation(i.e., the force required to separate the build surface203from the constrained surface212), will result due to the vacuum environment. Due to the vibratory input signal at the vibratory source220, the transparent glass214will be pulled down a distance “d,” at which time the vacuum environment breaks and the build surface203detaches from the constrained surface212or the transparent glass214. A downward displacement of the fourth member256will also result, as indicated inFIGS.2B and2C(the downward displacement is overemphasized in the drawings). The vibratory source220(e.g., the membrane224or the paper cone226) at this time may be considered a hinge for simplification. At the same time, the bias element268(e.g., the coil spring269) mounted to the second end265of the second member242will be gradually compressed, resulting in an increase in the force applied to the pressure sensor264. As indicated inFIG.2B, let fL_Liftdenote a vertical lift force(in the Z-direction) the fourth member256applies to the first side260of the transparent glass214. Likewise, let TR_Liftdenote the vertical lift force the second linkage system233applies to the second side261of the transparent glass214. Further, let fL_Pushand fR_Pushdenote the horizontal force (in the X-direction) applied to the first side260and to the second side261of the transparent glass214, respectively. A force balance provides the following relations (Equations 1a and 1b): |fseparation|=|fL_Lift|+|fR_Lift| and fL_Push+fR_Push=0. These relations are used below in describing a beneficial operation of a vibration-assisted SL process and apparatus, in accordance with various embodiments. Referring now toFIG.3A, a CAD model for a build part301used to test the applicability of a vibration-assisted SL system, such as, for example, the vibration-assisted SL system100or the vibration-assisted SL system200described above with reference toFIGS.1A and2A, is illustrated. As described below, controlled experiments are conducted to study the effect of vibration on the separation force. The CAD model includes different sections having different cross-sectional areas to study the relationship between (i) the printing cross-sectional area and the separation force and (ii) the difference between vibrating the constrained surface and not vibrating the constrained surface. Data from a first pressure sensor263and a second pressure sensor267(seeFIGS.2A and2B) is collected and analyzed as follows in regard to fabricating the build part301using the vibration-assisted SL system100described above with reference toFIG.1Aand its schematic counterpart, the vibration-assisted SL system200. As illustrated inFIG.3A, the CAD model includes four different sections. The dimensional size of each section is labeled inFIG.3. Basically, the cross-sectional shape of each section is a square and the cross-sectional area of each section is halved, section by section. Each layer thickness for the build part301is one-hundred micrometers (100 μm). A base section303(or a first section) includes sixty (60) layers and each of a second section305, a third section307and a fourth section309(or a top section) includes forty (40) layers. The additional twenty (20) layers for the base section303is to eliminate the influence of over compression in fabricating the first several build layers of the base section303. Details of the printing process for the build part301are as follows. First, forty (40) layers for the base section303are fabricated using a typical SL method, where no vibration is applied to the constrained surface (e.g., the transparent glass114inFIG.1A). Thus, for each layer, the constrained surface is separated from the build surface of the build part301by moving the platform downward without vibration applied to the constrained surface. An exposure time is set as forty seconds (40 s) for the first three layers and twelve seconds (12 s) for the subsequent layers. Subsequently, an additional twenty (20) layers for the base section303are added with vibration of the constrained surface enabled. Each of the second section305, the third section307and the fourth section309are then fabricated, each section including a first twenty (20) layers fabricated with vibration of the constrained surface disabled, followed by an additional twenty (20) layers fabricated with vibration of the constrained surface enabled. Referring now toFIG.3B, a method311for fabricating the build part301described above is illustrated. In a first step313, a thickness gap equal to one layer thickness (e.g., 100 μm) is formed by lowering a build platform (e.g., the build platform110described above with reference toFIG.1A) a distance sufficient to allow the resin to populate the gap between the constrained surface and the build platform (for the first layer) or the build surface (for all subsequent layers) and then raising the build platform to the layer thickness. In a second step315, ultraviolet light is exposed through the transparent glass of the constrained surface (e.g., through a portion of the transparent surface not masked) for a time sufficient to cure the resin in the gap. In a third step317, a decision is made whether to enable vibration or disable vibration of the constrained surface, as described above. Where vibration is enabled, a fourth step319enables vibration of the constrained surface for a period of time (e.g., five (5) seconds), followed by a fifth step321that stops the vibration. After the vibration is stopped, in a sixth step323, the build platform is again lowered a distance sufficient to allow the resin to populate or replenish a gap between the constrained surface and the build surface (e.g., six millimeters (6 mm)). If a subsequent layer is to be fabricated, in a seventh step325, the build platform is raised to form the gap (or the layer thickness) for the next layer. Where vibration is disabled or not enabled at the third step317, the method proceeds to the sixth step323and then proceeds accordingly. Once no further layers are fabricated, the method terminates. Referring now toFIGS.3C and3D, results from the test method used to fabricate the build part301using the vibration-assisted SL system100or the vibration-assisted SL system200, as described above with reference toFIGS.3A and3B, are illustrated. Data from the first pressure sensor263and the second pressure sensor267(seeFIGS.2A and2B) is sampled at a constant rate of 200 Hz, which is considered sufficient to capture the separation force during fabrication of each section of the build part301. Raw data is read from the first pressure sensor263and the second pressure sensor267with the corresponding time recorded. The raw data is converted into fL_Lift(corresponding to the first pressure sensor263) and fR_Lift(corresponding to the second pressure sensor267) through the following relations (Equations 2a and 2b): fL_lift(x)=159.3 log(x−23.15)−49.08 fR_Lift(x)=283.5 log(x)−859.8 The R-square values for the relations are 0.9836 and 0.9942, respectively, which is acceptable and indicates the natural logarithmic relations used to model the raw data provide a close fit with the raw data. By applying equation 1a, above, the separation force is obtained by summing fL_Liftand fR_Lift. The measured and then calculated separation force over time is illustrated inFIG.3C, with the separation force normalized by the force of gravity, g. Referring toFIG.3C, the data obtained is organized and plotted into eight groups labeled from A-H. The data from groups A-B is sampled from the base section303of the CAD model of the build part301as shown inFIG.3A. The data from groups C-D is sampled from the second section305of the CAD model. The data from groups E-F is sampled from the third section307of the CAD model. The data from groups G-H is sampled from the fourth section309of the CAD model. As described above, the data from groups A, C, E and G is obtained from a normal or typical SL printing process without applying vibration to the constrained glass and the data from groups B, D, F and H is obtained from a vibration-assisted SL printing process with applying the vibration to the constrained glass. By combining the data from groups A, C, E and G, a decreasing trend of the separation force as the build surface area decreases in the normal SL printing process is observed. However, the data from the groups B, D, F and H indicates the separation force is independent of the build surface area in the vibration-assisted SL printing process. Specifically, the force in the groups B, D, F and H appears caused by the upward and downward movement during vibration rather than a separation force due to the aforementioned vacuum or adhesive environment as is measured in the normal SL printing process without vibration. Referring now toFIG.3D, a plot of the mean value of the data and the standard deviation provide inFIG.3Cfor group A, C, E and G (normal SL printing process) and group B, D, F and H (vibration-assisted SL printing process), respectively, is provided. As indicated inFIG.3D, when comparing the data obtained from the normal SL printing process330and the data obtained from the vibration-assisted SL printing process332, it becomes apparent that as the build surface area increases, the vibration applied on the constrained surface results in a significant reduction of the separation force. Further, unlike other methods aiming to reduce the separation force, some of which are described above, the vibration-assisted SL printing process disclosed herein does not dramatically increase the mechanical construction complexity, even if the required maximum build surface area is large. Referring now toFIG.4, a vibration-assisted SL system400is illustrated. In contrast to the vibration-assisted SL system100and the vibration-assisted SL system200described above with reference toFIGS.1A and2A, which are representative of “top-down” SL processes and apparatus, whereby the top of the build part is progressively lowered during the fabrication process, the vibration-assisted SL system400is representative of a “bottom-up” SL process or apparatus, whereby the bottom of the build part is progressively raised by the platform. In accordance with various embodiments, the vibration-assisted SL system400includes a frame402configured to position an electromagnetic energy source404, such as, for example, an ultraviolet light projector406, a distance away from (e.g., a distance below) a resin tank408. In various embodiments, the resin tank408is configured to surround a build platform410and a constrained surface412which, in various embodiments, may comprise a transparent glass414having an upper surface413and a lower surface415, the lower surface415being generally oriented toward the ultraviolet light projector406and the upper surface413being generally oriented toward an upper surface of a resin409within the resin tank408. Similar to the foregoing discussion, a build part401is fabricated on or otherwise attached to the build platform410. In various embodiments, the build part401represents an accumulation of layers of the resin409that is cured, layer-by-layer, to form the build part401, each layer being cured by ultraviolet light being emitted from the ultraviolet light projector406and traveling upward through the resin tank408and the transparent glass414into a gap defined by a lower surface of the build part (i.e., a build surface403) and the upper surface413of the transparent glass414. While the foregoing described the system as including both the resin tank408and the transparent glass414, it will be appreciated that the transparent glass414may be incorporated into the resin tank408and be a part thereof. Still referring toFIG.4, the vibration-assisted SL system400includes a vibratory source420or, in various embodiments, a plurality of vibratory sources, such as, for example, a first vibratory source480and a second vibratory source481. The vibratory source420may, for example, include a piezo actuator482(or similar vibratory mechanism, such as, for example, a vibrating motor). In various embodiments, the piezo actuator482is disposed within a clamp483, that is itself disposed between the resin tank408and a mounting member484, the mounting member484being generally stationary with respect to the resin tank408. In various embodiments, the vibration-assisted SL system400further includes a force sensor485which, in various embodiments, may be disposed between the mounting member484and the clamp483. Similar to the discussion above, the force sensor485may be configured to provide raw data representative of a separation force developed between the build surface403and the upper surface413of the transparent glass414. In various embodiments, the vibration-assisted SL system400may include a computer system486(e.g., a processor) configured to control operation of the build platform410and the vibratory source420and to store data provided by the force sensor485. For example, the computer system486may be configured to control operation of a motor487configured to raise and lower the build platform410. The computer system486may also be configured to control operation of the vibratory source420via a first controller488which, in various embodiments, may include a microcontroller, digital-to-analog circuitry and a power amplifier. In various embodiments, the computer system486may also be configured to control operation of the force sensor via a second controller489which, in various embodiments, may include a microcontroller, analog-to-digital circuitry and resistance-to-voltage conversion circuitry. During operation, similar to the description above for the vibration-assisted SL system100, a lowermost build layer471of the resin409will be solidified following exposure of electromagnetic energy (e.g., ultraviolet light) through a mask image or via a pattern-controllable irradiating light source. A vacuum (or otherwise adhesive) environment may be formed between the build surface403of the build part401and the upper surface413of the transparent glass414. As the build platform410is raised to separate the build surface403and the constrained surface412or the transparent glass414, a separation force (i.e., the force required to separate the build surface403from the constrained surface412) will result due to the vacuum environment. In the presence of vibration introduced through the vibratory source420, however, the separation force is substantially reduced (or even eliminated) compared to the separation force that would result in the absence of such vibration. Thus, during operation of the vibration-assisted SL system400, the vibratory source420is activated, in various embodiments, subsequent to activation of the electromagnetic energy source404or the ultraviolet light projector406and curing of the lowermost build layer471. The vibratory source420remains activated for a period of time (e.g., five seconds (5 s)) or until the build surface403and the constrained surface412or the transparent glass414are separated, at which point the process repeats, similar to the process described with reference toFIG.3B. Referring now toFIG.5, various steps of a method500of fabricating a build part using a vibration-assisted SL system are described. As will be appreciated from the disclosure provided above, the method is applicable to both a top-down stereolithography process or apparatus and a bottom-up stereolithography process or apparatus. In a first step502, a build surface of a build part is separated a distance from a constrained surface to form a gap having a gap thickness (e.g., 6 mm) and a resin is allowed to flow into or otherwise populate, replenish or permeate the gap. In a second step504, the gap thickness is reduced to a layer thickness (e.g., 100 μm). In a third step506, an electromagnetic source of energy is irradiated through the constrained surface for a time sufficient to cure the resin residing in the gap. In a fourth step508, a vibratory source is activated to reduce the separation force required to be overcome in order to separate the build surface from the constrained surface. In a fifth step510, the build surface of the build part is separated the distance from the constrained surface to form the gap and the process repeated, layer-by-layer, until the build part is fabricated. In various embodiments, following the third step506, whereby the electromagnetic source of energy is irradiated through the constrained surface for a time sufficient to cure the resin residing in the gap is performed, a separating load is applied to a build platform to partially separate the build surface from the constrained surface a set distance (e.g., 50 μm), after which the vibratory source is activated to separate the build surface from the constrained surface. In various embodiments, following the third step506, whereby the electromagnetic source of energy is irradiated through the constrained surface for a time sufficient to cure the resin residing in the gap is performed, a separating load is applied to the build platform at or near the same time as the vibratory surface is activated to separate the build surface from the constrained surface. In various embodiments, the separating load may be configured to separate the build surface from the constrained surface at a fixed velocity (e.g., 5 μm/s), during which time the vibratory surface is activated to separate the build surface from the constrained surface. Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials. Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment”, “an embodiment”, “various embodiments”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Finally, it should be understood that any of the above described concepts can be used alone or in combination with any or all of the other above described concepts. Although various embodiments have been disclosed and described, one of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. Accordingly, the description is not intended to be exhaustive or to limit the principles described or illustrated herein to any precise form. Many modifications and variations are possible in light of the above teaching. | 33,959 |
11858214 | DETAILED DESCRIPTION The present disclosure is a self-supporting thermal isolator for a 3D printer that builds objects by extruding material from an extrusion nozzle of a print head onto a platen located in a heated build chamber. The thermal isolator forms a portion of a ceiling of the heated chamber and is configured to insulate components on an inlet side of the print head from the heated build space while an extrusion nozzle of the print head moves within a build plane of the heated build chamber. The print head inlet and motion control components of the printer are isolated from the heated chamber so that the temperature in the heated chamber is not limited by the temperature limits of these printer components. The apparatus enables the building of objects from high-temperature materials and the self-supporting feature facilitates use of the isolator in large-scale 3D printers. The self-supporting thermal isolator of the present disclosure has one end that attaches proximate a top edge of the build chamber and another end that secures to components that engage the print head and/or move the print head in an x-y plane, where the thermal isolator or barrier expands and contracts to maintain the thermal barrier between the heated chamber and the print head electronics and gantry, as the gantry or gantry bridge is moved back and forth in an x-direction as 3D parts are printed in a layer-by-layer manner. The self-supporting thermal barrier includes lightweight support rods that span a width of the chamber and are capable of withstanding high temperatures, and where ends of the support rods move along substantially planar surfaces proximate a ceiling of the heat chamber. As 3D printers become larger in scale, a thermal barrier or isolator that moves with the print head needs to span a larger length and width. Large-scale 3D printers include build envelopes that are 24 in. by 24 in. (576 sq. in.), 24 in. by 40 in. (970 sq. in.), 32 in. by 40 in. (1,280 sq. in.) and higher. A larger-scale thermal barrier can sag or buckle into the print plane and interfere with a part being printed. There is a need for a light-weight, self-supporting expandable and contractable thermal barrier that does not sag or buckle. However, the presently disclosed thermal barrier or isolator can also be used with 3D printers with smaller build envelopes. The present disclosure utilizes a self-supporting thermal isolator that is constructed with accordion folds that allow the thermal isolator to expand and contract as the print head moves in an x-y build plane of the heated build chamber. The thermal isolator includes a first baffle section and a second baffle section, each of which comprises an accordion-pleated panel. Due to the size of the large-scale 3D printers, an un-reinforced thermal isolator is typically not sufficiently rigid by itself to be self-supporting and can sag and/or buckle as the part is printed, resulting in printing errors or interference with the movement of the print head. The present disclosure utilizes spaced apart support rods secured to or within the thermal isolator as stiffeners for the baffle sections. The support rods substantially span a width of each baffle section of the thermal isolator and are in alignment with the accordion folds. The support rods are sufficiently strong or rigid to retain the thermal isolator or barrier in alignment with the print head carriage while being sufficiently light weight to be moved with the same drive as used to move the unsupported thermal isolator. It is typical that the rods are minimal in diameter or cross-section, in order to ensure that movements of the print head gantry are not impeded by a lack of contractability of the thermal isolator. If the rod diameters are too thick, they will make the contracted dimension of the thermal isolator too large to allow for adequate gantry movement to the outside edges of the print space. Due to economic constraints on the cost of the thermal isolators and the size of the actuators for moving the print head carriage, lightweight and inexpensive materials are utilized that provide the necessary expansion and contraction while being able to withstand high chamber temperatures and providing the necessary thermal insulation or barrier for electronics and print head movement apparatuses. A non-limiting, exemplary material of construction includes polytetrafluoroethylene (PTFE) coated fiberglass. The present disclosure may be used with any suitable extrusion-based 3D printer. For example,FIG.1illustrates a schematic view of an exemplary 3D printer10that has a substantially horizontal print plane, and where the part is printed and indexed in a substantially vertical z-direction on a build platen assembly14having a substantially planar surface16in the x-y plane. Parts are printed in a layer-by-layer manner moving a print head carriage16that carries print heads18pand18sin a x-y plane. The shown embodiment has an H-style x-y gantry, with gantry bridge15used for moving the print head carriage16. The print heads18pand18sextrude part material and optional support material supplied by consumable assemblies,12pfor part material and12sfor support material. Exemplary 3D printer10prints parts or models and corresponding support structures from the part and support material filaments, respectively, of consumable assemblies12, by extruding roads of molten material along toolpaths. During a build operation, successive segments of consumable filament are driven into an inlet end of print head18pand18swhere they are heated to a molten state in a liquefier within the print head. The molten material is extruded through nozzle tip in a layer-wise pattern to produce printed parts. Suitable 3D printers10include fused deposition modeling systems developed by Stratasys, Inc., Eden Prairie, MN under the trademark “FDM”. After layers are printed in the x-y plane, the platen assembly14is incremented downward a height of a layer in the z-direction. The process of printing a layer in the x-y plane by moving a print head carriage16supporting the print heads18pand18suntil a layer is printed and then indexing the platen assembly14a height of a layer in the z-direction is continued until the 3D part is printed. The 3D printer includes a heated build chamber22that contains the platen assembly14and an extrusion tip for each print head18pand18s, such that the 3D part is printed at a suitable warmer than ambient temperature for a particular material. The heated chamber includes a thermal isolator30that allows the print heads18pand18selectronics portions to be located outside the heated space, while the tip of the print head prints in a x-y plane within the heated chamber. The thermal insulator30includes baffle sections on either side of the print heads which move in concert with the gantry bridge15, to maintain the heated thermal space while insulating printer components from the heated chamber, such as disclosed in Swanson U.S. Pat. No. 6,722,872 and in Bosveld U.S. Patent Application Publication 2019/0210284 which discloses pleated insulators that are removably attached to the central portion. In other embodiments, the print head moves within the gantry bridge and the left and right thermal insulators attached to the central portion maintain their length as the insulators move, such as disclosed in Swanson U.S. Pat. No. 10,688,721. As illustrated, the thermal isolator30includes a first baffle section32having a left end34connected to the 3D printer10proximate a left edge27of the chamber28, and a right end36connected to the gantry bridge15. The thermal isolator30includes a second baffle section38having a right end40connected proximate a right edge29of the chamber22and a left end42connected to the gantry bridge15. The baffle sections32and38expand and contract as the gantry bridge15moves in the x-direction. The first and second baffle sections32and38are similarly constructed and include an accordion-pleated panel comprising a plurality of alternating top and bottom folds31and37, respectively, that span a width of each baffle section32and38in a y-direction, forming a series of pleats configured to expand and contract in the x-direction. Support rods100are affixed to the baffle sections32and38in parallel to the pleats and at intervals along the length of the panel, the support rods substantially spanning the width of the panel. The support rods100are configured to provide sufficient strength and rigidity to the panel to substantially prevent the panel from sagging or buckling as the panel is expanded and contracted along its length. The thermal isolator30may optionally include y-direction baffles within a tray of the gantry bridge15. The thermal isolator30illustrated inFIGS.1and2includes a front baffle section44having a front end46attached to a front end of the gantry bridge15and a back end48attached proximate the print heads18pand18swithin the gantry bridge15. The thermal isolator30also includes a back baffle section50having a back end52attached to a back end of the gantry bridge15and a front end54attached proximate the print heads18pand18s. The front and back baffle sections50and52include accordion folds in the y-direction, such that the print heads18pand18scan move in the y-direction which causes the front and back baffle section44and50to expand and contract. These y-direction baffles span a smaller area than the x-direction baffle sections32and38, and optionally may utilize the support rods of the present invention. The thermal isolator30with the first and second baffle sections32and38and the optional front and back baffle sections44and50is configured to expand and contract in the x-direction as the print heads18pand18smove in the x-direction and is configured to expand and contract in the y-direction as the print heads18pand18smove in the y-direction. The combination of the first and second baffle sections32and38and optional front and back baffle sections44and50, respectively, allows the print heads18pand18sto move in any direction in the x-y plane while acting as a ceiling of the heated chamber28to aid in maintaining a selected temperature within the heated chamber28. Referring toFIG.2, the gantry bridge15is moved proximate a left edge of the chamber28such that the first baffle section32is contracted and the second baffle section38is expanded. As mentioned before, due to the increased width of the first and second baffle sections32and38, spaced apart support rods are utilized within the accordion folds to retain the first and second baffle sections32and38in alignment with the gantry bridge15while preventing unwanted sagging or buckling of the first and second baffle sections32and38. With the first baffle section32in a contracted configuration with the spaced apart support rods in closer proximity to each other, the first baffle section32is a capable of supporting one or more tools without sagging, damaging or adversely affecting the life of the first baffle section32. Being capable of supporting tools is beneficial when working on large scale 3D printers, such as illustrated at10, because the tools can be retained in close proximity to the operator in a location that does not interfere with the repair or replacement of parts. While the first baffle section32is illustrated in a contracted configuration and the second baffle section38is illustrated in an expanded configuration, it is also within the scope of the present disclosure to have the second baffle section38in the contracted configuration and capable of supporting tools while the first baffle section32is in the expanded configuration, or any intermediate position between the two extremes. The pleated thermal isolator must be able to contract and expand according to the movement of the gantry bridge15. The support rods prevent the first and second baffle sections32and38from sagging during the expansion and contraction; with a large build size, the first and second baffle sections32and38will be large, and will need to expand and contract across the large space, without sagging into the thermal chamber. The baffle material itself would not be capable of supporting a large span, even with accordion folds. By way of non-limiting example, the first and second baffle sections32and38may contract to as small as 2.5″ in width, and extend as large as 43″ in width. Referring toFIGS.3and4, the thermal isolator30may alternatively omit the y-baffles, and include a different isolator configuration within the gantry bridge15which holds the 3D print heads such that the print head tip portion projects through a deformable portion51extending substantially along a width, into the heated thermal chamber. The deformable portion51includes flaps53and55attached to the gantry bridge15along three edges of an opening59, where edges within the gantry bridge15are free and form a slightly overlapping slit57, Portions of the liquefiers and the nozzle tips of the print heads18pand18sextend through the slit57, where the flaps53and55provide a thermal barrier to prevent the print heads18pand18sfrom creating a potentially large hot air leakage areas within the chamber22, while allowing the print heads18pand18sto move freely along a length of the central portion31. Maintaining the print heads18pand18soutside the heated chamber at a lower temperature aids in extending the life of their electrical components. The baffle flaps53and55are constructed of flexible, thermally tolerant fabric material, such as but not limited to polytetraafluoroethylene (PTFE) coated fiberglass, which can tolerate elevated thermal chamber temperature conditions while still permitting print head movement within the slit57maintaining closure of the flaps53and55adjacent to the print head movement path. However, other forms of thermal isolators within the gantry bridge15are within the scope of the present disclosure such as overlapping sheets with a slit therebetween. Referring toFIGS.5and6, the second baffle section38is illustrated in an expanded configuration where the right end40is connected proximate the right edge29of the chamber28and a left end42connected to the gantry bridge15. End portions of the support rods100, whether located fully internally within the baffle fabric, or extending beyond the fabric, rest on substantially planar surfaces62and68of “L” shaped members60and66secured proximate the front edge and the back edge of the chamber28. Vertical portions64and70of the “L” shaped members60and66, respectively, limit movement of the second baffle section38in the y-direction as the second baffle section38expands and contracts in the x-direction. The first baffle section32is a mirror image of the second baffle section38and also utilizes the “L” shaped members to support the support rods100while limiting movement of the left thermal isolator32in the y-direction. While “L” shaped members60and66are illustrated and described, the support members can have any suitable configuration including, but not limited a vertical edge upon which the support rod is supported, upwardly or downwardly sloped engaging surfaces and/or arcuately shaped surfaces. Referring toFIGS.7and8, the second baffle section38is further illustrated apart from the 3D printer. However, the same description applies to the first baffle section32.FIGS.7and8illustrate the second baffle section38in a position between fully contracted and fully expanded. The second baffle section38includes a left end plate41proximate the left end42and configured to be attached to the gantry bridge15and a right end plate39proximate the right end40configure to be attached proximate a right edge of the chamber28. The second baffle section38includes a plurality of groups of pleats80that are separated by support rods82that are secured between the adjacent plurality of groups of pleats80. As illustrated, the support rods82are spaced every five pleats from proximate a top edge84and hang proximate a bottom edge86such that the support rods82are configured to rest on the substantially horizontal portions of the “L” shaped members60and62. While the support rods82are illustrated being spaced every five pleats, the support rods82can be spaced apart any suitable number of pleat ranging from about two pleats to about ten pleats depending upon the size of the thermal isolator and the material of construction and more particularly the support rods82can be spaced apart from about three pleats to about eight pleats depending upon the size of the thermal isolator and the material of construction. As another option, the support rods could be placed in each pleat. Larger or taller pleats may need more closely spaced rods; smaller or shorter pleats may allow for the rods to be spaced further apart. Referring toFIGS.9and10, a pocket90is integral along the width W of the second baffle section38at the top edge84of the pleat. Typically, the pocket90is stitched into the pleats However, other securing mechanisms are within the scope of the present disclosure including, but not limited to glue, adhesive, buttons and snaps. The pocket90has a length such that a lower end92is proximate the bottom edge of the second baffle section38when in the compressed state where the pleats80are substantially adjacent to each other, as illustrated inFIG.2with the first baffle section30. A support rod100is inserted into an interior cavity92of the pocket90where the support rod100such that ends of the support rod100rest on the substantially horizontal portions62and68of the “L” shaped members60and66. While a hollow rod is illustrated, the support rod100can have any cross sectional geometry and can be constructed of any suitable material that is sufficiently light weight while being capable of withstanding printing temperatures and have sufficient strength to prevent the first and second baffle sections32and38from sagging or buckling during the printing process. By way of example, the support rods100can be made of carbon fiber, and could also be made of any suitable metal, such as steel or aluminum, or another composite material besides a carbon fiber. Carbon fiber rods are suitable for operation at heated chamber temperatures of up to 250° C. In the case where heated chamber temperatures exceed 250° C., the support rods could also be made of a suitable metal, such as steel or aluminum, or another high temperature composite material The support rods100must not deform or soften at printer operating temperatures. A hollow support rod100of larger diameter has significantly greater resistance to bending or sagging than a smaller, solid rod. Depending on the material selected, support rods100of an outer diameter as low as 0.17″ have been found to successfully support the weight of the first or second baffle section32and38without sagging. In another example, 0.25″ OD and 0.21″ ID hollow carbon fiber rods were used. In yet another example, 0.197″ OD and 0.118″ ID hollow carbon fiber rods were used. In another example, 0.196″ OD solid carbon fiber rods were used successfully. As an example, a sufficiently rigid support rod implementation would resist bending or sagging during heated printing operations. For example, stiffening rods smaller than 0.17″ may sag unfavorably when used in the first or second baffle section32or38of 35″ width. Although the first and second baffle sections32and38are not meant to withstand the placement of weights on their top surface, they may be subjected to additional load if maintenance personnel place tools or other items on its top surface while performing tasks. Without the support rods100, the first and/or second baffle sections32and38would fall into the heated chamber, and may damage internal printer activities or components. Additionally, the higher the temperature is in the heated chamber, the more rigid both the baffle section fabric, pleats, and support rods need to be in order to support its weight during printing. As the thickness of the baffle section fabric is increased, the number of support rods can be reduced, or the spacing increased. However, with increasing baffle section thickness, it becomes more difficult to contract the baffle sections so that the baffle sections do not limit the print head movement as it nears the chamber wall areas. Also, as the support rods used are increased in diameter, they may also limit the ability to contract the isolator enough that it also limits print head movement. For example, using a stiffening rod of more than 0.25″ in diameter can be too large for good baffle section compaction, or too heavy for easy movement by the gantry, such as in the case of a solid steel support rod. Another approach for stiffening the thermal isolator would be to increase the individual pleat heights, but then then additional machine height must be added to accommodate the large thermal isolator size. The larger the printer, the larger the baffle section width requirement becomes. It has been found that baffle section widths of greater than 25″ require stiffening support in addition to the typically known approaches for design which feature fabric thickness and single or double ply accordion pleat variations. By way of non-limiting example, baffle section widths of up to 44″ have successfully used stiffening rods with double pleated thermal isolator fabric, while allowing for compaction and good printer head movement. Once the support rod100is positioned with in the interior cavity92of the pocket90, the ends94may be sealed closed such as with stitching to retain the support rod100within the pocket90as the second baffle section38expands and contracts. While stitching is disclosed and illustrated to secure the rod100within the pocket90, other securing members are also contemplated, including but not limited to glue, adhesive, snaps and buttons. Alternatively, the ends92of the pocket90can be left open while retaining the support rod100therein. Alternatively, the second baffle section38can include cavities along a bottom fold configured to retain the spaced apart support rods. Although the present disclosure may have been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure. | 22,341 |
11858215 | DETAILED DESCRIPTION In the figures, certain features and components disclosed herein may be shown exaggerated in scale or in somewhat schematic form, and some details of certain elements may not be shown in the interest of clarity and conciseness. In some of the figures, in order to improve clarity and conciseness, one or more components or aspects of a component may be omitted or may not have reference numerals identifying the features or components. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to be broad enough to encompass both indirect and direct connections. Thus, if a first device couples to a second device, that connection may be through a direct connection or through an indirect connection via other devices, components, and connections. In addition, as used herein, the terms “axial” and “axially” generally refer to positions along or parallel to a central or longitudinal axis (e.g., central axis of a body or a port), while the terms “lateral” and “laterally” generally refer to positions or items located or spaced to the side of the central or longitudinal axis. As used herein, including in the claims, the word “or” is used in an inclusive manner. For example, “A or B” means any of the following: “A” alone, “B” alone, or both “A” and “B.” In various examples, a 3D printer includes a receiving platform, a feed mechanism to distribute a build material on to the receiving platform, and a radiant heater to soften, melt, or fuse portions of the build material, which is aided in some examples by application of a fusing agent. The build material may be, as examples, a polymer, a metal, or a ceramic. The build material that is to be used may be, as examples, powdered or granular. Some of the 3D printers that use a powdered build material also include a print head with nozzles to apply liquid on the build material. In these printers, the feed mechanism periodically distributes a horizontal layer of the build material from a reservoir on to the platform, forming a layer of build material on the receiving platform. The print head moves over the receiving platform and its nozzles spray an energy absorbing fusing agent, a colorant, or another liquid in a selected pattern across the layer of the build material on the platform. The selected spray pattern for the liquid may be based on data derived from a 3D model of an object that is to be built on the printer. The heater radiates energy to the deposited build material to bond/fuse those portions on which the fusing agent has been printed; whereas, portions that lack fusing agent do not heat sufficiently to fuse. The heater may include a lamp mounted in front of a reflector, and the lamp may emit light that includes infrared and/or visible light, as examples. The heater may be stationary or may move relative to the platform and the build material thereon. The movement of the heater may be synchronized with the movement of the feed mechanism or the movement of the print head. During heating, portions of the radiant energy from the heater may be reflected by the build material rather than being absorbed by the build material on the platform. Radiant energy may also be reflected by the platform or other features in the printer. In some examples, the problem of reflection from the build material is more likely where fusing agent is not present on the build material. In some situations, the reflected energy returns to the heater and is re-reflected by the reflector, returning to another portion of the build material. This process is known as multi-scattering. The result is a variable irradiance magnitude on the build platform that is dependent on the location and size of the fusing areas on the build platform at any given time. This creates differing irradiance values from build layer to build layer and from region to region on the same build layer resulting in increased irradiance received by various regions of the build material and unintentional, non-uniform heating or fusing of the build powder. To reduce the multi-scattering effect, a radiant barrier including energy absorbing baffles is installed in the heater. Some examples of such baffles include thin plates or sheets of material having a dark or flat color and placed at an appropriate location relative to the lamp. In some examples, the baffles include a plate or sheet of mica coated with high temperature optical black paint. Other materials are used in some baffles. In some examples, the baffles are disposed between the lamp and the reflector. A baffle may be located behind the lamp or alongside the lamp. In some heaters, the lamp is elongated and extends along a filament axis, parallel to the receiving platform. For an example, it is assumed that the filament axis is horizontal. Some examples include an arcuate baffle positioned vertically, perpendicular to the filament axis. Some examples include an axially extending baffle located above the lamp, opposite the receiving platform. When applied in a printing process to produce parts as disclosed herein, the various examples disclosed herein may reduce multi-scattering, provide heating that is more uniform across a region of the build material, improve material properties due to reduced thermal variation, achieve improved dimensional accuracy, reduce part defects, improve color accuracy when colors are used, or allow parts that are being built to be more closely spaced when building multiple parts simultaneously. Any of these benefits may make a printer more economical to operate or more desirable to use. Referring now to the view ofFIG.1, an electronic device in accordance with the principles disclosed herein is shown. In this example, the electronic device is a printer100, and more specifically, in this example, printer100is a 3D printer. Printer100includes a housing102for which a coordinate system may be defined by an x-axis, a y-axis, and a z-axis. In this example, the three axes are orthogonal with the x-axis extending lengthwise (left and right inFIG.1), the y-axis extending widthwise (into and out of the page inFIG.1), and the z-axis extending vertically (up and down inFIG.1). The z-axis may also be called an elevation axis, referring to an elevation of a part that may be built by printer100. The elevation axis extends, for example, between a receiving surface or platform and a movable heater. In housing102, printer100includes a print carriage114for distributing colorant, fusing agent, or multiple of these substances, a material feed mechanism116to deposit sequential layers of build material117on a receiving surface118, a printer heater120, and a carriage system122. Print carriage114includes a print head for delivering liquid droplets. Print carriage114, feed mechanism116, and heater120are slidingly mounted to carriage system122to move back-and-forth parallel to the x-axis across receiving surface118. As an example, carriage system122may include a guide bar and a common drive mechanism to move print carriage114, feed mechanism116, and heater120or may include separate drive mechanisms or guide bars for components114,116,120to move them together or separately. Other types of carriage systems are possible in various other examples of device100. In some examples, a carriage system mounts print carriage114, feed mechanism116, and heater120separately. In some examples, print carriage114, feed mechanism116, heater120or combinations thereof are mounted to move along the x-axis, y-axis, or z-axis, which may include combinations of these axes. In some examples, build material117is powdered or granular. Heater120may also be called a heater assembly or fusing module. Heater120includes a radiant energy absorbing barrier130that includes a radiant energy absorbing baffle132. In the example ofFIG.1, receiving surface118is a part of a movable platform126, disposed in a bin124. Platform126is vertically adjustable along the z-axis by a drive or lift mechanism128, and the receiving surface118is likewise vertically movable relative to feed mechanism116and heater120. For example, lift mechanism128may move platform126vertically downward along the z-axis in increments to allow receiving surface118to receive sequential layers of build material or print agent that build upon the previous layers. A deposited layer may receive liquid from print carriage114. The layer may next be heated by heater120passing over it. Portions of the layer may be bonded by the heat from heater120. During the printing process, an upper or outer layer129of build material or print agent is a receiving surface for a subsequent layer of build material or print agent. Thus, as sequential layers of build material are added, the previous layer is a new receiving surface for the next layer. In this manner, a part being printed may be completed as a three-dimensional (3D) object. Still referring toFIG.1, lift mechanism128may move platform126vertically upward when preparing for the removal of a printed part or when preparing for a new print task. In some examples, as a part is built layer upon layer, platform126is to maintain the upper layer129of the build material117at a selected distance134from the heater120or feed mechanism116, measured along the z-axis. Bin124may be for customer-installation into housing102or removable from housing102to facilitate shipping, for replacement or repair, for removal of a printed part following a print operation, or for another reason. In some examples, bin124with platform126is mounted in a separate housing. The separate housing may couple to housing102to form the assembly. FIGS.2and3show a radiant heater120A that is an example of the heater120inFIG.1. Printer heater120A includes a housing140that extends lengthwise from a first end141to a second end142and includes a transparent opening144located between ends141,142. Housing140includes multiple sockets146for receiving lamps. Transparent opening144includes glass, another transparent material, or is open, having no material extending across it. A set of X-Y-Z orthogonal axes are shown for heater120A and its housing140. In some examples, these axes correspond to the same directions as the X-Y-Z axes ofFIG.1. Within or coupled to housing140, heater120A includes a plurality of lamps160coupled to sockets146, a reflector170located behind lamps160with respect to opening144, a radiant barrier180that includes radiant energy absorbing baffles, and a connector152to provide power or control signals to lamps160. Portions of reflector170extend alongside lamps160, toward opening144. When installed in the system ofFIG.1, lamps160are spaced apart from receiving surface118and are located between radiant barrier180(e.g., radiant barrier130inFIG.1) and the receiving surface118. Lamps160and the reflector170are to direct radiant energy toward the receiving surface118and any build material117sitting on it. The radiant energy is to heat the build material. Barrier180is to absorb a portion of the radiant energy emitted by lamp160and to absorb a portion of the radiant energy reflected from build material117or receiving surface118. Barrier180is to limit or prevent this absorbed energy from traveling to build material117. At least in this manner, radiant barrier180is to limit an amount of radiant energy traveling toward the receiving surface118or build material117. In some examples, the passive action of radiant barrier180makes more uniform the spatial distribution of radiant energy traveling toward receiving surface118or build material117. Referring now toFIGS.1,2, and3, lamps160are sources of radiant heat. A lamp160includes a tubular bulb162having a cylindrical external surface163and extending between first and second ends164along a longitudinal filament axis166, which in this example is centrally located within tubular bulb162. Lamp160includes a heater filament168electrically coupled through ends164to sockets146and extending along filament axis166. Other configurations and arrangements of heat lamps, heater filaments, or sockets146are possible. As shown inFIGS.2and4, heater120A includes three of a first type of lamp160A to provide a first spectrum of radiant energy and one of a second type of lamp160B to provide a second spectrum of radiant energy. Other heater filament configurations, other types of lamps, or other quantities of lamps160A,160B may be included in other heater examples. Some examples have a single type of lamp or a single lamp160. Some examples include a heater filament that is not enclosed in a bulb. In some examples, a lamp160includes a quartz infrared halogen heat source. Referring toFIGS.2and3, reflector170is located behind a lamp160with respect to opening144. Reflector170extends in a first direction that is parallel to a filament axis166and in a second direction that is perpendicular to axis166. Reflector170includes a reflective surface172that extends axially along and circumferentially around a portion of each lamp160. In general, reflective surface172faces lamps160and transparent opening144. More specific to this example, reflector170is an assembly that includes multiple member reflectors173coupled to a frame member174. Reflectors173are laterally spaced apart, perpendicular to axis166, with gaps located between neighboring reflectors173. The lateral spacing may be uniform from one pair of neighboring reflectors173to another or may vary. A reflector173includes a rectangular channel, and the inner, reflective surface172of this channel includes a bottom or inner region and two side regions. In general, surface172is to face toward opening144. A reflector173and its reflective surface172extend axially along and circumferentially around a portion of one of the lamps160.FIGS.4to6provide additional views that include reflector170. In some examples, such as those with a single lamp160, reflector170includes a single member reflector173. Thus, the terms reflector170and reflector173describe similar or equivalent components. Referring toFIGS.2,5, and6, radiant barrier180includes multiple lateral baffles182, extending lengthwise at a non-zero angle with respect to filament axis166. Baffles182include thin plates or beams that are to absorb radiant energy. In this example, baffles182extend in length perpendicular to filament axis166. Lateral baffles182extend in height (or depth) towards opening144. Lateral baffles may extend in height parallel to a z-axis for housing140within 15 degrees of being parallel to the z-axis (e.g., the vertical axis). Baffles are coupled to reflector170by connector tabs184and by interconnections with reflectors173. Baffles182are spaced apart from one another axially by a baffle gap185, measured along axis166(FIG.4). In some examples, the baffle gap between baffles182varies from one pair of neighboring baffles182to another. A lateral baffle182extends laterally through the neighboring reflectors173and their reflective surfaces172. Baffle182includes multiple recesses186, having a recess186located within a reflector173to receive lamps160. The recesses186have different diameters to accommodate the different diameters of lamps160A,160B. InFIG.2, a baffle182extends around a portion of a lamp160in a circumferential direction with respect to the filament axis166because lamp160is received in a recess186. InFIGS.2-6, the multiple baffles182of radiant barrier180are incorporated into reflector170as an assembly. FIG.7shows a side view of the heater120A operating on a receiving surface118A, which may include the surface of a movable platform or a layer of build material previously deposited or most recently deposited. Lamp160is spaced apart from receiving surface118A by a selected spacing134A, and, on average, lateral baffles182of radiant barrier180are spaced further from surface118A, as is reflector173with its reflective surface172. Thus, in this example, lamp160is disposed between the receiving surface118A and the combination of radiant barrier180and reflector173, as was previously described. During operation, lamp160emits radiant energy190to heat the build material. The radiant energy includes multiple ray paths or rays traveling in multiple directions from surface163of lamp160. Examples of these ray paths or rays are shown and will be discussed. Rays191A,191B are emitted from lamp160and are absorbed by surface118A, after following different paths. Ray191A follows a direct path; whereas, ray191B first travels to reflector173and is reflected down to surface118A where it is absorbed. A ray192is emitted from lamp160toward receiving surface118A, is reflected by surface118A, is re-reflected by reflector173, and returns to surface118A to be absorbed. Thus, ray192is an example of re-reflection and absorption. In this example, ray192travels further along the x-axis before being absorbed by surface118A than ray191A travels before being absorbed. Other re-reflections may have more interactions with surface118A or reflector173. Ray191B includes a single reflection and without a re-reflection. A ray193travels from an upper region of lamp160and impinges upon a baffle182, which absorbs ray193. Ray193is directly absorbed by radiant barrier180and does not reach surface118A. A ray194is emitted from lamp160toward receiving surface118A, is reflected by surface118A, and is absorbed by a baffle182. Rays193,194are examples of controlled or eliminated radiation. Thus, the radiant energy absorbing barrier180with radiant energy absorbing baffles182is to control emission of radiant energy from a lamp160or heater filament168toward receiving surface118A and to control re-reflection of radiant energy from surface118A. In this example, eliminated ray194travels further along the x-axis than rays191A,191B,192travel along the x-axis before they are absorbed by receiving surface118A. In other examples, an eliminated ray may travel a shorter distance along the x-axis than does a ray that is absorbed by receiving surface118A. Regarding the descriptions in this disclosure that discuss rays being absorbed or reflected, it is to be understood that in some examples, an absorption or reflection by a surface may not be 100%. Some rays that are described as being absorbed at a particular surface may be partially reflected at that surface. Likewise, some rays that are described as being reflected at a particular surface may be partially absorbed at that surface. In addition, some amount of transmission of radiant energy through a surface may be possible during some interactions with some surfaces, such as the surface of a build material. In some examples, a radiant barrier or a radiant energy absorbing baffle is to absorb different spectrums of radiant energy emitted by multiple sources, such as lamps160A,160B. The emissions differences between lamps160A,160B may be based on having different heater filaments that include different materials or based on operating at different temperatures. In some examples, the radiant energy absorbed and controlled by a radiant barrier or a radiant energy absorbing baffle includes energy that is first absorbed by the receiving surface and is then reradiated by the receiving surface. Such re-emitted radiant energy may have a different wave length or a different spectrum of wavelengths than the absorbed radiant energy had, based on the difference in temperature of the receiving surface as compared to a higher temperature of the heater filament or the lamp surface. Referring now toFIG.8, radiant heater120B is another example of the heater120inFIG.1. Printer heater120B includes a housing140with a transparent opening144and a set of X-Y-Z orthogonal axes. Housing140and the axes are as described above and shown inFIG.3. Within or coupled to housing140, heater120B ofFIG.8includes a plurality of lamps160coupled to sockets146, a plurality of reflectors270located behind lamps160with respect to opening144, and a plurality of radiant barriers280that includes radiant energy absorbing baffles. A radiant barrier280is located between a lamp160and a reflector270. Portions of reflector270extend alongside lamps160, toward opening144. When installed in the system ofFIG.1, lamps160are spaced apart from receiving surface118and are located between radiant barriers280(e.g., radiant barrier130inFIG.1) and the receiving surface118. Lamps160and the reflectors270are to direct radiant energy toward the receiving surface118and any build material117sitting on it. The radiant energy is to heat the build material. Barriers280are to absorb a portion of the radiant energy emitted by lamps160and to absorb a portion of the radiant energy reflected from build material117or receiving surface118. Barriers280are to limit or prevent this absorbed energy from traveling to build material117. At least in this manner, radiant barriers280are to limit an amount of radiant energy traveling toward the receiving surface118or build material117. In some examples, the passive action of radiant barriers280makes more uniform the spatial distribution of radiant energy traveling toward receiving surface118or build material117. Continuing to referenceFIG.8, lamps160are as described above with reference to heater120A. For example, a lamp160includes a heater filament168extending along a longitudinal filament axis166within a tubular bulb162that includes a cylindrical external surface163. Heater120B includes three of a first type of lamp160A to provide a first spectrum of radiant energy and one of a second type of lamp160B to provide a second spectrum of radiant energy. Other heater filament configurations or lamp configurations may be included in other examples of heater120B. A reflector270includes a concave reflective surface272that extends as a channel parallel to filament axis166, and circumferentially around a portion of the corresponding lamp160. In general, reflective surface272faces lamp160and transparent opening144. Heater120A includes four pairs that include a lamp160and a reflector270. The pairs of lamps160and reflectors270are laterally spaced apart. FIGS.8and9show two views of the plurality of radiant barriers280. A radiant barrier280includes multiple lateral baffles282and a longitudinal baffle288. Baffles282,288include thin plates or beams that are to absorb radiant energy. Longitudinal baffle288extends lengthwise parallel to filament axis166, intersecting and coupling to lateral baffles282as an assembly or an integral component. As viewed in an X-Y plane, lateral baffles282extend lengthwise at a non-zero angle with respect to filament axis166and baffle288. In the example ofFIGS.8and9, lateral baffles282extend perpendicular to axis166. As shown most directly inFIG.8, lateral baffles282extend in a curved or arched path around a lamp160, in a circumferential direction with respect to the axis166. InFIGS.8and9, lateral baffle282is semicircular with an appropriately sized recess286to receive a lamp160A,160B. In general, the curvature of lateral baffles282and the corresponding concavity of reflective surface272of reflector270may include an arcuate or parabolic shape, or may have another shape that may be curved or angled. Baffles282extend in height towards opening144, parallel to a z-axis for housing140or within 15 degrees of being parallel to the z-axis (e.g., the vertical axis). Baffles282are spaced apart from one another axially by a baffle gap285(FIG.9). In some examples, the baffle gap between baffles282varies from one pair of neighboring baffles282to another. During some examples, the lateral baffles282of heater120B operate as was described for lateral baffles182of heater120A, including the interactions described for ray paths or rays191A,191B,192,193,194ofFIG.7. The additional interactions of longitudinal baffles288with radiant energy from lamps160of heater120B will be described with reference toFIG.8. FIG.8shows an end view of the heater120B operating on a receiving surface118B, which may include the surface of a movable platform or a layer of build material previously deposited or most recently deposited. During this discussion, individual lamps160are discussed, but it is understood that the principles that are described also apply to the other lamps160. Lamp160is disposed between the receiving surface118B and the combination of radiant barrier280, which includes lateral baffles282and longitudinal baffles288, and reflector272. During operation, lamp160emits radiant energy290to heat the build material. The radiant energy includes multiple ray paths or rays traveling in multiple directions from surface163of lamp160. Examples of these ray paths or rays are shown and will be discussed. Rays291A,291B are emitted from lamp160and are absorbed by surface118B, after following different paths. Ray291A follows a direct path; whereas, ray291B first travels to reflector270and is reflected down to surface118B where it is absorbed. A ray294A is emitted from a first lamp160toward receiving surface118B, is reflected by surface118B, and is absorbed by a longitudinal baffle288at a second lamp160. A ray294B is emitted from lamp160toward receiving surface118B, is reflected by surface118B, and is absorbed by a longitudinal baffle288at the same lamp160. Rays294A,294B are examples of controlled or eliminated radiation. Thus, a radiant energy absorbing barrier280with radiant energy absorbing longitudinal baffle288is to control emission of radiant energy from a lamp160or heater filament168toward receiving surface118B and to control re-reflection of radiant energy from surface118B. The above discussion is meant to be illustrative of the principles and various examples of the present disclosure. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications. | 26,051 |
11858216 | DETAILED DESCRIPTION The present subject matter provides systems, devices, and methods for solid freeform fabrication for the production of components (e.g., plastic, metal, and ceramic parts) for a variety of applications. In one aspect, the present subject matter provides an imaging device for use in imaging layers of a photocurable material. A common technique for producing an image using a laser to cure layers of resin in an SLA machine is to raster the laser across the build surface with the raster lines beginning and ending at the boundaries of cross sections of the object being built.FIGS.1-2depict a rastering mechanism (150) for use in imaging layers of photocurable resin. As shown inFIGS.1and2, a beam (156) of collimated radiation is emitted by a source (154). The beam (156) enters a prism (158) and is refracted. Upon exiting the prism (158), a second refraction occurs, and the result is a displaced beam (160). The prism (158) in this case is a square section with thickness exceeding the beam (156) diameter, but may in general be a polygon with an even number of parallel faces. In some instances, faces of the prism (158) may not need to be parallel, depending on the desired refraction and displacement behavior. In this embodiment, the prism (158) is rotated by a rotary actuator (162) which causes the displaced beam (160) to raster across the build surface (102). In this way, one or more of prism rastering modules (150) can be translated across the build surface (102) as shown inFIG.2, and bulk imaging can thereby be achieved while the sources (154) are switched on and off according to the cross section being imaged. In some embodiments, the beam displacement capacity of a refractive rastering mechanism is related to the size of the refractive prism being used. In general, the total line width produced by the previously described mechanism will be less than the space occupied by the rotating prism, which presents a geometric challenge when trying to use multiple rastering mechanisms to cover a build area.FIGS.3-10show one possible configuration for an SLA machine, generally designated (10), which overcomes this challenge. In the configuration ofFIGS.3-10, SLA machine (10) includes a build platform (102), a build vat (410), and an imaging system. The build platform (102) lowers into the build vat (410) which contains photocurable resin. A layer of material is imaged, and the build platform (102) moves upwards to allow resin to flow under that layer such that the next layer may be imaged. This process repeats until a component (400) is produced. As previously mentioned, any polygonal prism with an even number of edges may be readily used in a continuous rotation rastering mechanism. In this instance, in the configuration illustrated inFIGS.3-10, two octagonal prisms (414,416) are used. Each prism is used to raster three separate beams. In a multi-beam rastering mechanism, more beams will widen the area that may be imaged by a given prism, but it will also complicate the geometry of mounting and aligning the beam sources. In some configurations, this arrangement will in general increase the optical path length of a given beam source, in particular where sources are mounted further from the prism in order to accommodate all sources within the module, which will in turn increase the precision requirements for the beam sources. The number of beams passed through a given prism can be chosen to provide complete imaging of the build area without putting undue precision requirements on the beam sources. The size of the beams utilized can be configured such that any interference between beams as they pass through these prisms has no effect on the output from each rastering mechanism. In particular, for example, in a configuration designed for producing mesoscale and microscale components, it is not necessary to use a beam diameter that would result in interference between beams within the prism. If such an application is desirable, however, the thickness of the prism can be configured such that it allows the beams to be staggered such that they pass by each other in a skew fashion within the prism without intersection, and without a negative impact on the function of the other components of the module. Referring again to the configuration shown inFIGS.3-10, a first prism (414) can be used to raster a first set of 3 beams from 3 beam sources (430,432,436). A second prism (416) can be used to raster a second set of 3 beams from 3 beam sources (434,438,440). These prisms can be offset such that the three rastering beam patterns from each prism collectively image the entire build region, as will be further explained below. In the illustrated embodiments, rotation of these prisms (414,416) is achieved through a belt and pulley system, but may in general be achieved through any means of rotary actuation. In this instance, a motor (460) drives a pulley (462) which drives a belt (464) which in turn transmits rotary motion to two other pulleys (466,468) which drive the rotation of the prisms (414,416). Angular position of these prisms may be measured by encoders (not depicted) or other electronic angular measurement device. To illustrate the functionality of this laser and prism array, particular attention will be paid to one laser source (440) and the beam it produces (480). This beam (480) is incident upon the second rotating prism (416) and produces an exigent displaced beam (500). The exigent beam (500) is reflected by a mirror (426) such that the reflected beam is aligned substantially vertically. In general, vertical alignment is not strictly required, as long as the six exigent beams are proximately aligned with one another in order to simplify the process of reflecting them with a rotating mirror on to the build surface. The beam (500) is reflected by a second mirror (452) onto a panning mirror array (454). The other five beam sources (430,432,434,436,438) can be subjected to a similar process, with the exception that two exigent beams (496,498) do not require mirrors to achieve vertical alignment, as they are already vertical. In the illustrated configuration, three other mirrors (420,422,424) are used to achieve vertical alignment for three other exigent beams (492,494,490) respectively. The previously mentioned second mirror (452) reflects three of the exigent, vertically aligned beams (494,498,500) onto the panning mirror array (454) while another mirror (450) reflects the remaining three exigent, vertically aligned beams (490,492,496) onto the panning mirror array (454). Each beam will raster over a specified region on the surface of the build vat (410) in order to image part of the build area. In order to image the entire build area, it is desirable to have adjacent raster regions overlap slightly, and this overlap can be corrected in the control software during calibration. This will guarantee the ability to fully image the build area, accounting for the geometric tolerances of the components of the machine. Since two beams (494,500) use mirrors (422,426) to achieve vertical alignment in this configuration, there is no easily achievable configuration in which the edges of these mirrors (422,426) would not interfere with creating an overlap with the raster region defined by the central beam (498) exigent from this prism (416). As such, this configuration has these beams (494,498,500) spaced apart such that the gap between each raster region is slightly narrower than a given raster region. A second set of beams (490,492,496) from the other prism (414) is offset slightly in order to cover these gaps and provide for complete imaging of the build area. The panning mirror array (454) can be actuated by a motor (412) such that its rotation causes the rastering beams to traverse the entire build area. In some embodiments, position data for one or more of the prisms (414,416) and panning mirror array (454) can be measured in real time, used to calculate the positions of each of the six beams (490,492,494,496,498,500), and modulate each source (430,432,434,436,438,440) in order to image the component (400) that is being produced on the build platform (102). In another aspect, the presently-disclosed subject matter provides SFF systems, devices, and methods that form components from a powder composite material combination. Such systems, devices, and methods can be use with any of a variety of imaging systems, including but not limited to the prism rastering systems discussed above.FIGS.11-17depict a powder composite fabrication machine (20) in a first configuration.FIGS.11and12depict this machine (20) in its first position. In some embodiments, machine (20) includes a powder supply chamber (520) which contains a powder supply piston (518) and powdered material (512) for fabricating an object. A build chamber (522) contains a build platform (517) with an internal flow channel (515) and distribution chamber (516) for infusing resin into powder. In some embodiments, a filter (514) can be placed on top of the build platform (517) to prevent powder from flowing backwards into the array of holes on top of the build platform (517). These holes are used to infuse the powder (512) with resin. The powder supply piston (518) is raised to a second position which causes the powder (512) to emerge from the powder supply chamber (520). Powder can be transferred to the build platform (517) by a powder transfer device, such as a roller (510). In some embodiments, this roller (510) may utilize counter-rotation or electrostatic transfer to move powder (512) from the powder supply chamber (520) to the build platform (517). There may be excess powder lost in this process; managing excess powder may be accomplished by any of a variety of means known to those having skill in the art. In addition, although the embodiments shown and described use roller (510) as the powder transfer device, those having ordinary skill in the art will recognize that the concepts disclosed herein are equally applicable with any of a variety of other material delivery/deposition devices known in the art (e.g., a recoater blade, electrostatic powder transfer without a roller). FIGS.14and15depict the machine in a third position, with the powder transfer device (e.g., roller (510)) having been fully actuated to deposit a layer of powder (512) on the build platform (517). In this position, resin can be pumped into the flow channel (515) in the build platform (517) and into the distribution chamber (516) which allows the resin to access all of the holes in the top of the build platform (517). The resin flows through the filter (514) and soaks into the powder (512). A combination of forced flow and capillary effects causes complete infusion of the powder layer. Since this powder layer was produced independently of the resin infusion process, and the resin infusion process is controlled such that it does not significantly impact the density of the powder layer, the density of the powder layer may be determined by the parameters of the powder deposition process, and much higher powder loading densities may be achieved than in existing powder SFF technologies. As shown inFIGS.16and17, the infused layer may be imaged with a programmable planar light source (110), such as a DLP projector, with one or more other optical imaging device, including the refractive rastering system previously described, or with a combination of different light sources. In order to allow the infusion process to continue to subsequent layers, the cross-sectional image that is projected on the first layer of infused powder can be designed to allow the flow of resin to infuse subsequent layers. It can therefore be advantageous that these layers are imaged such that a porous structure is fabricated. If the layer were imaged as a solid cross section, the resulting structure may restrict the flow of resin to subsequent layers. Exemplary imaging processes that are able to achieve such a porous structure will be described below with reference toFIGS.35-38. FIGS.18and19depict a second configuration of the previously described powder composite SFF machine (20). In this configuration, a compressing piston (530) and extension arm (532) are used to densify the powder layer (i.e., to have a density that is greater than a free density after deposition) prior to infusion. Depending on the powder deposition parameters, the ideal density of powder may not be achieved during the deposition process, and additional means of powder densification may be desired. In this instance, the piston (530) is used to compress the deposited powder (512) to increase the volumetric powder loading density of the resulting component. This may improve the properties of the component as they pertain to post-processing, including but not limited to sintering or other thermal and/or chemical treatments. FIGS.20and21depict a third configuration of the previously described powder composite SFF machine (20). In this configuration, an additional powder supply chamber (546) is used; this source (546) provides support powder (542) via a support powder piston (544) whereas the original build powder (512) is only used for the body of the object being built. In this instance, the roller (510) is used as an electrostatic imaging device, depositing build powder (512) and support powder (542) in the appropriate shape to achieve the desired final object. The layer may be infused and imaged as previously described, with possible additional densification as previously described. The advantage of using two powder sources and electrostatic imaging, rather than a single powder source and optical imaging, is that multiple types of powder may be used. For example, it may be desirable to have the build powder be a polymer with desirable properties for investment casting, and to have the support powder be graphite or other high temperature material, such that the printed object can be directly used for investment casting without modification. Further, it may be desirable to use metal powder as the build powder, and graphite or other high temperature material as the support powder, such that the printed object may be placed in a furnace for sintering without additional post-processing or cleaning. The graphite in this instance would continue to support the object during the sintering process, and be readily removable following the sintering process since the resin binder would be burned out during this process. Further, it may be desirable to use a metal powder as the build material, and a non-metallic (e.g., plastic or ceramic) powder as a support material, which would be removed during the debinding process. Further, it may be desirable to use more than two types of powder, such as steel powder for the structure of an object, ceramic powder as an insulator, silicon or other semiconductor powder for functional electronic components, and copper or other metallic powder for conductive pathways. Powder size and composition may be selected such that the green part may be sintered at one sintering temperature; the benefit of this process would be the ability to integrate functional electronic systems into a printed part. It may be desirable to include additives in the resin in some applications. For instance, it may be desirable to include an electrolytic or otherwise conductive additive with the resin, to allow the system to control the electric charge at the build surface. This conductive additive can improve the operation in the implementation of an electrophotographic powder deposition system, for example, particularly if the powder being used is not otherwise electrically conductive. Additionally, it may be desirable to include a surfactant, to alter the wetting properties of the resin mixture as it permeates the powder substrate. This alteration may increase the speed of infusion and expedite the fabrication process overall. FIG.22depicts an algorithmic flow chart which details the powder fabrication process described previously. In general, any mechanism which produces a bulk powder layer, infuses that powder layer in situ in a non-selective manner, images the layer to produce a porous layer that is representative of a cross section of the object being built, and repeats this process until the full object is built, will achieve the benefits previously described. This object may be post processed with additional curing to cure the remaining fluid resin within the porous object to convert it to a solid object. It may also be post processed via a sintering treatment to partially or completely remove the resin binder and partially or completely densify the powder within. If the part is partially sintered, the new porous part may be filled with a tertiary material (e.g., a metal of lower melting point than the powder used in the original part) to create a non-porous final component. FIG.23depicts an algorithmic flow chart which details the additional process of increasing the density of the powder layer in the previously described fabrication method inFIG.21. In general, volumetric powder loading densities of 50-60% are common in pre-fabricated resin/powder mixtures that utilize dispersants to maintain the suspension of powder particles in the resin substrate. However, in powder metallurgy, densities in excess of 80% are commonly targeted in green parts that are intended to be sintered into fully dense final components. Densities greater than 50-60% (e.g., and in some embodiments in excess of 70%) may be achieved with a variety of powder deposition methods that do not involve resin; in order to achieve preferred green part powder loading densities, additional densification of powder layers may be required. In general, it is desirable to achieve as high a particle loading density as possible in the green part that is digitally fabricated. However, this is constrained by the fact that compression of powder particles can cause adhesion, which would interfere with the process of removing excess uncured material from the green part after fabrication. The process of removing excess material may be aided by a variety of methods, including but not limited to agitation, sonication, or treatment with a solvent or other chemical compound. In general, the highest particle loading density that does not correlate with a reduction in ability to remove excess material during post-processing is the most desirable particle loading density. This may be achieved through a variety of means, including but not limited to the previously described powder compression mechanism. In general, compression and infusion parameters may be selected such that one process does not interfere with the other. FIG.24depicts an algorithmic flow chart which details the process of applying build powder and support powder to electrostatically image a layer, followed by infusion and imaging of a porous section to complete the layer fabrication process. Additional densification may be used, and in general the support and build powder may be deposited in any order or simultaneously. As previously described, this enables the use of a wide variety of combinations of powders; additionally, it allows the imaging process to be independent of the part geometry, which may be advantageous in simplifying the imaging process. In general, any light source that can produce an imaging pattern that produces a porous component may be utilized; it does not need to produce an image that conforms to the part being produced, since the part layers are imaged electrostatically during powder deposition. FIG.25depicts a feedback system utilizing a camera (511) or other visual feedback mechanism for capturing images of the powder (512) at the build surface. For some formulations and configurations, as the powder (512) is infused with resin, it will darken in color, which can be detected by the camera (511) in order to validate that the infusion process is complete and uniform. This validation can help to ensure that infusion is completed prior to imaging with an imaging device (110). In the absence of a camera (511), a predefined amount of resin can be infused into the layer of powder (512) which could result in the powder (512) being either over-infused or inadequately infused, depending on the amount and magnitude of error in predicting the required amount of resin. FIGS.26and27depict a component and a method of producing that component using the previously described powder composite SFF methods with an improvement which reduces wasted powder. In the previously described method, all powder within the build area was infused with resin. Once powder is mixed with resin, it may be difficult to reclaim that powder for future use. Many powders, particularly metal and ceramic powders, are very expensive, and in the interest of reducing wasted material and fabrication costs, it is advantageous to limit the amount of powder that is infused with resin during the build process. As in the previously described SFF method, a build platform (602) is utilized which has a resin infusion channel (604) in order to infuse resin deposited on its surface. During this configuration of the build process, a skin (606) is imaged which is solid and does not allow for resin to permeate beyond its boundary. This skin (606) is imaged by digitally modulating the laser modules to produce a solid (ie non-porous) boundary layer. In general, this may be achieved with the mastering mechanism described herein, or may be achieved by utilizing a secondary imaging mechanism, such as a projector or laser galvanometer. The function of the skin (606) is independent of the means of production. This skin (606) starts along the surface of the build platform (602) and restricts which pores of the build platform (602) may supply resin to the object (600) and support structure (610) being fabricated during the build process. In this case, both the object (600) and support structure (610) are porous, in order to allow resin to flow through during the fabrication process. The benefit of using a solid skin (606) during the fabrication process is that there is a significant quantity of un-infused powder (608) which may be reclaimed and used during a subsequent build process. In conventional powder-based production, wherein a laser is used to fuse powder together to build the part, the thermal effects of this fusion process have a negative impact on the utility of the remaining powder. In order for quality to be maintained in subsequent builds, it is often necessary to discard unused powder entirely. Micro-scale metallic powders are very costly, and this method of production allows for the reclamation of a significant amount of unused powder after a build process, thus reducing waste and cost in the production process. Further details of the imaging process used to achieve this result are described inFIGS.41-44. In another aspect, as depicted inFIGS.28-32, the presently-disclosed subject matter provides another method of SFF that may be utilized for producing solid plastic components (ie not powder composite components), which takes advantage of the porous imaging techniques previously mentioned. A component (620) is fabricated on a build platform (602) which utilizes an infusion channel (604) to provide resin for infusion at the build surface. This process can be contained within a build chamber (624) with an imaging access window (626) which is transparent to allow imaging access by any optical imaging system capable of curing the resin that is utilized in the build process, but is chemically impermeable to allow for isolated atmospheric control within the build chamber (624). Similarly to the methods discussed above, the component (620) can be made porous, with a solid skin (622). In contrast to the powder composite structures formed by the previous methods, however, there is no powder, and new layers of liquid resin are produced by pumping resin through the component (610) to the top imaging surface, where a fluid surface forms (628). An advantage of this process is that it expedites the process of producing new layers of resin, since a newly imaged layer is not stuck to the bottom of a build vat, and does not require delamination prior to fabrication of the next layer, as is common in inverted build configurations, as previously described. In this instance, surface tension maintains the liquid layer (628) at the top surface of the component (620) being built; this may affect the geometry of the layer being produced, as will be addressed hereinbelow. FIGS.33and34depict an alternate configuration wherein a secondary support fluid (634) is added to the build chamber (630) via a support fluid port (632). This fluid is generally immiscible with the resin being used, and is of lower density than the resin being used, such that it may prevent overflow of resin from the top of the object (620) being built. Additionally, support fluid may be chosen such that geometric edge effects in the formation of the liquid surface (628) are mitigated. FIG.35depicts a further configuration wherein atmospheric control is utilized to increase the oxygen concentration within the build chamber (630). Dissolved oxygen inhibits free radical polymerization, which is the reaction commonly utilized within photopolymer resins. This additional oxygen creates a polymerization dead zone (638) in which little or no polymerization may occur. Polymerization of a new build layer will thus generally occur only within the active zone (636) of the liquid layer (628). While atmospheric oxygen is adequate to at least partially inhibit polymerization, it may be advantageous to increase oxygen concentration to control the thickness of the active zone and dead zone. In this instance, the support fluid (634) also acts as an oxygen barrier, to negate potential oxygen concentration gradient edge effects in the liquid layer (628). Alternatively, atmospheric oxygen control may also be used in the configuration depicted inFIGS.28-32if it is determined that concentration gradient edge effects will not reduce component precision beyond what is required far the particular application. FIG.36depicts a further configuration where resin is supplied through a build platform (602) to construct a porous part (620) with a solid skin (622). In this case, overflow resin (625) surrounds the part (620). A fill fluid (627) which is immiscible with the resin, which also has desirable viscous, optical, and thermal properties, is supplied through an array of entry ports (621) and exits the build chamber through drainage ports (623). This fill fluid (627) fills the gap between the overflow resin (625) and the imaging window (626). The fill fluid (627) may in some implementations be water, or other fluid with the required properties. In contrast to the support fluid (634) described above, which is selected to have a density that is greater than that of the resin being used, the fill fluid (627) can be selected to have a lower density than that of the resin. In this way, whereas support fluid (634) is designed to occupy much of the space within build chamber (630) around part (620) and prevent resin on the top layer from overflowing, the fill fluid (627) can be used in situations where the build chamber (630) would be mostly filled with resin, and the fill fluid (627) can be designed to flow across the top of the overflow resin (625), which ensures even distribution of new resin on top of the part (620) being built. In addition, in some embodiments, the fill fluid (627) is configured to absorb thermal energy created during the imaging process. During rapid fabrication involving photopolymer resin, a significant amount of heat is created, and this heat can negatively impact the mechanical properties of the part (620) being built. Adding a layer of this fill fluid (627) to act as a coolant for this process mitigates this issue. The particular cooling capacity of a given fluid will vary depending on the thermal interaction between the resin and the cooling fluid; certain fluids may be more suited for certain resins. The choice of cooling fluid should be made in order to optimize cooling effects (lowest interfacial thermal resistance) while also utilizing viscous interactions to assist in resin distribution. While the fill fluid (627) in this image completely fills the gap between the overflow resin (625) and the imaging window (626), in some instances an aft gap between the fluid (627) and imaging window (626) may be acceptable. Generally, the number of optical interfaces through which optical energy must travel in order to image a layer of material is reduced if there is no air gap, and the optical energy is less likely to be disrupted or lose precision if there is no air gap, but depending on the properties of the fluid (627) and the rate at which it flows through the build chamber (624), an air gap may be desirable. In another aspect of the presently-disclosed subject matter,FIGS.37-40depict an alternate configuration using a bottom-up build system, similar to the configuration described inFIGS.3-10. One of the primary challenges with a bottom-up build configuration is the requirement that a cured layer of material be delaminated from the bottom of the build vat before new resin can flow underneath the part for a new layer to be imaged. In this configuration, the bottom of the build vat (410) contains two layers, a rigid transparent window (413) and a flexible transparent window (411) separated from the rigid transparent window by a gap (e.g., an air gap). As a part (603) is withdrawn from the flexible window (411), flexion of the window (411) allows the window to be peeled away from the new layer rather than being pulled away all at once, which can result in a comparatively gentler delamination process. In some embodiments, a pressure sensor (415) can be provided in communication with the gap, and the pressure sensor (415) may be utilized as an indirect measure of the volume of air in the gap between the flexible window (411) and the rigid window (413) in order to determine when the flexible window (411) has returned to its original (i.e., non-deformed) position, and the next layer can be imaged. To further ameliorate the delamination problem, in some embodiments, resin is pumped through the build platform (602) and through the porous part (603) as in previously described configurations, By supplying resin through the part (603), this alleviates the challenge of overcoming viscous resistance when creating new layers of material, which is a significant limiting factor when optimizing the speed of this type of fabrication system. The porous internal structure of the part (603) being fabricated will create a vertical resin pressure gradient, which will result in lower fluid pressure at the build surface, and higher build pressure within the build platform (602). In order to alleviate this pressure gradient, and reduce any stress it may cause to the part (603), one or more additional resin channels (605) may be fabricated during the build process, and removed during post-processing. Even if the vertical pressure gradient cannot be completely diminished, the inclusion of the one or more additional resin channels (605) can be helpful to reduce the pressure to a level that would be unlikely to cause damage to the part (603). The channel (605) depicted here is a hollow resin supply conduit, with negligible resin pressure loss across its height when compared to the pressure gradient normally present in the part (603) being built. This method may in general be applied to any of the previously described methods and configurations for fabricating porous components by supplying resin through a build platform (602). In the aforementioned plastic fabrication methods, a porous part is produced. This part may require post-curing to solidify the remaining fluid resin within it. Alternatively, the remaining liquid resin may be drained, and the part may be filled with another polymer and cured. This polymer may be a photocurable resin, an epoxy resin, or other filler chosen to achieve desired mechanical properties. Additionally, the porosity of this part may be advantageous in an investment casting process, where the burnout properties of the component would be significantly improved by the reduction of material within the component. In another aspect, the present subject matter provides a method for forming an object by solid freeform fabrication. Regardless of the particular kind of SFF process used, a desirable degree of porosity can be achieved by controlling the irradiation of the photocurable materials. In some embodiments, for example, the imaging device used to irradiate the photocurable materials can be activated to image only a selected fraction (e.g., less than 40-70 percent) of the cross section of the object being built. In particular,FIGS.41-44depict a set of raster patterns producible with any of a variety of imaging systems, including the imaging system described inFIGS.3-10.FIG.41depicts a first cure pattern (640) used on a first layer, andFIG.42depicts a second cure pattern (642) used on a second layer. Assuming cure parameters are chosen properly, and build process alternates first (640) and second (642) cure patterns between adjacent layers, the net result will be a lattice structure with greater than 40-60% porosity, allowing for a structurally sound object that will readily allow fluid to flow through it. It should be noted that while the nominal porosity of the cured structure may be greater than 60%, it is desirable to have as low a porosity of the powder substrate as possible, as previously discussed. The combined porosity of the object being built, when this technique is applied to powder composite fabrication, will likely be lower than 15-25%. In general, a higher powder loading density will yield higher quality components, but will inhibit resin flow to a greater degree; it is therefore desirable to utilize a cure pattern which provides the minimal amount of structural integrity necessary for the component to remain intact during the build process and postprocessing, while maximizing cure pattern porosity to reduce resistance to resin flow. FIG.43depicts these cure patterns as applied to the plastic fabrication method described inFIGS.28-32, This method cures a solid skin (652) around a porous interior structure (650). This cure method may be achieved by using one or more programmable light sources, including the system described inFIGS.3-10. Alternatively, any of a variety of other programmable light sources, used individually or in combination together, can be used to achieve a desired cure pattern.FIG.44depicts the application of these cure patterns as applied to the composite fabrication method described inFIGS.26and27. As previously indicated, a porous structure (650) is imaged, with a boundary layer (654) separating the component from a solid skin (652). Lin-infused powder (656) can be preserved for future use. In this instance, the skin acts as a fluid flow conduit along with the boundary layer. If there are overhanging regions in the object being built that would normally require support structure, this may be replaced by fluid flow structures that allow resin to infuse these overhanging regions without attaching any support structure to them. The skin will still control the resin flow to preserve unused powder, and the boundary between the skin and the object being built allows the object to be supported by the surrounding powder (both infused and un-infused) without physical supports that directly connect to the object being built. As a result, the surface of the object will be unmarred by connection points from support material, as is typical in other SLA fabrication processes. The separation of the skin (652) from the object (650) provides additional fluid flow for infusion, and may reduce the amount of post-processing required when cleaning the component prior to sintering or other treatment. FIG.45depicts a cure pattern that may be utilized in any of the powder composite or porous polymer fabrication methods and configurations previously described. In some cases, it may be desirable to produce a component with multiple porous subsections (657,658). Assuming the walls (659) that divide these sections (657,658) are thin enough such that resin flow in subsequent layers is not unduly restricted, this may be implemented without substantially deviating from the previously described fabrication methods and configurations. There are several applications where this imaging method is advantageous. For example, when printing tooling for injection molding, it is often desirable to produce conformal cooling channels to control the temperature of the tooling during the injection process. These porous subsections can be used as conformal cooling channels to improve tooling performance. Further, the previously described methods of infiltrating a component during post-processing can be improved if different mechanical properties are desirable in different sections of a printed component. Porous subsections may be drained of uncured resin and infiltrated with different materials to produce enhanced flexibility, rigidity, toughness, strength, or other physical properties that are desirable for specific regions of a printed part. In the example of printed tooling, a zone may be defined by the interior surface of the tool with a particular thickness; this zone may be constructed as an isolated porous section, which may be filled with heat-resistant material to improve tooling performance, while additional zones beyond this first zone are constructed as conformal cooling channels around this inner zone. FIGS.46and47show the interaction between an infused layer and a second layer during infusion. As previously described, powder particles (660) are deposited on a build platform (602) and infused with resin. Menisci (662) form between these particles (660), which allows for gaps in which more particles may be deposited, but still provides enough resin which may be imaged to bind the powder together in a porous structure. A second layer of powder particles (664) are infused with resin, and new menisci (666) are formed during the process of infusing the second layer. This process is repeated until a complete component is produced. FIG.48shows an alternate method of enabling infusion and imaging of powder layers. If the atmosphere of the build area is controlled such that oxygen levels are raised, a polymerization dead zone forms at each of the menisci (662) in a given layer. This lowers the surface (668) at which polymerization may occur. An advantage of this method is that it allows yet more space for new powder to be deposited without compromising the ability of the system to bind together powder. In this regard, this system can provide stable binding between powder particles in which resin flow is not inhibited, and the arrangement of powder in the built component is homogeneous. This will provide the best possible green part for sintering during post-processing. FIGS.49and50depict an alternate configuration in which powder is directly fused to produce a printed component. In conventional laser sintering applications, a laser galvanometer is utilized to fuse sections of layers of powder to fabricate components, but such systems can typically achieve scanning speeds of less than 10 m/s. It is advantageous in these applications to have higher rastering rates to limit thermal effects which compromise resolution (e.g., weld beads forming during the binding process due to thermal saturation). Since the rastering module (150) previously described is indifferent to the wavelength of energy used, it may be implemented with any wavelength of energy, assuming an appropriate refractive material can be selected for the prism (158). In this implementation, the exigent beam (160) from the rastering module (150) is reflected off of a fixed mirror (670) and onto a panning mirror (674) controlled by a rotary actuator (672), similar to the imaging system described inFIGS.3-10. The resulting beam (676) is subsequently rastered over the powder layer (512) on the build platform, and digitally modulated to image a section of a part. In addition, whereas laser galvanometer systems can typically only achieve scan speeds of less than 10 m/s, the disclosed rastering module (150) can be operated at scan speeds of over 100 m/s while still maintaining very high precision in monitoring the position of the beam. FIG.51describes a method of producing a powder composite green part utilizing any of the previously described methods and configurations. In the previously described methods and configurations, resin is infused into powder through a build platform. The speed of this process is partially dependent on the speed of this infusion process. This speed may be improved by the addition of a Viscosity Reducing Agent (VRA) to the resin. Organic solvents, such as alcohols, may serve this purpose. Ideally, this VRA has a high vapor pressure, such that upon exposure to the build surface, and the heat created during the imaging process, the VRA will evaporate, producing a concentration gradient in which there is a high concentration of VRA in the resin that is contained in the body of a part being printed, and a low concentration of VRA at the build surface. FIG.52describes a second method for producing a green part. In the previously described methods and configurations, a skin and porous internal structure were imaged to construct the green part. In general, it may not be necessary to construct a full porous internal structure; it may be sufficient to construct a skeletal internal structure. As has been previously discussed, the importance of the internal structure of a green part is to provide structural support during the production and post-processing phases; any structure which is adequate to this task, while requiring as little material to be cured as possible, will optimize build time for a given component. In some cases, post-curing may be required to give the green part the required structural integrity to survive the debinding and sintering process. FIG.53describes a third method for producing a green part. This is a further variation on the method described inFIG.52. In this method, only a skin of the part is imaged. An important distinction between this method and previous methods, is that in this case, the “skin” that is imaged is defined such that the internal surface of this skin is the external surface of the part being produced. The process of imaging the skin leaves a significant amount of uncured resin within the part being built. This resin may be drained from or pumped out of the part after the printing process is complete, and the resulting component may be infused with wax or other binding medium. The skin may be removed by chemical treatment, resulting in a green part which contains only powder and the secondary binding medium. This method may be desirable in situations where the burnout properties of the photopolymers are suboptimal. Specifically, many typical photopolymers have measureable ash content remaining after a burnout process when used for investment casting. This ash content is typically measured as a fraction of the original volume of material. Although resins specifically intended for casting purposes may have ash content ratings of roughly 0.1%-0.25%, this may still be considered too high in some situations, in which case the use of a wax or other secondary binding medium may be beneficial. In PIM manufacturing, for example, waxes and other polymers that can be completely removed (i.e., have negligible ash content) during debinding and sintering are typically used. Some photopolymers have been developed with good burnout properties, but none perform as well as the polymers traditionally used in PIM manufacturing; this process takes advantage of the properties of all materials involved. In some implementations, the skin may be imaged as in previous configurations, and need not be removed prior to post-processing. The optimal implementation of this method will depend on the binding and powder materials utilized. FIG.54describes a method of producing a porous part, possibly utilizing the configuration described inFIGS.49and50. Rather than produce a green part, which is bound by a polymer binder, this method utilized direct fusion of powder feedstock to produce a partially sintered porous component. Typically, in laser sintering applications, there are significant internal stresses produced during the sintering process due to the shrinkage undergone by layers of material as they are sintered. By only partially sintering layers of material, these stresses can be largely avoided. This will produce a part that is an arrangement of powder particles only slightly adhered to one another, similar to a brown part produced after debinding a green part as previously described. As such, this part may be post-processed in a similar manner to produce a densified final component. Since this post-processing involves uniform heating, no additional thermal stresses are created during this process. FIGS.55and56describe methods of improving precision in the sintering process that may be applied to any of the aforementioned methods and configurations capable of producing brown parts for sintering. In general, it is desirable to achieve the highest powder loading density possible in a green part. This density is calculated as the volume of powder in a green part relative to the overall volume of the part. This also predicts the amount of shrinkage that will occur during sintering. Higher amounts of shrinkage may distort the part, compromising precision. In general, powder bed infusion methods can readily achieve approximately 60-65% powder loading density. After fabrication and debinding, a brown part is produced. This part may also be produced according to the methods and configurations described inFIGS.49,50, and54. This part can also be approximately 65% volumetrically dense. Multimodal powder, in which the particle size distribution contains multiple peaks, may be used to increase this initial density. Additionally, the density may be increased by subjecting the brown part to a secondary infusion process. In order to increase the powder loading density of the brown part, it may be infused with nanoparticles of the same material as the initial powder used during fabrication. Particles which are small enough to freely flow through the pores left in the brown part may be introduced by flowing a suspension of particles in a liquid carrier into the brown part, or by exposing the brown part to a bath of particles under ultrasonic stimulation to enhance particle fluidity. It should be noted that flowing particles or a liquid suspension of particles over a surface is an abrasive process; in order to preserve the structural integrity of the part, it may be necessary to subject the part to an initial partial sintering process to further bind particles together while maintaining enough porosity to allow for this secondary particulate infusion process. Once the brown part has been partially sintered and infused with particles, its void fraction (the volumetric fraction of non-powder material in the part) may be reduced from approximately 35% to approximately 10-12%, thus reducing the amount of shrinkage required to obtain a densified part and also reducing potential distortion. These methods of adding particulate matter to increase the volumetric fraction of powder in a green part can also have particularly advantageous effects when combined with the previously described method of imaging discrete porous zones within a part during fabrication. For example, isolating different zones in a green part can allow particular sections to be infused with particulate material prior to full sintering to achieve different densities in different regions of the finished part. A part may require a dense skin, but benefit from a porous interior; this may be applied to printed metal tooling with conformal cooling channels built into the interior of the tool. This may also apply to tooling such as drill bits, mill bits, router bits, and such, which would require a fully dense outer surface to form a cutting edge, but may benefit from a somewhat porous interior to allow coolant to be pumped through the tool. In this instance, small porous regions would have to be left as exit ports for the coolant flow, and the net result would be a high performance cutting tool that could be digitally fabricated with arbitrary geometry. In many of the previously described methods, reference has been made to metal and ceramic powders being used as a primary build material, particularly for the fabrication of green parts which can be sintered into partially or fully dense final components. In general, any powder or blend of powders may be utilized, and any resin with the desired flow properties to match the powder or powder blend may be utilized in this build process. Several additional options are described hereinbelow. A blend of plastic and graphite powder may be utilized such that the final product may be self-lubricating in nature. Additionally, blends of metal and graphite powder may be utilized to achieve an end product with similar properties. Blends of plastic and metal powder, wherein the ratio of plastic to metal is in excess of 5:1, may be utilized such that post processing via induction or microwave treatment causes additional fusion of adjacent plastic particles due to heat given off by metal particles. Additional combinations of powder may be used for build powder, and additional combinations of powder may be used as support powder, depending on the desired post-processing steps and desired end product. The present subject matter can be embodied in other forms without departure from the spirit and essential characteristics thereof. The embodiments described therefore are to be considered in all respects as illustrative and not restrictive. Although the present subject matter has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of the present subject matter. | 50,604 |
11858217 | Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present disclosure. DETAILED DESCRIPTION Reference now will be made in detail to exemplary embodiments of the presently disclosed subject matter, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation and should not be interpreted as limiting the present disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope of the present disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents. It is understood that terms such as “top”, “bottom”, “outward”, “inward”, and the like are words of convenience and are not to be construed as limiting terms. As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “a” and “an” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “substantially,” and “approximately,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a10percent margin. Here and throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. As described herein, exemplary embodiments of the present subject matter involve the use of additive manufacturing machines or methods. As used herein, the term “additive manufacturing” refers generally to manufacturing technology in which components are manufactured in a layer-by-layer manner. An exemplary additive manufacturing machine may be configured to utilize any desired additive manufacturing technology. In an exemplary embodiment, the additive manufacturing machine may utilize an additive manufacturing technology that includes a powder bed fusion (PBF) technology, such as a direct metal laser melting (DMLM) technology, an electron beam melting (EBM) technology, an electron beam sintering (EBS) technology, a selective laser melting (SLM) technology, a directed metal laser sintering (DMLS) technology, or a selective laser sintering (SLS) technology. In an exemplary PBF technology, thin layers of powder material are sequentially applied to a build plane and then selectively melted or fused to one another in a layer-by-layer manner to form one or more three-dimensional components. Additively manufactured objects are generally monolithic in nature, and may have a variety of integral sub-components. Additionally or alternatively suitable additive manufacturing technologies include, for example, Fused Deposition Modeling (FDM) technology, Direct Energy Deposition (DED) technology, Laser Engineered Net Shaping (LENS) technology, Laser Net Shape Manufacturing (LNSM) technology, Direct Metal Deposition (DMD) technology, Digital Light Processing (DLP) technology, Vat Polymerization (VP) technology, Stereolithography (SLA) technology, and other additive manufacturing technology that utilizes an energy beam. Additive manufacturing technology may generally be described as enabling fabrication of complex objects by building objects point-by-point, layer-by-layer, typically in a vertical direction; however, other methods of fabrication are contemplated and within the scope of the present disclosure. For example, although the discussion herein refers to the addition of material to form successive layers, the presently disclosed subject matter may be practiced with any additive manufacturing technology or other manufacturing technology, including layer-additive processes, layer-subtractive processes, or hybrid processes. The additive manufacturing processes described herein may be used for forming components using any suitable material. For example, the material may be metal, ceramic, polymer, epoxy, photopolymer resin, plastic, concrete, or any other suitable material that may be in solid, liquid, powder, sheet material, wire, or any other suitable form. Each successive layer may be, for example, between about 10 μm and 200 μm, although the thickness may be selected based on any number of parameters and may be any suitable size according to alternative embodiments. As used herein, the term “build plane” refers to a plane defined by a surface upon which an energy beam impinges during an additive manufacturing process. Generally, the surface of a powder bed defines the build plane; however, prior to distributing powder material across a build module, a build plate that supports the powder bed generally defines the build plane. Exemplary embodiments of the present disclosure will now be described in further detail.FIG.1schematically depicts an exemplary additive manufacturing system100. The additive manufacturing system100may include one or more additive manufacturing machines102. The one or more additive manufacturing machines102may include a control system104. The control system may include componentry integrated as part of the additive manufacturing machine102and/or componentry that is provided separately from the additive manufacturing machine102. Various componentry of the control system104may be communicatively coupled to various componentry of the additive manufacturing machine102. The control system104may be communicatively coupled with a management system106and/or a user interface108. The management system106may be configured to interact with the control system104in connection with enterprise-level operations pertaining to the additive manufacturing system100. Such enterprise level operations may include transmitting data from the management system106to the control system104and/or transmitting data from the control system104to the management system106. The user interface108may include one or more user input/output devices to allow a user to interact with the additive manufacturing system100. As shown, an additive manufacturing machine102may include a build module110that includes a build chamber112within which an object or objects114may be additively manufactured. In some embodiments, an additive manufacturing machine102may include a powder module116and/or an overflow module118. The build module110, the powder module116, and/or the overflow module118may be provided in the form of modular containers configured to be installed into and removed from the additive manufacturing machine102such as in an assembly-line process. Additionally, or in the alternative, the build module110, the powder module116, and/or the overflow module118may define a fixed componentry of the additive manufacturing machine102. The powder module116contains a supply of powder material120housed within a supply chamber122. The powder module116includes a powder piston124that elevates a powder floor126during operation of the additive manufacturing machine102. As the powder floor126elevates, a portion of the powder material120is forced out of the powder module116. A recoater128such as a blade or roller sequentially distributes thin layers of powder material120across a build plane130above the build module110. A build platform132supports the sequential layers of powder material120distributed across the build plane130. The additive manufacturing machine102includes an energy beam system134configured to generate a plurality of energy beams such as laser beams or electron beams, and to direct the respective energy beams onto the build plane130to selectively solidify respective portions of the powder bed136defining the build plane130. As the respective energy beams selectively melt or fuse the sequential layers of powder material120that define the powder bed136, the object114begins to take shape. Typically with a DMLM, EBM, or SLM system, the powder material120is fully melted, with respective layers being melted or re-melted with respective passes of the energy beams. Conversely, with DMLS or SLS systems, typically the layers of powder material120are sintered, fusing particles of powder material120to one another generally without reaching the melting point of the powder material120. The energy beam system134may include componentry integrated as part of the additive manufacturing machine102and/or componentry that is provided separately from the additive manufacturing machine102. The energy beam system134may include one or more irradiation devices configured to generate a plurality of energy beams and to direct the energy beams upon the build plane130. For the embodiment shown inFIG.1, the energy beam system134includes a first irradiation device138and a second irradiation device140. In other embodiments, an energy beam system134may include three, four, six, eight, ten, or more irradiation devices. The plurality of irradiation devise may be configured to respectively generate one or more energy beams that are respectively scannable within a scan field incident upon at least a portion of the build plane130. For example, the first irradiation device138may generate a first energy beam142that is scannable within a first scan field144incident upon at least a first build plane region146. The second irradiation device140may generate a second energy beam148that is scannable within a second scan field150incident upon at least a second build plane region152. The first scan field144and the second scan field150may overlap such that the first build plane region146scannable by the first energy beam142overlaps with the second build plane region152scannable by the second energy beam148. The overlapping portion of the first build plane region146and the second build plane region152may sometimes be referred to as an interlace region154. Portions of the powder bed136to be irradiated within the interlace region154may be irradiated by the first energy beam142and/or the second energy beam148in accordance with the present disclosure. To irradiate a layer of the powder bed136, the one or more irradiation devices (e.g., the first irradiation device138and the second irradiation device140) respectively direct the plurality of energy beams (e.g., the first energy beam142and the second energy beam148) across the respective portions of the build plane (e.g., the first build plane region146and the second build plane region152) to melt or fuse the portions of the powder material120that are to become part of the object114. The first layer or series of layers of the powder bed136are typically melted or fused to the build platform132, and then sequential layers of the powder bed136are melted or fused to one another to additively manufacture the object114. As sequential layers of the powder bed136are melted or fused to one another, a build piston156gradually lowers the build platform132to make room for the recoater128to distribute sequential layers of powder material120. As the build piston156gradually lowers and sequential layers of powder material120are applied across the build plane130, the next sequential layer of powder material120defines the surface of the powder bed136coinciding with the build plane130. Sequential layers of the powder bed136may be selectively melted or fused until a completed object114has been additively manufactured. In some embodiments, an additive manufacturing machine may utilize an overflow module118to capture excess powder material120in an overflow chamber158. The overflow module118may include an overflow piston160that gradually lowers to make room within the overflow chamber158for additional excess powder material120. It will be appreciated that in some embodiments an additive manufacturing machine may not utilize a powder module116and/or an overflow module118, and that other systems may be provided for handling powder material120, including different powder supply systems and/or excess powder recapture systems. However, the subject matter of the present disclosure may be practiced with any suitable additive manufacturing machine without departing from the scope hereof. Still referring toFIG.1, in some embodiments, an additive manufacturing machine102may include a monitoring system162. The monitoring system162may be configured to detect a monitoring beam (not shown) such as an infrared beam from a laser diode and/or a reflected portion of an energy beam, and to determine one or more parameters associated with irradiating the sequential layers of the powder bed136based at least in part on the detected monitoring beam. The one or more parameters determined by the monitoring system162may be utilized, for example, by the control system104, to control one or more operations of the additive manufacturing machine102and/or of the additive manufacturing system100. The monitoring system162may be configured to project a monitoring beam (not shown) and to detect a portion of the monitoring beam reflected from the build plane130. Additionally, and/or in the alternative, the monitoring system162may be configured to detect a monitoring beam that includes radiation emitted from the build plane, such as radiation from an energy beam reflected from the powder bed136and/or radiation emitted from a melt pool in the powder bed136generated by an energy beam and/or radiation emitted from a portion of the powder bed136adjacent to the melt pool. The monitoring system162may include componentry integrated as part of the additive manufacturing machine102and/or componentry that is provided separately from the additive manufacturing machine102. For example, the monitoring system162may include componentry integrated as part of the energy beam system134. Additionally, or in the alternative, the monitoring system162may include separate componentry, such as in the form of an assembly, that can be installed as part of the energy beam system134and/or as part of the additive manufacturing machine102. Referring now toFIG.2, a perspective view of the additive manufacturing machine102fromFIG.1is shown. The first build plane region146represents a portion of the build plane130transecting the first scan field144, and the second build plane region152represents a portion of the build plane130transecting the second scan field150. The breadth of the first scan field144may be defined by a scannable range of the first energy beam142. The breadth of the second scan field150may be defined by a scannable range of the second energy beam148. Such a scannable range may be defined by operability limitations of the energy beam system134and/or quality limitations of objects114formed using the additive manufacturing machine102. For example, energy beam system134may be capable of scanning an energy beam at a maximum angle of incidence. Additionally, or in the alternative, one or more object parameters of an object114may depend on the incidence angle of an energy beam and the resulting energy incident upon the build plane130. In various embodiments, the breadth of the first scan field144and/or the second scan field150may be fixed or adjustable. When additively manufacturing an object114with a plurality of energy beams (e.g., the first energy beam142and the second energy beam148), respective portions of the object114may be formed using respective ones of the plurality of energy beams. In some embodiments, build parameters for the object114may define which portions of the object114are irradiated by the respective energy beams. An object114or a portion of an object114that extends into both the first build plane region146and the second build plane region152will be additively manufactured in part by the first energy beam142and in part by the second energy beam148. An object114or a portion of an object114that extends into the interlace region154may be additively manufactured by the first energy beam142, the second energy beam148, or in part by the first energy beam142and in part by the second energy beam148. Referring now toFIG.3, a top view of an exemplary object slice300is shown. The object slice300is oriented substantially parallel to the build plane130. The object slice300may be embodied in a three-dimensional computer model of an object114to be additively manufactured, such as in a computer aided design (CAD) program. Additionally, or in the alternative, the object slice300may be embodied in a build file (e.g., a two-dimensional build file) executable by an additive manufacturing machine102, such as an additive manufacturing file (AMF), a 3D manufacturing file (3MF), a standard tessellation language file (STL) or the like. The build file may include a series of contours, or slices, that respectively define the portions of a layer of powder material120to be selectively irradiated by the energy beam system134. The object slice300may be superimposed with the build plane130. Respective portions of the object slice may be assigned to one or more of the plurality of irradiation devices, such as the first irradiation device138and/or the second irradiation device140, of the energy beam system134. As shown inFIG.3, the object slice300includes a first contour zone302superimposed with the first build plane region146, and a second contour zone304superimposed with the second build plane region152. A portion of the first contour zone302and the second contour zone304are superimposed with the interlace region154. The interlace region154may be divided by a midline305. The midline305may be determined with reference to the build plane130and/or with reference to an object slice300. For example, the midline may traverse the interlace region154at a position such that a first portion (e.g., 50%) of the interlace region154on a first side of the midline305is adjacent to the first build plane region146, and a second portion (e.g., 50%) of the interlace region on a second side of the midline305is adjacent to the second build plane region152. The first portion of the interlace region154and the second portion of the interlace region154may encompass a substantially symmetric proportion of the build plane130or a substantially asymmetric proportion of the build plane130. Additionally, or in the alternative, the midline305may traverse the interlace region154at a position such that a first portion (e.g., 50%) of an object114on a first side of the midline305is adjacent to the first build plane region146, and a second portion (e.g., 50%) of the object on a second side of the midline305is adjacent to the second build plane region152. The first portion of the object114and the second portion of the object114may encompass a substantially symmetric proportion of the build plane130or a substantially asymmetric proportion of the build plane130. An interlace path306delineates the first contour zone302from the second contour zone304. The first contour zone302may be assigned to the first irradiation device138and/or the first energy beam142. The second contour zone304may be assigned to the second irradiation device140and/or the second energy beam148. The interlace path306may delineate a contour boundary, such as an interlacing boundary, between the first energy beam142and a second energy beam148. The first energy beam142and the second energy beam148may remain on their respective sides of at least a portion of the contour boundary. Additionally, or in the alternative, the first and second energy beams142,148may follow respective contour paths that interlace with one another. In some embodiments, the interlace path306may traverse at least a portion of the object slice300along a route that follows the midline305. Additionally, or in the alternative, the interlace path306may traverse at least a portion of the object slice300along a route that departs from the midline305. The object slice300includes a plurality of contour zones308. The contour zones308represent discrete regions of the object slice300that can be differentiated from one another. The energy beam system134may direct the one or more energy beams along a contour path that traverses respective ones of the contour zones308and/or the discrete regions of the object slice represented by the contour zones308. By way of example, as shown inFIG.3, an object slice300may include a plurality of boundary contour zones310, and a plurality of interior contour zones312. The plurality of boundary contour zones310may define a boundary of the object slice300, such as an outer perimeter314of the object slice300and/or an interior perimeter316transecting the object slice300. The interior contour zones312may represent an interior portion of the object slice300. An interior contour zone312may be delimited by a contour border318and/or one or more boundary contour zones310. As shown inFIG.3, the interlace path306delineating the first contour zone302from the second contour zone304may traverse at least a portion of the object slice300along a route that coincides with one or more contour borders318. Additionally, or in the alternative, the interlace path306may traverse at least a portion of the object slice300along a route that crosses one or more contour zones308. The contour zones308may be differentiated from one another in respect of one or more properties of the respective contour paths followed by respective ones of the one or more energy beams, in respect of one or more properties of the one or more energy beams, and/or in respect of one or more properties of the object114resulting from irradiation by the one or more energy beams. For example, the contour zones308may be differentiated from one another in respect of properties of the respective contour paths such as the timing, sequence, pattern, or combinations of these. Additionally, or in the alternative, the contour zones308may be differentiated from one another in respect of one or more irradiation parameters of the one or more energy beams such as scanning speed, scanning time, beam spot size, energy density, or combinations of these. Further in addition or in the alternative, the contour zones308may be differentiated from one another in respect of one or more object parameters of the object114resulting from irradiation by the one or more energy beams such as energy density, melt pool size, temperature, material density, consolidation pattern, crystalline structure, or combinations of these. By way of example, as shown inFIG.3, the one or more energy beams may follow and/or define a contour path that traverses a contour zone308in a back-and-forth manner in a first direction320, while advancing across a contour zone308in a second direction322. The contour zones308may be arranged in a plurality of rows, as shown inFIG.3, and/or in any other desired orientation. FIG.4shows a portion of an exemplary object slice300, with two exemplary pathways for an interlace path306. The object slice300shown inFIG.4includes a plurality of contour zones308(e.g., one or more interior contour zones312) traversing an interlace region154. Adjacent contour zones308may define respective contour borders318. The plurality of contour zones308may have any desired shape, and may be configured and arranged about the object slice300with any desired manner. As shown, the plurality of contour zones308are configured and arranged as substantially linear strips distributed substantially uniformly across the object slice300. The plurality of contours zones308traverse the interlace region154with an oblique orientation relative to the midline305of the interlace region154. While the respective contour zones308shown inFIG.4appear substantially similar to one another, the contours zones308may additionally or alternatively be dissimilar to one another. For example, the contour zones308may have a uniform, random, or semirandom area. Additionally, or in the alternative, the contour zones308may have linear and/or curvilinear contour borders318. The respective contour zones308include a plurality of contour paths404. A first plurality of contour paths404corresponding to a first contour zone302may be adjacent to a second plurality of contour paths404corresponding to a second contour zone308. The contour border318may be defined by adjacent portions of the first and second plurality of contour paths404. As shown, for example, in a first enlarged view406ofFIG.4, a contour border318may be defined by adjacent portions of a first and second plurality of contour paths404irradiated by a first irradiation device138(FIG.1) assigned to a first build plane region146. An interlace path306may traverse an interlace region154along a route that follows the midline305, along a route that follows and/or defines one or more contour borders318, and/or along a route that traverses one or more contour zones308between respective contour borders318. As shown inFIG.4, the first interlace path306,400traverses at least a portion of the interlace region154along a route that follows the midline305. Also as shown, a second interlace path306,402traverses at least a portion of the interlace region154along a route that follows and/or defines one or more contour borders318. The first interlace path306,400the second interlace path306,402may additionally or alternatively traverse one or more contour zones308(e.g., one or more interior contour zones312). When traversing a contour zone308, an interlace path306may follow a route that corresponds to the midline305and/or a route that diverges from the midline305. An interlace path306may follow a rout that includes a linear trajectory, a curvilinear trajectory, a uniform trajectory, a random trajectory, and/or a semi-random trajectory. As shown inFIG.4, the first interlace path306,400traverses a plurality of contour zones308along a route that follows the midline305. As shown, for example, in a second enlarged view408ofFIG.4, an interlace path306(e.g., the first interlace path400) may be defined by adjacent portion of a first plurality of contour paths404irradiated by a first irradiation device138(FIG.1) and second plurality of contour paths404irradiated by a second irradiation device140(FIG.1) assigned to a second build plane region152. In some embodiments, the interlace path306(e.g., the first interlace path400) may intersect a contour border318. Also as shown inFIG.4, the second interlace path306,402traverses a plurality of contour zones308along a route that diverges from the midline305. The second interlace path306,402traverses a plurality of contour zones308along a route that includes a trajectory perpendicular to one or more contour borders318. In some embodiments, an interlace path306may traverse a contour zone308along a route that follows and/or defines a contour path within the contour zone308. An interlace path306may traverse a plurality of contour zones308along a route that follows and/or defines a contour border318. As shown, for example, in a third enlarged view410ofFIG.4, a contour border318may be defined by an interlace path306(e.g., the second interlace path402) that includes a first plurality of contour paths404irradiated by a first irradiation device138(FIG.1) and second plurality of contour paths404irradiated by a second irradiation device140(FIG.1) assigned to a second build plane region152. An interlace path306may additionally or alternatively traverse a plurality of contour zones308along a route that follows and/or defines a contour border318. As shown, for example, in a fourth enlarged view412ofFIG.4, a contour path404may be defined by an interlace path306(e.g., the second interlace path402) that includes a first plurality of contour paths404irradiated by a first irradiation device138(FIG.1) and second plurality of contour paths404irradiated by a second irradiation device140(FIG.1) assigned to a second build plane region152. Tradeoffs may exist between routing alternatives for an interlace path306. For example, an interlace path306that passes through a contour zone308may influence one or more object parameters of the object114resulting from irradiation by the one or more energy beams such as energy density, melt pool size, temperature, material density, consolidation pattern, crystalline structure, or combinations of these. As another example, a location for an interlace path306may influence one or more irradiation parameters such as scanning speed, scanning time, beam spot size, energy density, or combinations of these. Additionally, or in the alternative, a location of an interlace path306may influence one or more production parameters, such as irradiation time, processing time, allocation of irradiation time and/or processing time between respective irradiation devise of an energy beam system134. An interlace path306that traverses the interlace region154along a route that follows the midline305, such as the first interlace path400, may represent a lowest value across the interlace region154. A lowest value across the interlace region154, such as along the midline305, may minimize the proportion of the interlace region154occupied by an interlace path306, which may minimize and/or balance an effect of the interlace path306on one or more object parameters, one or more irradiation parameters, and/or one or more production parameters. An interlace path306that follows the midline305may correspond to a substantially symmetric allocation and/or a substantially asymmetric allocation of an object slice300between respective irradiation devices of an energy beam system134. For example, the proportion of an object slice300on a first side of the midline305(e.g., the proportion of the object slice300corresponding to the first build plane region146may differ from the proportion of the object slice300on the second side of the midline305(e.g., the proportion of the object slice300corresponding to the second build plane region152. Such a difference in the proportion of the object slice300allocated between the respective irradiation devices may influence one or more production parameters. For example, a difference in the proportion of the object slice300allocated between respective irradiation devices may introducing differences in an allocation of irradiation time and/or processing time between respective irradiation devise of an energy beam system134. Such differences in irradiation time and/or processing time may influence one or more irradiation parameters such as scanning speed, scanning time, beam spot size, energy density, or combinations of these. Such differences in irradiation time and/or processing time may additionally or alternatively influence one or more object parameters of the object114resulting from irradiation by the one or more energy beams such as energy density, melt pool size, temperature, material density, consolidation pattern, crystalline structure, or combinations of these. As another example, an interlace path306that traverses the interlace region154along a route that follows and/or defines a contour border318, such as the second interlace path402, may avoid or prevent an influence by the interlace path306upon one or more irradiation parameters and/or object parameters within the contour zones308adjacent to the contour border318. In some embodiments, an interlace path306that follows and/or defines a contour border318may correspond to a substantially symmetric allocation and/or a substantially asymmetric allocation of an object slice300between respective irradiation devices of an energy beam system134. An asymmetric allocation between respective irradiation devices may influence one or more production parameters and/or one or more irradiation parameters such as scanning speed, scanning time, beam spot size, energy density, or combinations of these. Such an influence on production parameters and/or irradiation parameters may additionally or alternatively influence one or more object parameters of the object114resulting from irradiation by the one or more energy beams such as energy density, melt pool size, temperature, material density, consolidation pattern, crystalline structure, or combinations of these. As yet another example, an interlace path306that traverses a contour zone308along a trajectory that is perpendicular to one or more contour zones308may represent a lowest value across a contour zone308. A lowest value across a contour zone308may minimize the proportion of the contour zone308occupied by an interlace path306, which may minimize and/or balance an effect of the interlace path306on one or more object parameters, one or more irradiation parameters, and/or one or more production parameters. Additionally, or in the alternative, an interlace path306may traverse a contour zone308along a route that follows and/or defines a contour path within the contour zone308. An interlace path306that follows and/or defines a contour path within the contour zone308may avoid or prevent an influence by the interlace path306upon one or more irradiation parameters and/or object parameters within the contour zones308. In some embodiments, it may be advantageous for the interlace path306to follow and/or define a contour border318, for example, because the contour border318would have already existed in the object slice300and, as such, an influence of the interlace path306upon the respective portions of the contour zones308may be minimized or avoided. Additionally, or in the alternative, it may be advantageous for the interlace path306to follow and/or define a contour path within a contour zone308, for example, because the contour path would have already existed in the contour zone308and, as such, an influence of the interlace path306upon the respective portion of the contour zones308may be minimized or avoided. In some embodiments, it may be additionally or alternatively advantageous for an interlace path306to follow a path across an object slice300that provides for a substantially symmetric allocation of the object slice300between respective irradiation devices of an energy beam system134, for example, because a substantially symmetric allocation between the respective irradiation devices may minimize and/or avoid differences in an allocation of irradiation time and/or processing time between respective irradiation devise, which may minimize and/or avoid an influence one or more irradiation parameters and/or one or more object parameters. In some embodiments, as shown, for example, in the enlarged views406,408,410,412ofFIG.4, the individual contour paths that define a contour border318and/or an interlace path306may have a regular and/or an irregular alignment and/or orientation. For example, a contour border318and/or an interlace path306may appear to have an irregular alignment and/or orientation when considered at relatively small scalar dimensions. At such small scalar dimensions, a contour border318and/or an interlace path306may appear to follow a jagged or interlocking path. Additionally, or in the alternative, the contour border318and/or the interlace path306may appear to have a regular alignment and/or orientation when considered at relatively large scalar dimensions. At such large scalar dimensions, a contour border318and/or an interlace path306may appear to follow a relatively uniform linear or curvilinear path. A contour border318and/or an interlace path306may be described with reference to scalar dimensions as appropriate for the context. For example, for purposes of control commands for an irradiation device, contour paths of an irradiation device are generally described with relatively small scalar dimensions corresponding to the precision level of the irradiation device. Additionally, or in the alternative, general characteristics of contour zones308, contour borders318, and/or interlace paths306may be described with relatively large scalar dimensions, such as when describing shapes or patterns of contour zones308, and/or respective portions of an object slice300corresponding to respective build plane regions. The respective contour paths404shown inFIG.4are depicted as straight lines. In some embodiments, the contour paths404may follow a linear or curvilinear path, which may include a substantially straight line. Additionally, or in the alternative, in some embodiments, a contour path404may follow a more complex pathway. As shown inFIG.5A, a contour path404may include a complex pattern500that follows a trajectory502. By way of example, the complex pattern500may include facets with uniform and/or irregular features. In some embodiment, adjacent contour paths404may include overlapping features, such as overlapping facets. For example, a first contour path504and a second contour path506may overlap one another. The first contour path504may include first facets508that overlap with the second contour path506, and/or the first contour path504may include second facets510that extend away from the second contour path506. The second contour path506may include third facets512that overlap with the first contour path504, and/or the second contour path506may include fourth facets514that extend away from the first contour path504. In some embodiments, as shown, for example, inFIG.4, respective contour zones308may be uniformly filled with contour paths404that follow a substantially continuous route. Additionally, or in the alternative, as shown inFIG.5B, a contour zone308may include a combination of irradiation zones550that are designated to receive direct irradiation from an energy beam, and adjacent zones552that are designated to receive indirect radiation. A first contour zone554and a second contour zone556may define an interlace path306and/or a contour border318. The first contour zone554may include a plurality of first irradiation zones558. The plurality of first irradiation zones558may be designated to receive direct irradiation from a first energy beam142(FIG.2). The second contour zone556may include a plurality of second irradiation zones560. When the first contour zone554and a second contour zone556define an interlace path306, the plurality of second irradiation zones560may be designated to receive direct irradiation from a second energy beam148(FIG.2). When the first contour zone554and a second contour zone556define a contour border318, the plurality of second irradiation zones560may be designated to receive direct irradiation from the energy beam142(FIG.2). In accordance with the present disclosure, an additive manufacturing system100may include a control system104configured to define an interlace path306across an interlace region154of an object slice300, and/or to determine one or more contour zones308for an object slice300. An interlace path306and/or corresponding contour zones308may be determined using a route-finding algorithm. Generally, a route-finding algorithm may be is configured to find a route across a zone from a source to a destination. The zone may be characterized as an array of vertices, and the route-finding algorithm may be considered to search the vertices to find a route that satisfies predefined search criteria. For example, a route-finding algorithm may be configured to determine a lowest value search using weighting values assigned to edges that connect adjacent vertices. By way of example, a route-finding algorithm may include and/or be based at least in part on a best-first algorithm (e.g., an A* algorithm), a depth-first algorithm, a breadth-first algorithm, a uniform value algorithm, a greedy algorithm, or combinations of these. An exemplary best-first algorithm may include and/or be based at least in part on Dykstra's algorithm and/or an A* algorithm. An A* algorithm may be configured to select vertices from a search fringe in order of lowest estimated total value for expanding the fringe, where the total value is the sum of values from a source vertex to a destination vertex. An exemplary A* algorithm may include an error-admissible algorithm (e.g., a weighted A* algorithm), an iterative deepening algorithm, a simplified memory bounded algorithm, and so forth. An interlace path306may be determined for one or more object slices300, such as all or a portion of the object slices300corresponding to an object114. At least a portion of a respective object slice300may be divided into a plurality of vertices. For example, an interlace region154of an object slice300may be divided into a plurality of vertices. Weights may be assigned to constituent edges of the respective vertices according to one or more parameters. An interlace path306transecting the interlace region154may be determined for the object slice300. An exemplary depth-first algorithm may be configured to select vertices from a search fringe in order of deepest vertices (e.g., the furthest vertex from the source vertex). An exemplary breadth-first algorithm may be configured to select vertices from a search fringe in order of shallowest vertices (e.g., the closest vertex from the source vertex). An exemplary greedy algorithm may be configured to select vertices from a search fringe in an order of lowest heuristic value for expansion, which may correspond to the vertex estimated to be nearest to a destination vertex. An exemplary uniform value algorithm may be configured to select a lowest value vertices for expansion. In some embodiments, one or more arrays of vertices may be determined. For example,FIGS.6A-6Crespectively depict an array600of vertices602corresponding to an object slice300. The array600may include vertices602for at least a portion of the interlace region154. The vertices602in the respective arrays600may be assigned weighting values corresponding to constituent edges of the vertices602, and the weighting values may be utilized to define an interlace path306across the interlace region154.FIG.6Ashows an array600of vertices602designated by an indicator “i” representing a weighting value of a constituent edge corresponding to one or more irradiation parameters.FIG.6Bshows an array600of vertices602designated by an indicator “o” representing a weighting value of a constituent edge corresponding to one or more object parameters.FIG.6Ashows an array600of vertices602designated by an indicator “p” representing a weighting value of a constituent edge corresponding to one or more production parameters. Weighting values for any one or more of the vertices602may be used to determine the interlace path306. In some embodiments, vertices602designated by an indicator “X” may be ignored or excluded from the route-finding algorithm. For example, these vertices602may correspond to portions of the object slice300outside of the interlace region154, such as portions of the object slice300corresponding to the first build plane region146and/or the second build plane region152. Additionally, or in the alternative, the vertices602designated by an indicator “X” may correspond to a portion of the build plane130located outside of the object slice300, such as portion of the build plane130intended to define a pathway604through the object114. Additionally, or in the alternative, vertices602that that correspond to portions of the object slice300outside of the interlace region154may be included in the route-finding algorithm. In some embodiments, the object slice300may be repositioned relative to the build plane130when the route-finding algorithm determines an interlace path306that includes one or more of such vertices602initially corresponding to portions of the object slice300outside of the interlace region154. The vertices602in the array600may correspond to vertices602in a build file used to define the object114, such as an object slice300. All or a portion of the vertices602may be utilized to define an interlace path306. For example, a selection of vertices602may be utilized. Vertices602selected for inclusion in the array600may correspond to one or more parameters of an object114or one or more object slices300defined by a build file, such as one or more geometric parameters of the object114and/or object slice300. Exemplary geometric parameters may include edges, corners, interior regions, and so forth. Additionally, or in the alternative, vertices602selected for inclusion in the array600may correspond to one or more irradiation parameters defined by a build file, such as such as scanning speed, scanning time, beam spot size, energy density, or combinations of these. Vertices602selected for inclusion in the array600may additionally or alternatively correspond to one or more object parameters defined by a build file, such as one or more object parameters intended to be achieved by the one or more energy beams such as energy density, melt pool size, temperature, material density, consolidation pattern, crystalline structure, or combinations of these. In some embodiments, vertices602selected for inclusion in the array600may include a plurality of vertices602corresponding to points along one or more contour borders318. In some embodiments, vertices602may be selected for inclusion in the array600based at least in part on one or more parameters corresponding an object114that was previously additively manufactured, such as parameters corresponding to a previous iteration of the object114presently to be, or currently being, additively manufactured. Additionally, or in the alternative, vertices602may be selected for inclusion in the array600based at least in part on one or more parameters corresponding to one or more previously irradiated object slices300of an object114being additively manufactured. Vertices602may be selected for inclusion in the array600, additionally or alternatively, based at least in part on one or more parameters corresponding to one or more object slices300of a previous iteration of the object114. The one or more parameters used to select vertices602for inclusion in the array600may include the geometric parameters of the object114or one or more object slices300, the one or more irradiation parameters, the one or more object parameters, and/or the one or more productivity parameters. The one or more parameters may include parameters defined by the build file and/or parameters determined by a monitoring system162(FIG.1). Weighting values may be assigned to respective edges connecting the vertices602selected from the build file. All or a portion of the edges may be assigned weighting values. The weighting values may be assigned based at least in part on an influence on the one or more parameters corresponding to the vertices602in the event that the interlace path306does or does not pass through the respective vertices602. In some embodiments, a relatively high weighting value may correspond to an undesirable influence on a respective parameter. Additionally, or in the alternative, a relatively low weighting value may correspond to a desirable influence on a respective parameter. A relatively intermediate weighting value may correspond to a neutral influence on a respective parameter. The weighting values may be determined parameter information, such as information pertaining to one or more parameters of an object114or object slice300defined by a build file, such as one or more geometric parameters of the object114and/or object slice300. In some embodiments, weighting values may be determined based at least in part on one or more parameters corresponding an object114that was previously additively manufactured, such as parameters corresponding to a previous iteration of the object114presently to be, or currently being, additively manufactured. Additionally, or in the alternative, weighting values may be determined based at least in part on one or more parameters corresponding to one or more previously irradiated object slices300of an object114being additively manufactured. Weighting values may be determined, additionally or alternatively, based at least in part on one or more parameters corresponding to one or more object slices300of a previous iteration of the object114. The one or more parameters used to determine weighting values may include the geometric parameters of the object114or one or more object slices300, the one or more irradiation parameters, the one or more object parameters, and/or the one or more productivity parameters. The one or more parameters may include parameters defined by the build file and/or parameters determined by a monitoring system162(FIG.1). In some embodiments, the vertices602selected from the build file may be determined based at least in part on the weighting values assigned to respective edges. For example, vertices602may be selected from the build file when the weighting values satisfy one or more selection criteria. The one or more selection criteria may be determined such that the vertices602selected from the build file includes those most likely to influence the route-finding algorithm and/or such that the vertices602selected from the build file excludes those least likely to influence the route-finding algorithm. Additionally, or in the alternative, the vertices602selected from the build file may be determined based at least in part on one or more contour paths404of one or more of the plurality of energy beams142,148. For example, vertices602may be selected based at least in part on a distance and/or time along a contour path404, and/or a change in direction and/or a rate of change of a contour path404. Additionally, or in the alternative, vertices602may be selected based at least in part on a distance or time along a contour path404(and/or a change in direction or a rate of change of a contour path404) corresponding to an effectible change (or an effectible rate of change) to an object parameter as a result on a change in an irradiation parameter. For example, vertices602may be selected based at least in part on an effectible change (or an effectible rate of change) to energy density, melt pool size, temperature, material density, consolidation pattern, crystalline structure, or combinations of these. The effectible change (or an effectible rate of change) may depend at least in part on a change (or a rate of change) to one or more irradiation parameters such as scanning speed, scanning time, beam spot size, energy density, or combinations of these. FIGS.7A-7Cshow exemplary graphs700depicting a lowest value path702between vertices602based on the sum of weighting values of constituent edges. A lowest value path702may be utilized to define an interlace path306across an interlace region154, for example, using an array600of vertices602such as those as shown inFIGS.6A-6C. By way of illustration,FIG.7Ashows a graph700with weighting values based on a first criterion,FIG.7Bshows a graph700with weighting values based on a second criterion, andFIG.7Cshows a graph700with weighting values based on a third criterion. In some embodiments, the third criterion used for the weighting values in the graph700shown inFIG.7Cmay include the weighting values based on the first criterion shown inFIG.7Aand the weighting values based on the second criterion shown inFIG.7B. For example, the weighting values in the graph700shown inFIG.7Cmay be a sum of the weighting values based on the first criterion and the weighting values based on the second criterion. For the graph700shown inFIG.7A, a lowest value path702from vertices “A” to vertices “F” passes through vertices “B” and vertices “D”, with a sum of weighting values of 8 (e.g., 1+3+4=8). By contrast, a path from vertices “A” to vertices “F” that passes through vertices “C” and/or vertices “E” would provide a sum of weighting values of at least 16 (e.g., for vertices “C”, 4+5+3+4=16; and for vertices “E”, 4+6+5+4=19). For the graph700shown inFIG.7B, a lowest value path702from vertices “A” to vertices “F” passes through vertices “C” and vertices “D”. The lowest value path702for the graph700shown inFIG.7Bdiffers from the lowest value path702for the graph700shown inFIG.7Cbecause of the difference in weighting values. As shown inFIG.7B, the lowest value path702passing through vertices “C” and vertices “D” has a sum of weighting values of 22 (e.g., 2+4+18=22). By contrast, for the graph700shown inFIG.7B, a path from vertices “A” to vertices “F” that passes through vertices “B” and/or vertices “D” would provide a sum of weighting values of at least 23 (e.g., for vertices “B”, 2+3+15+14=35; and for vertices “D”, 2+4+3+14=23). For the graph700shown inFIG.7C, a lowest value path702from vertices “A” to vertices “F” passes through vertices “C”, vertices “E”, and vertices “D”. The weighting values for the graph700shown inFIG.7Cmay be a sum of the weighting values for the graphs700shown inFIGS.7A and7B. As shown inFIG.7C, the sum of weighting values for the lowest value path702has a sum of weighting values of 42 (e.g., 6+10+8+18=42). By contrast, the sum of weighting values for a path from vertices “A” to vertices “F” that passes through vertices “B” is at least 23 (e.g., 10+18+18=46). As illustrated by the graphs700shown inFIGS.7A,7B, and7C, the lowest value path702from a starting vertices602(e.g., vertices “A”) to an ending vertices602(e.g., vertices “F”) may differs as between the respective weighing values (e.g., as between the graph700shown inFIGS.7A and7B). Additionally, or in the alternative, the lowest value path702from a starting vertices602(e.g., vertices “A”) to an ending vertices602(e.g., vertices “F”) may differs as between a sum of the weighting values relative to the respective weighting values considered individually (e.g., as between the graph700shown inFIGS.7C and7Aand/orFIGS.7C and7B). A lowest value path702may be determined for a multitude of vertices602using a route-finding algorithm. An interlace path306may be based at least in part on a route-finding algorithm, and/or a lowest value path702determined using a route-finding algorithm. An exemplary interlace path (Ip)306may include a sequence of vertices (vi)602, such that Ipwhich=(v1, v2, . . . , vn) in viis adjacent to vi+1 for 1≤i<n, with the interlace path Ip306being of length n−1 from v1to vn. The sequence of vertices vi602that defines the interlace path Ip306across the interlace region154includes edges ei→j704incident to vertices vi706and vj708. In some embodiments, the control system104and/or a route-finding algorithm may be configured to determine one or more route parameters. The route parameters may be utilized to evaluate the performance of a route-finding algorithm, to identify opportunities for improved interlace paths306for objects114and/or object slices300. For example, the control system104and/or a route-finding algorithm may determine and/or maintain an interlace path database that includes data pertaining to lowest value paths702determined by a route-finding algorithm and/or interlace paths306corresponding thereto. The data may be determined on a per object114and/or a per object slice300basis. The data may additionally or alternatively be determined with respect to one or more respective interlace regions154. Statistical parameters may be determined to analyze and/or benchmark performance of the control system104and/or one or more route-finding algorithms. By way of example, a benchmarking parameter may be determined, such as a percentage of surface area of an object114and/or of one or more object slices300irradiated per energy beam, and/or a difference in irradiation time as between respective energy beams. In some embodiments, the benchmarking parameters may include one or more irradiation parameters, one or more object parameters, and/or one or more production parameters. In some embodiments, a route-finding algorithm may be initiated for an object and/or one or more object slices300when a benchmarking parameter exceeds a threshold condition, such as when an actual or expected benchmarking value exceeds a threshold condition. For example, a route-finding algorithm may be initiated when a threshold is exceeded for an actual or expected percentage of surface area irradiated per energy beam, and/or for a difference in irradiation time as between respective energy beams. Referring now toFIG.8, an exemplary interlace path306determined from an array600of vertices602using a route-finding algorithm is shown. The array600of vertices602may correspond to an object slice300. The array600of vertices602includes a plurality vertices602identifiable by their respective coordinates in the array600. For example, a first vertex800may be located at coordinates (I,3) and a second vertex802may be located at coordinates (E,12). As shown, the interlace path306traverses an interlace region154of an object slice300from a source border804to a destination border806. The sequence of vertices (v1, v2, . . . , vn)602in the interlace path Ip306may include a source vertex710and a destination vertex712. The interlace path306may begin at the source vertex710and/or may end at the destination vertex712. A possible interlace path306follows constituent edges ei704such that Ip=(ev1→v2, ev2→v3, evn-1→vn). The constituent edges ei→j704may be weighted according to a function w(p)=Σ1≤i≤nw(ei). Over a set of k possible interlace paths306, a selected interlace path306may provide a minimum sum of edge weights, such that Ip=w(p). When the respective edges704have an identical weighting (e.g., when the respective edges ei→j704are weighted according to a function w(e)→{1}), the interlace path306may be the path that has the fewest edges. The source vertex710may have a defined or variable position. For example, the source vertex710may be located anywhere along a source border804of the interlace region154. The destination vertex712may have a defined or variable position. For example, the destination vertex712may be located anywhere along a destination border806of the interlace region154. In some embodiments, an interlace path306may be determined from a fixed source vertex710and a variable destination vertex712. The interlace path306may follow the lowest weighted path from the fixed source vertex710on the source border804to a plurality of destination vertices712along the destination border806. The destination vertex712that provides the lowest weighted path from the fixed source vertex710may be selected for the interlace path306. In some embodiments, an interlace path306may be determined from a variable source vertex710and a fixed destination vertex712. The interlace path306may follow the lowest weighted path from a plurality of source vertices710on the source border804to the fixed destination vertex712along the destination border806. The source vertex710that provides the lowest weighted path to the fixed destination vertex712may be selected for the interlace path306. In some embodiments, an interlace path306may be determined from a variable source vertex710and a variable destination vertex712. The interlace path306may follow the lowest weighted path from a plurality of source vertices710on the source border804to a plurality of destination vertices712along the destination border806. The source vertex710and the destination vertex712that provide the lowest weighted path may be selected for the interlace path306. As shown inFIG.8, vertices602near a border808of the interlace region154may have relatively higher weighting values. Additionally, or in the alternative, vertices602within a middle region of a contour zone308may have relatively intermediate weighting values. Vertices602along a contour border318may additionally or alternatively have relatively lower weighting values. Further additionally or alternatively, vertices602near a boundary of the object slice300, such as a boundary defining a pathway604through the object slice300, have relatively higher weighting values, such as relatively higher weighing values as compared to a border808of the interlace region154. By way of illustration, vertices602near a border808of the interlace region154are shown inFIG.8with weighting values of 7, vertices602within a middle region of a contour zone308are shown inFIG.8with weighting values of 5, vertices602along a contour border318are shown inFIG.8with weighting values of 1, and vertices602along a boundary defining a pathway604through the object slice300are shown inFIG.8with weighting values of 9. Vertices602along a contour border318as between the boundary defining the pathway604and the adjacent contour zone308have weighting values of 3. Using the weighting values shown inFIG.8, a lowest value path810traversing the interlace region154begins at a source vertex710located at coordinates (I,1) and ends at a destination vertex712located at coordinates (E,16). The lowest value path810may be selected as the interlace path306. Beginning from the source vertex710at coordinates (I,1), the lowest value path810follows a contour border318to the vertex at coordinates (F,5), at which point the lowest value path810traverses a contour zone308. At coordinates (F,8), the lowest value path810routes around relatively higher-weighted vertices602surrounding a pathway604, following a contour border318from coordinates (F,8) to (H,8) and from (H,8) to (H,11). The lowest value path810intersects an additional contour border318at coordinates (H,12), which gives the lowest value path810to the destination vertex712. It will be appreciated that the lowest value path810may reflect a balance between a plurality of criteria, such as one or more irradiation parameters, one or more object parameters, and/or one or more production parameters. Any suitable route-finding algorithm may be used to define an interlace path306. In some embodiments, an interlace path306may be determined based at least in part on a route-finding algorithm that utilizes one or more features of Dijkstra's algorithm, which provides data structure may be defined for storing and querying partial solutions sorted by distance from the source vertex710. FIG.9shows a flowchart depicting an exemplary method900of defining an interlace path306. At block902, an initial vertex vi602is defined. The initial vertex vi602may be located at an outer perimeter314of the object slice300(FIG.3) somewhere within the interlace region154. The initial vertex vi602may be a source vertex710. At block904, a subsequent vertex602is defined. The subsequent vertex602may be a destination vertex712. At block906, an initial lowest value may be assigned for a path from the initial vertex602, such as the source vertex710, to the subsequent vertex602, such as the destination vertex712. In some embodiments, at block908, the route-finding algorithm may assign weighting values to constituent edges corresponding to one or more vertices602in an array600of vertices602(v1, v2, . . . , vn). Additionally, or in the alternative, weighting values may have previously been assigned. The array600of vertices602may include the initial vertex vi602and the subsequent vertex602. At block910, the route-finding algorithm may determine a path across the array600of vertices602from the initial vertex vi602to the subsequent vertex602that has a lower value than the initial lowest value. When the route-finding algorithm determines such a lower value, at block912, the route-finding algorithm designates the determined path as the lowest value path702,810. At block914, an interlace path306may be determined based at least in part on the lowest value path702,810. Additionally, or in the alternative, at block914, the lowest value path702,810may be designated as the interlace path306. Additionally, or in the alternative, the route-finding algorithm may return to block910, and again look for a path from the initial vertex to the subsequent vertex602that has a lower value than current lowest value path702,810. In some embodiments, the route-finding algorithm may return to block902, and a different initial vertex602may be defined. Additionally, or in the alternative, the route-finding algorithm may return to block904, and a different subsequent vertex602may be defined. In some embodiments, all vertices602may be initially marked as unvisited. The route-finding algorithm may define an unvisited set of vertices602that includes the unvisited vertices602. One or more of the unvisited vertices602may be assigned a tentative weighting value. The initial vertex vi602may be set to zero. The unvisited vertices602may be set to infinity. The initial vertex vi602may be set to the current vertex602. For the current vertex602, the route-finding algorithm may consider one or more unvisited vertices602neighboring the current vertex602and determine their tentative weighting values through the current vertex602. The tentative weighting values may be compared to the current assigned value and assign the smaller one. For example, if the current vertex602is set to zero, and the edge connecting the current vertex602with a neighboring vertex602(e.g., vertex “C” inFIG.7C) has a weighting value of 6, then the weighting value through vertex “B”602from the current vertex602will be 0+6=6. If vertex “B” was previously marked with a weighting value greater than 6, the weighing value for vertex “B” may be changed to 6. Otherwise, the current value for vertex “B” may be retained. For example, vertex “B” may be changed from an initial value of infinity to a value of 6. When at least some of the neighboring vertices602to the current vertex602have been checked (e.g., when all of the neighboring vertices602have been checked), the current vertex602may be marked as visited and removed from the unvisited set. Vertices602marked as visited may be labeled with the lowest value path810from the initial vertex. In some embodiments, it may be unnecessary to check a visited vertex602again after it has been checked and removed from the unvisited set. For example, a checked vertex may never be checked again. Once at least some (e.g., all) of the neighboring vertices602to the current vertex602have been checked, an unvisited vertex602with the smallest tentative distance may be set as the new current vertex602, and neighboring vertices602to the new current vertex602may be checked. The route-finding algorithm may continue updating neighboring vertices602with respective lowest values, marking then-current vertices602as visited, and moving onto a next unvisited vertices602until the destination vertex712has been marked as visited. The route-finding algorithm may conclude when the destination vertex712has been marked visited. For example, the destination vertex712may eventually be marked visited and the route-finding algorithm thereafter concluded when determining a route between two specific vertices602, such as a source vertex710and a destination vertex712. Once the destination vertex712has been marked as visited, the lowest value path810to from the initial vertex vi602to the destination vertex712is determined or determinable. For example, the lowest value path810may be traced from the destination vertex712back to the initial vertex vi602. Additionally, or in the alternative, the route-finding algorithm may be concluded when the smallest tentative distance among vertices602remaining in the unvisited set is infinity. For example, the smallest tentative distance among vertices602remaining in the unvisited set may be infinity when determining a complete traversal of an array600and/or when there is no connection between the initial vertex602and remaining unvisited vertices602. In some embodiments, a lowest value path810may be determined prior to the destination vertex712having been visited. For example, the route-finding algorithm may be concluded when the destination vertex712has the smallest tentative distance among all unvisited vertices602, since the destination vertex712could then be selected as the next current vertex602. In some embodiments, the route-finding algorithm makes no attempt of directional exploration towards the destination vertex712, but rather, the next current vertex602may be determined solely or at least in part based on the weighted value (or tentative weighted value) from the source vertex710. This route-finding algorithm may therefore expand outward from the source vertex710, considering every vertex602that provides a lower value path until reaching the destination vertex712. As such, the route-finding algorithm may be configured to necessarily find the lowest value path810. However, in some embodiments, the processing time required to find the true lowest value path810may be impractical. Accordingly, in some embodiments, the route-finding algorithm may include one or more features that may provide a reduced processing time. In some embodiments, a library of visited vertices602may be maintained. The route-finding algorithm may utilize the library of visited vertices602in lieu of reprocessing the visited vertices602when additively manufacturing an object114. The library of visited vertices602may be updated as one or more vertices are visited. When additively manufacturing an object114in a first instance, a route-finding algorithm may be limited to a maximum processing time and the tentative lowest value path810as of the expiration of the maximum processing time may be taken as the lowest value path810and/or may be designated as the interlace path306for the first instance. A first portion of vertices602may be visited when additively manufacturing an object114in the first instance, with a second portion of vertices602remaining unvisited. The first portion of vertices602may be added to the library of visited vertices602. A next instance when the object114is additively manufactured, the route-finding algorithm may visit a third portion of vertices602, and the third portion of visited vertices602may be added to the library of visited vertices602. The third portion of visited vertices602may be a subset of the second portion of visited vertices602. Over a series of instances of additively manufacturing an object114, the library of visited vertices602may grow and the lowest value path810and/or the interlace path306may be refined. Additionally, or in the alternative, a library of similar visited vertices602may be maintained. When processing a first object slice300, a route-finding algorithm may be limited to a maximum processing time and the tentative lowest value path810as of the expiration of the maximum processing time may be taken as the lowest value path810for the first object slice300and/or may be designated as the interlace path306for the first object slice300. A first portion of vertices602may be visited when processing the first object slice300, with a second portion of vertices602remaining unvisited. A subsequent object slice300may have a plurality of similar vertices602relative to a preceding object slice300, such as the first object slice300. The first portion of vertices602visited by the route-finding algorithm may be added to the library of similar visited vertices602. For example, vertices602from among the first portion of vertices602that have respective similar vertices602in a subsequent object slice300may be added to the library of similar vertices602. When processing the subsequent object slice300, the route-finding algorithm may utilize the values from the library of similar vertices602. The respective similar vertices602of the subsequent object slice300may be marked as visited and the route-finding algorithm may utilize the weighting values from the library of similar vertices602without visiting the corresponding similar vertices602in the subsequent object slice300. When processing the subsequent object slice300, the route-finding algorithm may visit a third portion of vertices602, and the third portion of visited vertices602may be added to the library of similar visited vertices602. Over a series of object slices300, the library of similar visited vertices602may grow and the lowest value path810and/or the interlace path306may be refined. In some embodiments, a priority queue may be utilized. Vertices602that satisfy one or more prioritizing criterion may be added to the priority queue. The route-finding algorithm may visit vertices602in the priority queue before visiting other vertices602. Additionally, or in the alternative, the route-finding algorithm may visit vertices602in order of priority. By way of example, vertices602may be assigned a priority based on weighting value and/or a location within an object slice300. A vertex602may be assigned a priority based at least in part on whether the vertex602is located along a contour border318or within a contour zone308. A vertex602within a contour zone308may be assigned a priority based at least in part on whether the vertex602is located within an interior contour zone312or a boundary contour zone310. Vertices602located along a contour border318may be prioritized over vertices602located within a contour zone308. Additionally, or in the alternative, vertices602may be prioritized over one another based at least in part on their respective proximity to a contour zone308and/or their respective proximity to an outer perimeter314and/or an interior perimeter316. Vertices602may be prioritized over one another based at least in part on their respective proximity to a source vertex710and/or a destination vertex712. Further, vertices602may be additionally or alternatively prioritized over one another based at least in part on their respective proximity to a midline305and/or a border808of an interlace region154. As another example, vertices602may additionally or alternatively be prioritized over one another based at least in part on their relative proximity to an interlace path306determined for a preceding object slice300and/or for a previous object114. In some embodiments, a route-finding algorithm may utilize one or more heuristic functions h(n) to define an interlace path306. The heuristic function may be configured to estimate the lowest value path810from a current vertex602to a destination vertex712. A heuristic function may be configured to allow a route-finding algorithm to visit vertices602that are considered to have a higher likelihood of leading to a lowest value path810. For example, one or more heuristic functions may be utilized to approximate one or more aspects of a lowest value path810. A heuristic function may trade optimality, completeness, accuracy, or precision for processing time. By way of example, a best-first search algorithm (e.g., A* algorithm) may be configured to utilize one or more heuristic functions h(n). In an exemplary embodiment, the route-finding algorithm may include an A* algorithm. The route-finding algorithm may be configured to define an interlace path306that minimized the function f(n)=g(n)+h(n), where n is the current vertex602on a path, h(n) is a heuristic function, g(n) is the actual value of the path from a source vertex710to the current vertex602. The route-finding algorithm may maintain a tree or heap of paths originating at the source vertex710and extend the respective paths one edge at a time until a termination criterion is satisfied. The route-finding algorithm may determine which of the paths to extend based at least in part on the value of the path g(n) and a heuristic function h(n) configured to estimate the value required to extend the path all the way to the destination vertex712. The route-finding algorithm may terminate when the path chosen to extend, when minimizing the function f(n)=g(n)+h(n), is a path from the source vertex710to the destination vertex712, and/or if there are no paths eligible to be extended. A priority queue may be utilized to perform the repeated selection of minimum (estimated) value paths to expand. At respective step of the algorithm, the vertex602with the lowest f(n) value may be removed from the queue for processing. The f(n) and g(n) values of its neighboring vertices602may be updated accordingly, and these neighbors are added to the queue. The route-finding algorithm may continue until a goal vertex602has a lower f(n) value than any vertex602in the queue and/or until the queue is empty. The route-finding algorithm may keep track of the path to each vertex602from its predecessor on the lowest value path810, for example, so that the route-finding algorithm may output the actual sequence of vertices602for the lowest value path810. The destination vertex712may point to its predecessor vertex602, and each sequential predecessor vertex602may point to its predecessor, until a vertex602points to the source vertex710. The heuristic function h(n) may include a heuristic interlace path and/or a heuristic contour zone. As an example, the heuristic interlace path may be determined based at least in part on an interlace path306for a previous object slice300and/or an interlace path306for a previously manufactured object114. Additionally, or in the alternative, the heuristic interlace path may include, and/or may be determined based at least in part on, a midline305and/or a contour border318. The heuristic interlace path may, additionally or alternatively, include and/or be based at least in part on a shortest distance between the source vertex710and the destination vertex712. The heuristic function h(n) may improve the route-finding algorithm's convergence on a lowest value path810, while maintaining correctness, when the heuristic function h(n) is admissible. A heuristic function h(n) is admissible when h(n)>g(n) for every vertex602, which means an admissible heuristic function h(n) never overestimates the true lowest value path810to a vertex602, such as a destination vertex712. Rather, an admissible heuristic function underestimates the actual value of the lowest value path810. For an admissible heuristic function, h(n)=0 at the destination vertex712. When a heuristic function h(n) underestimates the true lowest value path810, the route-finding algorithm can be configured to utilize the heuristic function h(n) in a manner that is guaranteed to find the actual lowest value path810. With a non-admissible heuristic, a route-finding algorithm might return a lowest value path810that is not the actual lowest value path810. An admissible heuristic may include and/or be based at least in part on a relaxed description of an estimated lowest value path810. In some embodiments, an admissible heuristic may utilize and/or be based at least in part on a pattern database that stores exact solutions to partial paths within the lowest value path810. Additionally, or in the alternative, an admissible heuristic may utilize and/or be based at least in part on one or more inductive learning methods. In addition to being admissible, in some embodiments, the heuristic function h(n) may be consistent. A heuristic function h(n) is consistent when, for every vertex602and each successor vertex602, the heuristic value upon reaching a destination vertex712is less than or equal to the sum of the incremental value upon reaching the successor vertex602and the heuristic value of reaching the destination vertex712from the successor vertex602. A consistent heuristic function h(n) satisfies the following criteria: h(n)≤k(n,n′)+h(n′) AND h(d)=0, where h(n) is the heuristic value from a vertex to a destination vertex, k(n,n′) is the incremental value from the vertex to a successor vertex, h(n′) is the heuristic value from the successor vertex to the destination vertex, and h(d) is the heuristic value at the destination vertex. When a heuristic function h(n) is consistent, the route-finding algorithm can be configured to utilize the heuristic function h(n) in a manner that is guaranteed to find the actual lowest value path810without processing any vertex602more than once. A consistent heuristic is also an admissible heuristic. When a route-finding algorithm utilizes a consistent heuristic, the value of a solution path to a vertex602is the lowest possible value under the criteria considered by the route-finding algorithm. In some embodiments, admissible criteria for a heuristic function h(n) may be relaxed such that a solution path determined by a route-finding algorithm is no worse than (1+ε) times the lowest value solution path. Such a relaxed heuristic function may be referred to as being ε-admissible, or as an ε-admissible heuristic function. While an admissible heuristic function h(n) returns a solution path that is the lowest value path810, equally meritorious paths may exist. In some embodiments, it may be undesirable for a route-finding algorithm to consume additional processing time considering equally meritorious paths. The admissible criterion can be relaxed using an ε-admissible heuristic to reduce processing time while still assuring that the solution path is no worse than (1+ε) times the lowest value path810. The route-finding algorithm may additionally or alternatively utilize a memory-bounded search function and/or a pruning function. For example, a route-finding algorithm may utilize an Iterative deepening A* (IDA*) function and/or a memory bounded A* function such as a Simplified Memory Bounded A* (SMA*) function. A route-finding algorithm that utilizes an IDA* function may at each iteration, perform a depth-first search, and then prune a branch when its total value f(n)=g(n)+h(n) exceeds a threshold. The threshold may initially be an estimate of the value at an initial state. The threshold may increase for each iteration of the route-finding algorithm. At each iteration, the threshold used for the next iteration may be the minimum value of all values that exceeded the current threshold. A route-finding algorithm that utilizes an SMA* function may prune vertices602when expansion has revealed a less promising value than expected. An SMA* function may allow the route-finding algorithm to explore branches and backtrack to explore other branches. In some embodiments, a route-finding algorithm may be configured to utilize one or more contraction hierarchies. A contraction hierarchy may be configured to allow the route-finding algorithm contract (e.g., reduce) the number of vertices602to be processed between a source vertex710and a destination vertex712. A contraction hierarchy may be based at least in part on hierarchies of various portions of an object slice300, such as contour zone308(e.g., boundary contour zones310and/or interior contour zones312), contour borders318, outer perimeters314, and/or interior perimeter316. A contraction hierarchy may include a preprocessing phase and/or a query phase. Iterative contractions may be performed during the preprocessing phase, with a contraction candidate vertex, v, temporarily removed from the graph and a shortcut created between neighboring vertices {vu, vw} when a witness search reveals that a lowest value path810from vuto vwincludes the contraction candidate vertex, v. The contraction, or shortcut, reduces the number of edges in the graph. Bottom-up or top-down heuristics may be utilized to determine an order in which vertices602are considered for contraction. A bottom-up heuristic may select a next contraction candidate vertex602after the previous contraction has been completed. The next contraction candidate vertex602may be selected based at least in part on the net number of edges added when contracting a vertex602. The bottom-up heuristic may seek to minimize the number of shortcuts by reducing the number of edges in the graph, for example, by maintaining a counter for a plurality of vertices602and incrementing the counter when a neighboring vertex602is contracted, with vertices602that have a lower counter value being prioritized over vertices602width higher counters. A top-down heuristic may utilize a vertex602ordering that has been precomputed before performing contractions. The vertices602may be ordered based at least in part on one or more nested dissections. A nested dissection may be used to determine how many potential lowest value paths810utilize a given vertex602. Vertices602that are needed for a larger number of potential lowest value paths810may be prioritized over those needed for a smaller number of potential lowest value paths810. By way of example, vertices602located along contour borders318may be prioritized over vertices602located within contour zones308. A contraction hierarchy may preprocess at least a portion of the vertices602between adjacent contour borders318, such as between adjacent interior contour zones312, and/or from a contour border318between an boundary contour zone310and an interior contour zone312to an adjacent contour border318. Additionally, or in the alternative, a contraction hierarchy may preprocess at least a portion of the vertices602between an outer perimeter314and an adjacent contour border318, and/or between an interior perimeter316and an adjacent contour border318. At the query phase of a contraction hierarchy, a bidirectional search may be performed. The bidirectional search may start from a source vertex710and a destination vertex712on the original graph, as augmented by the contractions created in the preprocessing phase. Following the query phase, the route-finding algorithm may determine the lowest value path810by recursively unpacking respective contracted vertices602in the contraction hierarchy. In some embodiments, a highest priority vertex602on the lowest value path810between a source vertex710and a destination vertex712may be the source vertex710, the destination vertex712, or a vertex602with higher priority than both the source vertex710and the destination vertex712. As such, a vertex, v, that minimizes the sum of: f(vs,v)+f(v,vd) may be included on the lowest value path810from the in the original graph, where f(vs,vu) is the value of the source vertex, vs, to the vertex, v, and f(vu,vd) is the value from the vertex, v, to the destination vertex vd. When the sum of: f(vs,v)+f(v,vd) is minimized, the following equality is satisfied: f(vs,v)+f(v,vd)=f(vs,vd). As a result, both directions of the bidirectional search may contract only those edges leading to higher priority vertices602in the hierarchy, which allows for a relatively small search space. By way of example, in some embodiments, a source vertex710may be located at a first outer perimeter314, a destination vertex712may be located at a second outer perimeter314, and a higher priority vertex may be located at a contour border318between the source vertex710and the destination vertex712. Additionally, or in the alternative, a source vertex710may be located at a first contour border318, a destination vertex712may be located at a second contour border318, and a higher priority vertex602may be located at a contour border318between the first contour border318and the second contour border318. In some embodiments, the first contour border318may be adjacent to a first outer perimeter314, and/or the second contour border318may be adjacent to a second outer perimeter314. In some embodiments, a route-finding algorithm may utilize heaps and/or trees. A heap is a tree-based data structure in which all the vertices602of the tree have a specific order. If there are N vertices602in a queue, and each vertex602has a respective weight, a heap may be used to prioritize the N vertices602in the queue, such that higher priority vertices602will be visited before others. As vertices602are visited, neighboring vertices602may be added to the heap. A lowest weight tree may be used to traverse vertices602in the interlace region154. Heap may be used to store the vertices602not yet included in the lowest weight tree. For example, a minimum heap may be used as a priority queue to get the minimum weight vertex602from the set of vertices602not yet included in the lowest weight tree. One or more heaps may be assigned to particular portions of interlace region154, such as to resolve particular portions of concern. Any desired implementation of a heap may be utilized, including a binary heap, a binomial heap, a Fibonacci heap, and so forth. In some embodiments, one or more heaps may be utilized in combination with a contraction hierarchy. In some embodiments, a route-finding algorithm may perform a search, such as a multi-directional search from a plurality of vertices602, of one or more heaps. For example, a multi-directional search may be performed using a plurality of heaps and/or contraction hierarchies respectively corresponding to a plurality of contour borders318. Binomial heaps and/or mergeable heaps may be utilized, for example, to allow pairs of heaps to be merged together. By way of example, a heap may be assigned to a boundary contour zone310and/or an interior contour zone312adjacent to the boundary contour zone310. Such a heap may be utilized, for example, to determine a source vertex710and/or at least a portion of a lowest value path810between a source vertex710and a vertex602corresponding to a contour border318adjacent to the boundary contour zone310corresponding to the destination vertex712. Additionally, or in the alternative, a heap may be utilized to determine a destination vertex712and/or at least a portion of a lowest value path810between a destination vertex712and a vertex602corresponding to a contour border318adjacent to the boundary contour zone310corresponding to the destination vertex712. In some embodiments, a heap may be utilized to determine at least a portion of a lowest value path810between adjacent contour borders318and/or intersecting contour borders318. A heap may additionally or alternatively be utilized to determine a810around feature of an object slice300that may be designated as non-traversable interlace path306and/or a feature of an object slice300designated as preferentially avoided by an interlace path306. For example, a heap may be utilized to determine a lowest value path810around a boundary contour zone310delimited by an interior perimeter316. Now turning toFIGS.10A and10B, another exemplary build plane1000is shown that includes a plurality of interlace regions154. The build plane1000shown inFIGS.10A and10Bmay correspond to an additive manufacturing system100and/or an additive manufacturing machine102that is configured to irradiate a build plane1000with at least two energy beams and/or with at least four energy beams. The build plane1000shown inFIG.10Aincludes a first interlace region1002, a second interlace region1004, a third interlace region1006, a fourth interlace region1008, and/or a fifth interlace region1010. The first interlace region1002represents the overlapping portion of a first build plane region1012and a second build plane region1014. The first build plane region1012corresponds to a scan field of a first energy beam from a first irradiation device. The second build plane region1014corresponds to a scan field of a second energy beam148from a second irradiation device140. The second interlace region1004represents the overlapping portion of the second build plane region1014and a third build plane region1016. The third build plane region1016corresponds to a scan field of a third energy beam from a third irradiation device. The third interlace region1006represents the overlapping portion of the third build plane region1016and a fourth build plane region1018. The fourth build plane region1018corresponds to a scan field of a fourth energy beam from a fourth irradiation device. The fourth interlace region1008represents the overlapping portion of the fourth build plane region1018and the first build plane region1012. The fifth interlace region1010represents the overlapping portion of the first build plane region1012, the second build plane region1014, the third build plane region1016, and the fourth build plane region1018. In some embodiments, an interlace path306may be determined for the first interlace region1002, the second interlace region1004, the third interlace region1006, the fourth interlace region1008, and/or the fifth interlace region1010. For example, as shown inFIG.10B, an object slice300may overlap a plurality of interlace regions (e.g., the first interlace region1002, the second interlace region1004, the third interlace region1006, the fourth interlace region1008, and/or the fifth interlace region1010). An object slice300may include a plurality of segments. For example, as shown inFIG.10B, an object slice300may include a first segment1050, a second segment1052, a third segment1054, and/or a fourth segment1056. An interlace path306may be determined with respect to a plurality of segments, such as the first segment1050, the second segment1052, the third segment1054, and/or the fourth segment1056. The respective interlace paths306may correspond to one or more of the plurality of energy beams. For example, the first segment1050may include a first interlace path1058with respect to the first interlace region1002, a second interlace path1060with respect to the second interlace region1004, a third interlace path1062with respect to the third interlace region1006, and a fourth interlace path1064with respect to the fourth interlace region1008. Additionally, or in the alternative, the third segment1054may include a fifth interlace path1066with respect to the first interlace region1002, a sixth interlace path1068with respect to the fifth interlace region1010, a seventh interlace path1070with respect to the third interlace region1006, and an eighth interlace path1072with respect to the fifth interlace region1010. The first interlace path1058and/or the fifth interlace path1066may respectively delineate a first interlacing boundary and/or a fifth interlacing boundary between the first energy beam and the second energy beam148. The second interlace path1060may delineate a second interlacing boundary between the second energy beam148and the third energy beam. The third interlace path1062and/or the seventh interlace path1070may respectively delineate a third interlacing boundary and/or a seventh interlacing boundary between the third energy beam and the fourth energy beam. The fourth interlace path1064may delineate a fourth interlacing boundary between the fourth energy beam and the first energy beam. The sixth interlace path1068and/or the eighth interlace path1072may respectively delineate a sixth interlacing boundary and/or an eighth interlacing boundary. The sixth interlacing boundary and/or the eighth interlacing boundary correspond to any combination of at least two of: the first energy beam, the second energy beam148, the third energy beam, and/or the fourth energy beam. In some embodiments a route-finding algorithm may be used to determine a plurality of interlace paths306, such as a plurality of interlace paths306corresponding to the interlace regions154shown inFIGS.10A and10B. The route-finding algorithm may determine a lowest value path810for one or more of a plurality of interlace paths306, and one or more of the plurality of interlace paths306may be based at least in part on the respective lowest value path810. Now turning toFIGS.11A and11B, determination of exemplary interlace paths306for the object slice300shown inFIGS.10A and10Bwill be described. Referring toFIG.11A, in some embodiments, one or more heuristic functions h(n) may be utilized. For example, one or more heuristic functions h(n) may be utilized to define heuristic contour zones corresponding to the respective build plane regions. As shown, one or more heuristic functions h(n) may be utilized to define a first heuristic contour zone1100corresponding to the first build plane region1012, a second heuristic contour zone1102corresponding to the second build plane region1014, a third heuristic contour zone1104corresponding to the third build plane region1016, and/or a fourth heuristic contour zone1106corresponding to the fourth build plane region1018. The one or more heuristic functions h(n) may define one or more heuristic interlace paths. For example, a first heuristic interlace path1108may delineate a first heuristic interlacing boundary between the first energy beam and the second energy beam148, a second heuristic interlace path1110may delineate a second heuristic interlacing boundary between the second energy beam148and the third energy beam, a third heuristic interlace path1112may delineate a third heuristic interlacing boundary between the third energy beam and the fourth energy beam, a fourth heuristic interlace path1114may delineate a fourth heuristic interlacing boundary between the fourth energy beam and the first energy beam, and/or a fifth heuristic interlace path1116may delineate a fifth heuristic interlacing boundary between the second energy beam148and the fourth energy beam. In some embodiments, the one or more heuristic functions h(n) may be determined based at least in part on one or more heuristics corresponding to surface area of the object slice300and/or irradiation time of the respective energy beams. Additionally, or in the alternative, the one or more heuristic functions h(n) may be determined based at least in part on one or more heuristics corresponding to a shortest distance for an interlace path306and/or a shortest aggregate distance of all interlace paths306. Various heuristic functions h(n) may be selected individually, or in combination, based at least in part on desired properties. For example, a heuristic function h(n) may be selected that prioritizes equivalent allocation of surface area and/or scanning among at least some of the energy beams. Additionally, or in the alternative, a heuristic function h(n) may be selected that prioritizes a shortest distance for one or more interlace paths306and/or a shortest aggregate distance for a plurality of interlace paths306. Weighting values may be assigned to a plurality of selected heuristics, for example, when selected in combination, such as to assign relative priorities to a plurality of criteria. FIG.11Bshows an illustrative allocation of a plurality of contour zones and locations of a corresponding plurality of interlace paths306. The contour zones and interlace paths306shown inFIG.11Bdiffer from those shown inFIGS.10B and11Ain order to illustrate a potential output of one or more route-finding algorithms. In some embodiments, a route-finding algorithm may utilize one or more heuristic functions such as the heuristic functions described with reference toFIG.11A. The contour zones and interlace paths306may be determined using one or more heuristic functions h(n), such one or more heuristic functions h(n) that include one or more heuristic contour zone and/or one or more heuristic interlace paths306. In some embodiments, the respective contour zones and corresponding interlace paths306may provide a balance of a plurality of parameters, such as one or more irradiation parameters, one or more object parameters, and/or one or more production parameters. For example, the respective contour zones and corresponding interlace paths306may balance a production parameter with an object parameter. Additionally or in the alternative, the respective contour zones and corresponding interlace paths306may balance an irradiation parameter with an object parameter, and/or an irradiation parameter with a production parameter. The production parameter may be or include one or more of irradiation time, processing time, and/or allocation of irradiation time and/or processing time between respective irradiation devise of an energy beam system134. The object parameter may be or include energy density, melt pool size, temperature, material density, consolidation pattern, and/or crystalline structure. The irradiation parameter may be or include scanning speed, scanning time, beam spot size, and/or energy density. Now turning toFIG.12, and exemplary control system104will be described. An exemplary control system104includes a controller1200communicatively coupled with an additive manufacturing machine102. For example, the controller1200may be communicatively coupled with a management system106and/or an energy beam system134. The controller1200may also be communicatively coupled with a user interface108. The controller1200may include one or more computing devices1202, which may be located locally or remotely relative to the additive manufacturing machine102. The one or more computing devices1202may include one or more processors1204and one or more memory devices1206. The one or more processors1204may include any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, logic device, and/or other suitable processing device. The one or more memory devices1206may include one or more computer-readable media, including but not limited to non-transitory computer-readable media, RAM, ROM, hard drives, flash drives, and/or other memory devices1206. As used herein, the terms “processor” and “computer” and related terms, such as “processing device” and “computing device”, are not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein. A memory device1206may include, but is not limited to, a non-transitory computer-readable medium, such as a random access memory (RAM), and computer-readable nonvolatile media, such as hard drives, flash memory, and other memory devices. Alternatively, a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used. As used herein, the term “non-transitory computer-readable medium” is intended to be representative of any tangible computer-based device implemented in any method or technology for short-term and long-term storage of information, such as, computer-readable instructions, data structures, program modules and sub-modules, or other data in any device. The methods described herein may be encoded as executable instructions embodied in a tangible, non-transitory, computer readable media, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. Moreover, as used herein, the term “non-transitory computer-readable medium” includes all tangible, computer-readable media, including, without limitation, non-transitory computer storage devices, including, without limitation, volatile and nonvolatile media, and removable and non-removable media such as a firmware, physical and virtual storage, CD-ROMs, DVDs, and any other digital source such as a network or the Internet, as well as yet to be developed digital means, with the sole exception being a transitory, propagating signal. The one or more memory devices1206may store information accessible by the one or more processors1204, including computer-executable instructions1208that can be executed by the one or more processors1204. The instructions1208may include any set of instructions which when executed by the one or more processors1204cause the one or more processors1204to perform operations. In some embodiments, the instructions1208may be configured to cause the one or more processors1204to perform operations for which the controller1200and/or the one or more computing devices1202are configured. The memory devices1206may store data1210accessible by the one or more processors1204. The data1210can include current or real-time data, past data, or a combination thereof. The data1210may be stored in a data library1212. As examples, the data1210may include data1210associated with or generated by an additive manufacturing system100, including data1210associated with or generated by a controller1200, an additive manufacturing machine102, a user interface108, a management system106, and/or a computing device1202. The data1210may also include other data sets, parameters, outputs, information, associated with an additive manufacturing system100, such as those associated with the additive manufacturing machine102, the user interface108, and/or the management system106. The one or more computing devices1202may also include a communication interface1214, which may be used for communications with a communication network1216via wired or wireless communication lines1218. The communication interface1214may include any suitable components for interfacing with one or more network(s), including for example, transmitters, receivers, ports, controllers, antennas, and/or other suitable components. The communication interface1214may allow the computing device1202to communicate with the additive manufacturing machine102. The communication network1216may include, for example, a local area network (LAN), a wide area network (WAN), SATCOM network, VHF network, a HF network, a Wi-Fi network, a WiMAX network, a gatelink network, and/or any other suitable communication network1216for transmitting messages to and/or from the controller1200across the communication lines1218. The communication lines1218of communication network1216may include a data bus or a combination of wired and/or wireless communication links. The communication interface1214may additionally or alternatively allow the computing device1202to communicate with a user interface108and/or a management system106. The management system106may include a server1220and/or a data warehouse1222. As an example, at least a portion of the data1210may be stored in the data warehouse1222, and the server1220may be configured to transmit data1210from the data warehouse1222to the computing device1202, and/or to receive data1210from the computing device1202and to store the received data1210in the data warehouse1222for further purposes. The server1220and/or the data warehouse1222may be implemented as part of a control system104. The controller1200may include one or more route-finding models1224, which may utilize the data1210, including the data library1212, and/or other data sets, parameters, outputs, information, associated with the additive manufacturing system100, such as those associated with the additive manufacturing machine102, the user interface108, and/or the management system106. The one or more route-finding models1224may additionally or alternatively utilize data1210from the data warehouse1222, which may be transmitted to the controller1200from the server1220. The control system104may be configured to determine a plurality of contour zones308for an object slice300and/or to determine one or more corresponding interlace paths306for an object slice300in accordance with the present disclosure. For example, the controls system may include one or more route-finding models1224configured to define an interlace path306and/or corresponding contour zones308in accordance with the present disclosure. The control system104may be configured to output one or more control command based at least in part on the plurality of contour zones308for the object slice300and/or the one or more corresponding interlace paths306for an object slice300. The one or more control commands may be configured to cause an energy beam system134to irradiate a layer of a powder bed136with the plurality of energy beams. Further aspects of the invention are provided by the subject matter of the following clauses:1. A method of additively manufacturing an object, the method comprising: defining an interlace path for a plurality of energy beams from an energy beam system based at least in part on a route-finding algorithm, the interlace path delineating a first contour zone of a build plane assigned to a first one of the plurality of energy beams from a second contour zone of the build plane assigned to a second one of the plurality of energy beams; and outputting a control command based at least in part on the interlace path, the control command configured to cause the energy beam system to irradiate a layer of a powder bed with the plurality of energy beams.2. The method of any preceding clause, wherein the method further comprises: irradiating a layer of a powder bed with the plurality of energy beams based at least in part on the control command, the first contour zone being irradiated by the first one of the plurality of energy beams and the second contour zone being irradiated by the second one of the plurality of energy beams.3. The method of any preceding clause, wherein at least a portion of the interlace path follows and/or defines a contour border.4. The method of any preceding clause, wherein at least a portion of the interlace path traverses a contour zone.5. The method of any preceding clause, wherein the route-finding algorithm is configured to determine a lowest value path between a source vertex and a destination vertex.6. The method of any preceding clause, wherein the route-finding algorithm comprises a best-first algorithm, a depth-first algorithm, a breadth-first algorithm, a uniform value algorithm, and/or a greedy algorithm.7. The method of any preceding clause, wherein the route-finding algorithm is configured to determine a lowest value path from an array of vertices corresponding to a build file executable by an additive manufacturing machine.8. The method of any preceding clause, wherein respective vertices in the array of vertices are connected by edges that have weighting value determined based at least in part on one or more irradiation parameters, one or more object parameters, and/or one or more production parameters.9. The method of any preceding clause, wherein at least some of the vertices in the array are assigned a priority based at least in part on whether the respective vertex is located along a contour border and/or within a contour zone.10. The method of any preceding clause, wherein the route-finding algorithm is configured to determine a lowest value path based at least in part on a heuristic function.11. The method of any preceding clause, wherein the heuristic function is admissible.12. The method of any preceding clause, wherein the heuristic function is determined based at least in part on a midline and/or a contour border.13. The method of any preceding clause, wherein the route-finding algorithm is configured to utilize a contraction hierarchy.14. The method of any preceding clause, wherein the contraction hierarchy is configured to preprocess at least a portion of the vertices between adjacent contour borders, and/or wherein the contraction hierarchy is configured to preprocess at least a portion of the vertices from a contour border between an boundary contour zone and an interior contour zone to an adjacent contour border.15. The method of any preceding clause, wherein the route-finding algorithm is configured to search a heap assigned to a contour border and/or to search a heap assigned to a contour zone.16. The method of any preceding clause, wherein the route-finding algorithm is configured to balance one or more irradiation parameters, one or more object parameters, and/or one or more production parameters.17. An additive manufacturing system, the system comprising: an additive manufacturing machine; and a control system, wherein the control system is configured to: define an interlace path for a plurality of energy beams based at least in part on a route-finding algorithm, the interlace path delineating a first contour zone of a build plane assigned to a first one of the plurality of energy beams from a second contour zone of the build plane assigned to a second one of the plurality of energy beams; and output a control command based at least in part on the interlace path, the control command configured to cause an energy beam system to irradiate a layer of a powder bed with the plurality of energy beams.18. The additive manufacturing system of any preceding clause, wherein the additive manufacturing machine comprises the energy beam system, and wherein the energy beam system is configured to irradiate a build plane using at least two energy beams and/or at least four energy beams.19. The additive manufacturing system of any preceding clause, wherein the control system is configured to define an interlace path based at least in part on a heuristic function, the one or more heuristic function comprising a heuristic contour zone and/or a heuristic interlace path.20. The additive manufacturing system of any preceding clause, wherein the additive manufacturing system is configured to perform the method of any preceding clause.21. A computer-readable medium comprising computer-executable instructions, which when executed by a processor, cause the processor to perform a method of additively manufacturing an object, the method comprising: defining an interlace path for a plurality of energy beams from an energy beam system based at least in part on a route-finding algorithm, the interlace path delineating a first contour zone of a build plane assigned to a first one of the plurality of energy beams from a second contour zone of the build plane assigned to a second one of the plurality of energy beams; and outputting a control command based at least in part on the interlace path, the control command configured to cause the energy beam system to irradiate a layer of a powder bed with the plurality of energy beams.22. The computer-readable medium of any preceding clause, comprising computer-executable instructions, which when executed by a processor, cause the processor to perform the method of any preceding clause. This written description uses exemplary embodiments to describe the presently disclosed subject matter, including the best mode, and also to enable any person skilled in the art to practice such subject matter, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the presently disclosed subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | 115,180 |
11858218 | DESCRIPTION There are significant benefits and risk reduction that can be realised by automating the sealing and cutting of the tubes. Equipment available to perform the task of sealing and aseptic disconnection have a range of shortcomings, including:expensive (i.e. capital outlay and/or consumables per cut (e.g. aseptic disconnection devices, crimp sleeves, Clipster® aseptic tube disconnection system);time consuming to operate or apply,hazardous (e.g. crimp sleeve cutter, cut crimp sleeve producing sharp corners often seeing need for fitting of additional protective cover component);require significant length of tube and/or room around tube to operate equipment and produce seal and achieve disconnection;require services for non-manual/non-battery-operated devices (AC power, compressed air) for otherwise portable devices;restrictions on tubing material (i.e. RF (radio frequency) sealer only works on tubes containing polar material e.g. PVC, EVA);restrictions on tubing dimensions (i.e. outer diameter and wall thickness) ability to seal reliably and safely on fluid filled tube (e.g. RF tube sealer can arc when sealing fluid-filled tubes, grounding to fluid in tube resulting in pin hole in tube wall). The potential benefits of embodiments of the disclosure especially when integrated into a piece of equipment can address several shortcomings of many of the current tube seal and cut options available. Benefits include:reliable seal and cut process providing consistent seals and separation of the tubing without the need for scissors or other sharps (that are often used to separate sealed tubes but pose a special risk to operator with opportunity for biohazardous contamination);ability to perform seal and cut operation on a range of different tube materials and sizes with changes to operating parameters and minor reconfiguration;relatively quick seal and cut cycle time;integrated into platform with required safeguards protecting operator;tight integration of tube seal and cut equipment allowing shortest possible tubing lengths. This allows most compact and cost-effective disposable set and in some situations, can result in reduced media losses (i.e. waste) and highest performance (i.e. fluid delivery control/dispense accuracy);automation minimising need for operator interaction;no significant cost per seal and cut (as is the case with techniques using consumable), Accordingly, embodiments of the disclosure incorporate the improved tube seal and cut device into this prior art equipment. These embodiments achieve rapid seal and cut cycle time whilst maintaining robust and reproducible seals and cuts. These embodiments also systematically avoid exposing the operator to heat hazard and breach of the tubing which are risks with some of the current disconnection methods and can leads to process leakage and possible product or even batch loss Electrically heated sealing irons are often used to seal tubing formed from thermoplastic materials. Typically, the sealing irons have a non-stick coating to avoid having the tube material stick to the iron and leaving a residue. Where such devices are used for tube-sealing, they are also manually operated. This requires the person operating to have the dexterity and vision to load and unload the tubing and peel it off the iron in the case where the tubing sticks slightly, and to ensure there is either no residue or to remove the same so as to not adversely impact subsequent welds. In addition, for seal integrity and operator safety, current technology is limited to a relatively long cycle time (i.e. multiple minutes) as the unit can only heat up, seal and cool down with the unit latched closed. Embodiments also incorporate a cutting detail on an anvil that opposes the sealing iron. This feature is used in impulse and RF (Radio Frequency) sealers used for tubes. The idea is that the tubing material melts and flows, thinning to the point where the tubing material is cut through but with adjacent surfaces ensuring the seal is fully established. Thus, the cut or separation point is achieved aseptically with internal surfaces of the tube (and contents) never being exposed to the outer surface. In the disclosed embodiments, the anvil or seal back-up is attached to a door that is hinged out of the way to allow disposable set loading, but then latched closed ensuring that the tube location and anvil geometry are correctly established. In addition, the door is interlocked to ensure the operator cannot gain access to heat or pinch point hazards whilst tube seal and cut operation occurs. The disclosed embodiments:carry out tube seal and cut operation by clamping a heated sealing iron against a tube through a non-stick membrane which helps to avoid tube sticking following the cut and seal operation;retract the sealing iron (after optimal seal and cut parameters have been executed (i.e. time, force & temp) allowing short seal and cut cycle time and allowing access by an operator without excessive delay for required manual interaction and without access/exposure to heat and pinch hazards;keep the sealing iron at optimum temperature without operator having access/exposure to heat and pinch hazards. The membrane is thin and flexible, which allows it to adapt and contort to the shape of the sealing iron (and surrounding insulating shroud). The fact that the membrane is non-stick enhances the seal and cut with adequate release properties to avoid tube sticking, and aids unloading (automated or manual) following the seal and cut cycle. In terms of equipment design and suitability for cleanroom installation/operation, the membrane also serves to isolate the heater and associated actuating and other mechanisms that might otherwise pose a clean/cleanable design challenge. The membrane becomes the surface that the operator is faced with and required to keep clean and maintain, which provides another significant benefit. Embodiments of the disclosure have the iron pre-heated to a temperature that conducts through the thin membrane material quickly to cause requisite melting and then retract the iron after the cut or tube separation is fully established. These aspects underpin the relatively rapid cycle time that can be routinely achieved and required to maximise productivity benefits and follow consistent, leak free seal and cut performance requirements. Referring toFIGS.1A-1E, a tube seal apparatus100according to an example embodiment of the disclosure is shown in sequence. Tube seal apparatus100has a heating block or tube sealing iron1translationally disposed in an insulating shroud2. Sealing iron1has a sealing end12having a stepped portion at its sealing surface end. Insulating shroud2has a tube clamp end14having a narrowed portion corresponding to the stepped portion of sealing end12. A seal back up or anvil5is disposed at the tube clamp end14of insulating shroud2and is attached to a rigid reaction surface limiting finger access by operator or safety-interlocked door (not shown inFIGS.1A-1E). Anvil5has a small tube cutting detail16on anvil5facing tube clamp end14of insulating shroud2. Cutting detail16may be configured as a raised portion that causes thinning of the tubing material after sealing has already been established in this section of tubing. This allows ready separation of the tube ends by operator with minimal to no pulling or peeling force required to disconnect newly established sealed tube ends and without the need for tools or sharps and without posing a risk of tube seal breaching. A non-stick membrane3is disposed between the tube clamp end14of insulating shroud2and anvil5. A tube4to be sealed is placed between the non-stick membrane3and anvil5. Insulating shroud2is configured to operate in a reciprocating fashion towards and retracted away from anvil5. Sealing iron1is configured to operate in a reciprocating fashion advanced towards and retracted away from anvil5and also configured to move relative to insulating shroud2. Sealing iron1and insulating shroud2may be reciprocated using mechanisms as discussed below with reference toFIGS.3A-3C. FIGS.1A-1Edepict the tube seal and cut sequence. Referring toFIG.1A, the starting position is shown with insulating shroud2and sealing iron1fully retracted from anvil5. Referring toFIG.1Bthe commencement of the sealing cycle is shown with insulating shroud2and sealing iron1advanced and compressing tube4through membrane3towards anvil5. Referring toFIG.1C, a further development of the sealing cycle is shown wherein insulating shroud2and sealing iron1are further advanced and compress tube4through membrane3against cutting detail16on anvil5, and wherein the material of tube4is melted and sealed with sealing iron1maintaining pressure. Material flows away from cutting detail16as sealing iron1comes into contact with cutting detail16through membrane3to cut through tube4. Referring toFIG.1D, a seal and cut consolidating position is depicted wherein tube material solidifies with sealing iron1retracted. In this configuration, insulating shroud2remains forward and clamped against tube4as tube material solidifies to ensure the seal remains established, especially for tubing material with high stiffness and restoration forces that could cause the seal to be breached or otherwise compromised during short solidification period. Referring toFIG.1E, a seal and cut completed position is depicted wherein insulating shroud2and sealing iron1are both retracted away from anvil5and wherein tube4has been sealed and cut or separated into two separate pieces allowing disconnection of the tube and connected items on either side of the newly established cut or separation point from each other, The insulating shroud2helps to reduce energy usage due to radiating and convective losses. In this configuration it also plays an important role in clamping the tube4and providing a temperature gradient that limits the melt boundary in the tube4, especially for thin wall tubing and stiff tubing where the restoring forces could otherwise result in stress at molten transition that would likely cause a breach in the tube wall. This Insulating shroud2clamps the tube4to isolate the transition from a flat, clamped tube to its natural circular state from the high temperature/melting zone. It thereby serves to provide the necessary margins for a more robust seal, especially on thin-wall (e.g. 0.5 mm or less) tubing. In addition, if the tube4being sealed is fluid filled, insulating shroud2serves to help occlude the fluid and push it out of the seal and high temperature zone, helping avoid high temperature exposure of the fluid. This reduces possible boiling and excess pressure generation by fluid/generated gas that might cause a rupture of molten tube wall during the sealing process. Depending on the application, there may also be residual or induced tension on the tube4. Since insulating shroud2is configured as a clamp, it could also serve to isolate the tension and avoid the seal being compromised by tube4remaining under tension that could otherwise quite easily lead to elongation or stretching of molten section of tube leading to a seal or tube wall breach. In terms of the integration of this tube seal apparatus100, it may be utilised in various configurations to support sealing and cutting of different tubing materials and wall thickness. On a bag filler where there are a number of bags in a row, a door may cover all of the bags and fill tubes with continuous or individual anvils backing up each tube but with a traversing sealer. In this respect, a single sealer would help provide uniformity in terms of force and temperature to each of the tubes it was accessing and overall, if servicing multiple positions, considerably reducing cost and complexity of the equipment control system by avoiding having multiple sealing heads. Also, with a bag filler embodiment, the bags are often sequentially filled and having a single, traversing device means tube cutting and sealing can happen directly following bag filling and whilst next bag is being filled. In this way, productivity is maximised by avoiding seal and cut at the conclusion of all bags being filled. Instead, this invention could make bags available for more timely removal and subsequent processing sequentially and directly after completion of the tube seal and cut process. Referring toFIG.2, a bag filler application18is depicted indicating progressive filling of bags20by tubes4, sealing and cutting by tube seal apparatus100and then bag20removal. Referring toFIGS.3A-3C, another example embodiment. This embodiment incorporates many of the features described in the previously described embodiments. In this embodiment depicted here, the iron1and shroud2do not move relative to one another and are moved together, and their sealing end and tube clamp end, respectively do not have corresponding narrowed features. Referring toFIG.3A, a tube seal and cut device is shown in standby position ready for set/tube4loading. The membrane3is fixed to a membrane holder on chassis6where a 3″ (75 mm) wide web or strip of membrane film that is clamped into a holder which helps form/achieve the required convex 2D profile. This membrane holder is removable from the platform for membrane replacement and maintenance if required. A typical example of where this seal and cut device would be used is where bags need to be aseptically sealed and separated after being filled with a desired volume of fluid. In this instance, the disposable set including bags and fill tubes would be loaded on to the system with the tube section to be sealed and cut running in front of the membrane3in the required location and then the door7would be closed over the tube4, bringing the anvil5into position. Referring toFIGS.3B and3C, the tube seal and cut system is shown in the sealing position. Continuing the bag filling example, following filling of the bag, the heated sealing iron1assembly is actuated forward, pushing the tube4against the anvil5through the non-stick membrane3, resulting in sealing and cutting/separation of the tube4as outlined above with respect toFIGS.1A-1E. The mechanism used to motivate/actuate the components actively participating in the sealing function may be a pneumatic cylinder and electric actuator or, as shown in the figures, a guided ball screw actuator with electric motor assembly9which moves a sealing iron1assembly carrier10. Force control with the ability of the sealing iron assembly to maintain force by moving forward during the sealing operation as the tube melts and flows is an important and beneficial aspect of this system to achieve reproducibility. This could also be achieved using a guided pneumatic cylinder (for pneumatically actuated system). For the electric actuator, force control can be achieved using torque (i.e. motor current) control or with alternative embodiment using spring loaded head with variable positioning (i.e. stroke) controlling the force applied during the sealing operation. At the conclusion of the sealing cycle, the heated sealing iron1assembly is retracted backward away from the membrane3and anvil5and seeing the molten tube4material solidify to complete the seal and cut detail. This sealing process might be repeated several times, traversing to allow sealing and separating of a multitude of adjacent tubes4. At the conclusion of the process, the door7is opened and the filled, sealed and separated bags removed for subsequent processing (labelling, packaging, freezing, etc.). Exemplary parameters for operation are as follows: Iron temperature: working range=100° C.→200° C. typical sealing range dependent on tubing. Nominal setting=160° C. Possible high temperature of 350° C. for intermittent operation. Iron contact time: working range=6→>30 sec, dependent on tubing. Iron pressure/force: working range=80 N→200 N. Nominal setting=120 N. The iron1may be comprised of aluminium or other suitable thermally conductive materials. The shroud2and anvil5may be comprised of a polyether ether ketone (PEEK) or other suitable materials with high continuous working temperature capability. The non-stick membrane3may be comprised of PEEK or polyimide film or other suitable materials that are suitably thin and flexible to allow heat to be readily conducted through it from sealing iron assembly to tube whilst also having ability to withstand process temperatures intermittently without degradation. Features of the disclosed embodiments may be combined, rearranged, omitted, etc., within the scope of the invention to produce additional embodiments. Furthermore, certain features may sometimes be used to advantage without a corresponding use of other features. Many alternatives, modifications, and variations are enabled by the present disclosure. While specific embodiments have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. Accordingly, Applicants intend to embrace all such alternatives, modifications, equivalents, and variations that are within the spirit and scope of the present invention. | 17,250 |
11858219 | DETAILED DESCRIPTION The disclosed embodiments may be employed to fabricate or repair of composite structures that incorporate a cell-based structural array, sometimes referred to as a cell-based sandwich structure, in which a structural array of cells is sandwiched between two facesheets. These cell-based structural arrays can be used to transfer loads, or for other purposes. Referring toFIG.1, one example of a cell-based structural array50is an RF (radio frequency) structural aperture50athat is used for communication and is integrated into the skin52of an aircraft fuselage54. As shown inFIG.2, the RF structural aperture50acomprises an array56of cells58sandwiched between inner and outer facesheets60,62to form a composite sandwich structure. Although the structural RF aperture50ais shown as being located in the aircraft fuselage54, it may be located in other areas of the aircraft, including but not limited to wings, cowls, stabilizers, doors, etc. Moreover, although an aircraft application is illustrated, the cell-based structural array50may be incorporated into structures used in other applications, such as, for example and without limitation, land or sea vehicles, spacecraft, satellites, etc. Referring also toFIG.3, the cells58are formed by walls64that are joined together along their mutual edges by a suitable resin bonding adhesive that form adhesive fillets or vertical bondlines68. The walls64are also joined to the inner facesheet60and/or to RF antenna elements72(FIG.2) by bonding adhesive forming adhesive fillets or horizontal bondlines70. Each of the cells58may include one of the RF antenna elements72that is adapted to receive and/or transmit RF communication signals. In the illustrated example, the cells58have a substantially rectangular cross-section, however other cross-sectional cell shapes are possible. The structural RF aperture50ashown inFIGS.1-3is merely illustrative of a wide range of cell-based structural arrays that may be fabricated and/or repaired using the method and apparatus described below in greater detail. During fabrication and/or rework of a cell-based structural array50it may be necessary to thermally cure the walls64and/or the bonding adhesive forming the bondlines68,70. Referring now toFIGS.4and5, the cell-based structural array50may be thermally cured using a bank66of tooling blocks74, each of which is inserted into one of the cells58and has a shape that is the negative of the cell58. Each of the tooling blocks74includes a tool body75having an embedded, thermally conductive, magnetic susceptor76that generates heat. As will become apparent below, the susceptor76may comprise a single susceptor element or multiple susceptor elements. As used herein, “embedded” refers to the susceptor76being incorporated within, surrounded by, attached to or mounted on the tool body75. Internal heating of each tooling block74by a susceptor76results in uniform cell heating regardless of the position of the cell within the array56. The heat generated internally in the susceptor76is conducted through the tool body75to the surrounding cell walls64and to the adhesive bondlines68,70. The tooling blocks74may be ganged, i.e. tightly grouped together, within the bank66and in the illustrated example are arranged in linearly aligned rows84thereof. The rows84can be closely spaced from each other. In this example, the rows84of tooling blocks74within the bank66are aligned with each other, however in other examples they may be staggered relative to each other. The tooling blocks74are aligned to match the configuration of the cells58, The tool body75can be formed of a low friction material such as PTFE (Polytetrafluoroethylene), however other materials are possible, providing that they do not block electromagnetic fields. The tool body75may also be formed of other rigid or semi-rigid materials, including metal, that is coated with a layer of low friction material that allows the tool block74to slide into easily and out of the cells58. The susceptors76are formed of a thermally conductive metal such as aluminum, steel, carbon, iron, copper or a metal alloy, capable of absorbing electromagnetic energy and converting it into heat. As will be described below in more detail, the heat generated within the susceptors76is used to thermally cure the adhesive bondlines68,70and/or other features of the cells58. In order to control the maximum temperature to which the tooling blocks74are heated, the susceptors76may be formed of conductive materials that are also magnetic. For example, the susceptors76may be formed of ferromagnetic materials such as alloys of iron (Fe), nickel (Ni) or cobalt (Co), or ferrimagnetic materials such as, without limitation, ferrites. In the case of susceptors76that are formed of magnetic materials, a susceptor material is chosen that has a Curie temperature close to but slightly higher than the cure temperature of the bondline adhesive. When using magnetic susceptors, the heat produced by the susceptor76decreases as the temperature increases to the Curie temperature, thereby preventing overheating of the cells58while ensuring proper cure of the adhesive bondline at its cure temperature. Each of the tool bodies75has a cross-sectional shape substantially matching that of cells58and is in substantially face-to-face contact with the surrounding walls64, the inner facesheet60and the adhesive bondlines68,70. In the example shown inFIG.4, the susceptors76are round tubes having a hollow center82and a circular cross-sectional shape, while the susceptors76in the example shown inFIG.5are square tubes102that are also hollow but have a substantially square cross-sectional shape. Each of the susceptors76shown inFIGS.4and5comprises a single susceptor element (tubes98and102) that is centrally located within, and extends the entire height of the tooling blocks74, causing the heat generated within the susceptor76to be evenly distributed throughout the cell58. In the examples shown inFIGS.4and5, the susceptors76include an exposed portion76athat extends above the respective tool bodies75, but in other examples described later, the tool bodies75may extend above the susceptors76. As will be discussed below in more detail, the susceptors76may have other shapes and may comprise more than a single susceptor element. The efficiency of a susceptor76is dependent upon its shape, and its orientation relative to the electromagnetic field90. Generally, the outer extremities of an elongate, magnetic susceptor76of the type shown inFIGS.4,5and6do not magnetize due to surface effects referred to as shape demagnetization. Susceptors76that have their long dimension parallel to the direction of the electromagnetic field90are least affected by the demagnetization. Conversely, susceptors76that have their short dimension oriented parallel to the electromagnetic field90are most affected by the demagnetization. Referring now toFIGS.6and7, an electromagnet86includes at least one induction coil88powered by a source of high frequency AC (alternating current)92controlled by a controller96. Excitation of the induction coil88by the high frequency AC source92produces an electromagnetic field90. The induction coil88is oriented such that the electromagnetic field90extends normal (perpendicular) to the rows84of ganged tooling blocks74. The electromagnetic field90induces the flow of electrical currents in the susceptors76. These electrical currents include Eddy currents that flow through the susceptors76and cause internal joule heating of the susceptors76throughout the array56. In the case of susceptors76formed of ferromagnetic or ferrimagnetic materials, the induced currents include hysteresis currents generated by magnetic hysteresis losses. These currents are induced equally in all of the susceptors76because all of the susceptors are subjected to the same electromagnetic field90. As a result of these internal currents, all of the cells58of the array56are heated evenly and quickly at the same rate. This even and uniform heating of the cells58, including the bondlines68,70, reduces or eliminates over-curing or under-curing of the adhesive bondlines68,70. Moreover as mentioned above, heating of the cells58internally by the susceptors76allows even, uniform heating within the individual cells58. When tightly ganged together, the heat generated within each of the tooling blocks74does not affect the adjacent tooling blocks74, because they heat independently of each other and at the same rate. The use of magnetic susceptors76provides self-regulation of the temperature since the susceptors76heat up to, but do not exceed, their Curie temperature. In some applications, the array56of cells58may include certain components such as the RF antenna elements72, that may be subject to damage caused by undesired “rogue heating” when subjected to the magnetic field90. This rogue heating can be avoided by orienting the induction coil88such that it is aligned substantially perpendicular to the heat sensitive components. For example in the illustrated application, the induction coil88is oriented perpendicular to the RF antenna elements72, and parallel to the rows84of tooling blocks74that are to be heated. In the example shown inFIG.6, the induction coil88is located beneath the cell-based structural array50, however in other examples it may be located above the array50. In either of these examples, the distance between the induction coil88and the tooling blocks74is such that the susceptors76are located within and therefore magnetically coupled with, the electromagnetic field90. The efficiency of the susceptors76increases with decreasing distance thereof from the induction coil88because they absorb a greater amount of energy from the electromagnetic field90, allowing them to generate more heat. In still other examples, the structural array50with the installed tooling blocks74may be positioned in the center of the electromagnetic field90. Centering the structural array50within the electromagnetic field90in this manner may increase the uniformity of the portion of the field that is coupled with the susceptors76. In some applications it may be necessary or desireable to employ two of the induction coils88that are oriented perpendicular to each other. One of the two induction coils88is oriented to produce an electromagnetic field90that is normal to the rows84of tooling blocks74and the other induction coil88oriented to produce an electromagnetic field90that is parallel to the rows84. The two induction coils88, which are oriented perpendicular to each other, can be alternately energized in order to heat adjacent walls of the cells58 Depending on the application, one or more temperature sensors94may be incorporated in or located near the tooling blocks74in order to sense the temperature of the tooling blocks74and detect whether desired temperatures are being achieved. The temperature sensors94send signals representing the measured temperature to the controller96in a feedback loop95, allowing the controller96to adjust the electrical power applied to the induction coil88, thereby controlling the electromagnetic field intensity to achieve uniform regulation of cell adhesive temperature throughout the entire cell-based structural array50. This temperature control may be particularly useful where the susceptors76are not formed of magnetic materials that provide self-regulation of their temperature, and therefore and have the potential to overheat. FIG.8illustrates additional details of one example of a tooling block74of the type shown inFIG.6. The tooling block74includes a tool body75having a cross-sectional shape substantially matching that of the cells58. The tool body75may be formed of any suitable material capable of allowing the heat generated by a centrally located susceptor76to be conducted to the surrounding features of the cells58, including the adhesive bondlines68,70. The centrally located round tube98forming the susceptor76may be formed of any suitable conductive metal capable of being magnetically coupled with the induction coil88. The round tube98has a hollow center82that functions to increase its magnetic susceptibility. The hollow center82also aids in more uniformly distributing the heat generated within the susceptor76. In the illustrated example, the round tube98has an exposed upper portion76athat extends above the top of the tool body75. The exposed upper portion76afacilitates insertion of the susceptor76into the tool body75as well as insertion and subsequent removal of the tooling blocks74from the cells58. In other examples, however, the top of the tube98may be flush with, or be recessed beneath the top of the tooling block74. FIG.9illustrates another example of a tooling block74of the type shown inFIG.5. The centrally located susceptor76comprises a square tube102having a cross-sectional shape that is substantially square and has a hollow center82. FIG.10illustrates a further example of a tooling block74provided having an embedded susceptor76in the form of a one conductive wire ring100that is wrapped around and recessed within the outer peripheral surface of the tool body75. In this example, the tool body75includes an upper extension75athat is configured to facilitate installation and removal of the tooling blocks74from the cells58, either by hand or using gripping/transfer fixtures. FIG.11illustrates another example of a tooling block74, similar to that shown inFIG.10, but wherein the tool body75is provided with a plurality of embedded, spaced apart wire rings100that function as susceptors76that are distributed along the height of the tool body75. While three wire rings100are shown, the tool body75may be provided with any number of the wire rings100. In the example shown inFIG.10, the single wire ring100located near the top of the tool body75primarily heats only the upper regions of a cell58, while in the example ofFIG.11, the use of multiple wire rings100distributed throughout the height of the tool body75results in substantially uniform heating of the entire cell58. In still another example (not shown), a single wire ring100may be spirally wound around the tool body75along its length. Attention is now directed toFIG.12which illustrates still another example of the tooling block74. In this example, the tool body75has a central through hole106, and a susceptor76in the form of conductive metal elements such as rods104passing longitudinally through the tool block74at each corner thereof. By positioning the rods104at each corner of the tool body75, the heat generated by the susceptors76is locally targeted and distributed along the adhesive vertical bondlines68. The efficiency of the rods104in generating heat may be increased by connecting the rods104in loops with two sides in-line with the electromagnetic field90. Similarly, although not shown in the drawings, additional susceptors76may be embedded within other areas of the tool body75in order to locally direct heat to other features of the cells58. When using susceptors76having the configuration shown inFIG.12, the coil88should be oriented such that the electromagnetic field90extends parallel to the long dimension of the rods104. Thus, when using the susceptors76ofFIG.12in the structural array50shown inFIG.6, the coil88should be oriented such that it produces an electromagnetic field90having vertical orientation relative to the structural array50. Attention is now directed toFIGS.13-16which illustrate the sequential steps in producing a further example of the tooling block74. Referring toFIG.13, a central tool body core110is produced that has a rectangular cross-sectional shape, a central through hole106, and a plurality of longitudinally spaced apart, continuous grooves or recesses108in and around its outer surface. The tool body core110may be formed of any suitable material such as PEEK (polyether ether ketone) or PEK (polyetherketone), and may be produced by any of several manufacturing processes such as molding, machining, or additive manufacturing. For example, the tool body core110, including the grooves108may be formed layer-by-layer by an additive manufacturing process such as FDM (fused deposition modeling) or other known3D printing techniques. Next, as shown inFIG.14, wire rings100, which function as susceptors76, are installed respectively within the grooves108. In those examples where the tool body core110is produced by additive manufacturing, it may be possible to form the wire rings100layer-by-layer by the additive manufacturing process used to produce the tool body core110. Referring toFIG.15, heat pipes105comprising thermally conductive metal rods are positioned diagonally across and spaced outwardly from the corners of the tool body core110. Next, as shown inFIG.16, a tool body outer shell111is installed around the tool body core110and the heat pipes105. The tool body shell111is formed of a suitable material such as PTFE and can be produced by machining, molding or additive manufacturing techniques, following which the tool body core110and the heat pipes105are inserted into the tool body shell111. Alternatively, the tool body outer shell111may be overmolded around the tool body core110and heat pipes105. Other assembly techniques are possible. In use, the wire rings100which act as susceptors76, generate heat at the outer periphery of the tool body core110, evenly throughout its length. The heat generated by the wire rings100is conducted through the tool body outer shell111and is absorbed by the heat pipes105. The heat pipes105concentrate the heat at the outer corners of the tool body outer shell111, in close proximity to the vertical adhesive bondlines68within the cells58. Similar heat pipes105may be embedded within the outer shell111in order to locally concentrate heat in other areas of the cells58, if desired. Reference is now made toFIG.17which broadly illustrates the steps of a method of thermally curing a cell-based composite structure, such as a cell-based structural array50having adhesive bondlines68,70. At112, susceptors76are installed in a plurality of tooling blocks74. Depending upon the configuration of the susceptors76, they may be inserted into tool bodies75either before or after the tooling blocks74are inserted into the cells58of the cell-based structural array50. At114, the tooling blocks74are inserted into cells58of the cell-based structural array50, either individually by hand or in groups using a holding/transfer fixture (not shown). At114, an induction coil88forming part of an electromagnet86generates an electromagnetic field90that extends substantially perpendicular to the rows84of tooling blocks74. At118the susceptors76are inductively heated using the electromagnetic field90. More specifically, the susceptors76absorb electromagnetic energy from the electromagnetic field90, inducing the flow of electrical currents in the susceptors76that produce heat. At120, the adhesive bondlines68,70joining the cells58together are thermally cured using heat generated by the susceptors76and transferred through the tool bodies75. Embodiments of the disclosure may find use in a variety of potential applications, particularly in the transportation industry, including for example, aerospace, marine, automotive applications and other application where cell-based structural components such as a cell-based structural arrays are employed. Thus, referring now toFIGS.18and19, embodiments of the disclosure may be used in the context of an aircraft manufacturing and service method122as shown inFIG.18and an aircraft124as shown inFIG.19. Aircraft applications of the disclosed embodiments may include, for example, without limitation, composite cell cores used in composite sandwich structures, and RF apertures, to name only a few. During pre-production, exemplary method122may include specification and design126of the aircraft124and material procurement128. During production, component and subassembly manufacturing130and system integration132of the aircraft124takes place. Thereafter, the aircraft124may go through certification and delivery134in order to be placed in service136. While in service by a customer, the aircraft124is scheduled for routine maintenance and service138, which may also include modification, reconfiguration, refurbishment, and so on. Each of the processes of method122may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on. As shown inFIG.19, the aircraft124produced by exemplary method122may include an airframe140with a plurality of systems142and an interior144. Examples of high-level systems142include one or more of a propulsion system146, an electrical system148, a hydraulic system150, and an environmental system152. Any number of other systems may be included. Although an aerospace example is shown, the principles of the disclosure may be applied to other industries, such as the marine and automotive industries. Systems and methods embodied herein may be employed during any one or more of the stages of the production and service method122. For example, components or subassemblies corresponding to production process130may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft124is in service. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production stages130and132, for example, by substantially expediting assembly of or reducing the cost of an aircraft124. Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft124is in service, for example and without limitation, to maintenance and service138. As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of each item in the list may be needed. For example, “at least one of item A, item B, and item C” may include, without limitation, item A, item A and item B, or item B. This example also may include item A, item B, and item C or item B and item C. The item may be a particular object, thing, or a category. In other words, at least one of means any combination items and number of items may be used from the list but not all of the items in the list are required. The description of the different illustrative embodiments has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different illustrative embodiments may provide different advantages as compared to other illustrative embodiments. The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated. | 23,546 |
11858220 | Reference will now be made to the exemplary embodiments illustrated, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. DETAILED DESCRIPTION As used herein, “adjacent” refers to the proximity of two structures or elements. Particularly, elements that are identified as being “adjacent” may be either abutting or connected. Such elements may also be near or close to each other without necessarily contacting each other. The exact degree of proximity may in some cases depend on the specific context. An initial overview of technology embodiments is provided below and then specific technology embodiments are described in further detail later. This initial summary is intended to aid readers in understanding the technology more quickly but is not intended to identify key features or essential features of the technology nor is it intended to limit the scope of the claimed subject matter. Although the traditional PE overmold approach for protecting undersea cable junctions is effective, this technique is commonly performed in the field and is time consuming and expensive. Alternatives to the PE overmold do exist, such as utilizing a metal pressure vessel with O-ring seals, however, reliability is an issue. Thus, there is a need for a PE protective housing for undersea cable junctions that can be formed reliably, more quickly, and at less expense than the traditional PE overmold approach. Accordingly, a method of coupling polymeric components utilizing electromagnetic energy is disclosed that can quickly provide reliable and watertight joints. The method can include obtaining a first component having a first coupling portion, a second component having a second coupling portion, and a susceptor. The method can also include mating the first and second components such that the susceptor is proximate the first and second coupling portions. In addition, the method can include applying electromagnetic energy to the susceptor. The susceptor can convert the electromagnetic energy to heat, which can melt portions of the first and second coupling portions about the susceptor to couple the first and second components to one another upon solidification. In one aspect, a polymeric component assembly is disclosed. The polymeric component assembly can include a first component having a first coupling portion. The component assembly can also include a second component having a second coupling portion. Additionally, the component assembly can include a susceptor proximate the first and second coupling portions. The susceptor can be operable to convert electromagnetic energy to heat sufficient to melt the first and second coupling portions. A solidified portion of the first and second coupling portions about the susceptor can couple the first and second components to one another. In one aspect, a polymeric protective housing for a cable junction is disclosed. The protective housing can include a cable having a first coupling portion. The protective housing can also include an end cap having second and third coupling portions. The protective housing can further include a shell having a fourth coupling portion. The protective housing can still further include a first susceptor proximate the first and second coupling portions. The first susceptor can be operable to convert electromagnetic energy to heat sufficient to melt the first and second coupling portions. In addition, the protective housing can include a second susceptor proximate the third and fourth coupling portions. The second susceptor can be operable to convert electromagnetic energy to heat sufficient to melt the third and fourth coupling portions. A solidified portion of the first and second coupling portions about the first susceptor can couple the cable and the end cap to one another. A solidified portion of the third and fourth coupling portions about the second susceptor can couple the end cap and the shell to one another. One example of a polymeric component assembly100is illustrated inFIGS.1-3.FIG.1shows a side view of the component assembly100. End views of the component assembly100are shown inFIGS.2A and2B. In general, the component assembly100can comprise components101a-ecoupled to one another, although any suitable number of components can be included in such an assembly. As described in more detail below, the components101a-ecan be coupled by welding or fusing utilizing electromagnetic energy (e.g., induction heating) and embedded susceptors to assist in localized heat generation. In one aspect, the components101a-eof the component assembly100can form at least a portion of a cable (e.g., a data cable, a telecommunications cable, a power cable, etc.) and/or a protective housing for a cable junction, as shown. Although the present technology will be discussed in the context of cables and protective housings for cable joints, it should be recognized that the component assembly and principles disclosed herein can be utilized in any suitable device, mechanism, or technology area, such as undersea acoustic surveillance, undersea power grids, telecommunication systems, oil and gas industry, oceanographic applications, terrestrial sealing technology, etc. In addition to these examples, those skilled in the art will recognize the many different applications that this technology can be applied to, and that the examples identified herein are not meant to be limiting in any way. Essentially, those skilled in the art will recognize that the present invention technology can be applied in a variety of disciplines and to a variety of applications where components, typically constructed of polymeric materials, are to be coupled to one another. In the side cross-sectional view of the component assembly100shown inFIG.3, this example illustrates segments of a cable (identified as component101a) joined at102. The cable101acan be any suitable type of cable known in the art (e.g., a data cable, a power cable, etc.) and can be of any suitable construction or configuration. The joining or junction of cable segments can be accomplished using any suitable device or structure and by any suitable technique or process known in the art. The components101b-dcan be configured to provide a suitable housing or protective barrier for the cable junction102. In some examples, the components101b-dcan at least partially form a pressure boundary (e.g., pressure vessel) about the cable junction102, such as for use in underwater applications. In some examples, the component101e(e.g., a “feedthrough”) can be included to provide communication and/or power through the protective housing or barrier formed by the components101b-dto a device103(e.g., an electronic device) located within the protective housing or barrier. Although only a single component101eis illustrated, it should be recognized that any suitable number of such components can be included, such as distributed about the component101don a circular pattern106(FIG.2B). Any of the components101a-ecan therefore form at least a portion of a cable assembly or a protective housing for a cable junction as illustrated in the figures. As shown in the exploded cross-section view ofFIG.4A, component101a(e.g., a cable) and101binclude features that can be utilized or configured to facilitate coupling with one another. For example, the component101acan have a coupling portion110a, which in the example of the component101abeing a cable can be any suitable portion of the outer surface of the cable (e.g., a cable jacket). The component101b(e.g., an end cap in the illustrated example) can have a coupling portion110bconfigured to mate, interface, or otherwise facilitate coupling the component101bwith the outer surface coupling portion110aof the component101a. The coupling portion110bcan include an opening111bformed in and defined by a flange112b. In one aspect, the outer surface coupling portion110aof the component101acan be configured to fit within the opening111bof the coupling portion110bof the component101b. Stated differently, the opening111bcan be configured to receive the outer surface coupling portion110aof the component101a. In this case, the component101a, or in this example the cable, extends through the component101b, or in this example the end cap. In the illustrated example, the coupling portions110a,110beach have a cylindrical configuration, although this is not intended to be limiting, as any suitable configuration or geometry can be utilized. The component assembly100can also include one or more susceptors120aproximate the coupling portions110a,110b(e.g., embedded close to the joint interface). The susceptors120acan be operable to convert electromagnetic energy (e.g., radio frequency (RF), magnetic fields, etc.) to heat sufficient to melt and fuse the coupling portions110a,110bat the joint interface, such that a solidified portion or region (indicated at104ainFIG.3) of the coupling portions110a,110babout the susceptor120acouples the components101a,101bto one another. In other words, the susceptor120acan be heated by its presence in (i.e., being exposed to) an electromagnetic field (i.e., by absorbing electromagnetic energy) and can transfer heat to the surrounding coupling portions110a,110bby thermal conduction and/or radiation to melt the coupling portions110a,110b, causing at least a portion of the material of the coupling portions110a,110bto weld or fuse together to form a localized welded or fused region. This can form a strong, contiguous bond (e.g., polymer chains mix and link between components) coupling the components101a,101bto one another. The susceptor120acan therefore provide internal heat generation for melting the coupling portions110a,110b. In one aspect, the components101a,101bare welded or “fused” directly to one another, which prevents separation of the components101a,101bwithout causing their destruction. In other words, it is the materials proximate the susceptors that melt and diffuse into one another to secure the components101a,101bto one another, thus creating a permanent and irreversible bond between the components. By joining the components101a,101bin this manner, in which the components themselves are melted to “fuse” or secure one component to another, the components may therefore not be separated without damaging or destroying the parts, unlike other joining processes (i.e., adhesives) in which the components remain essentially intact and are adhered to another by an intermediary material. Additionally, the manufacturing processes utilized to produce the components may provide suitably smooth surface finishes (e.g., devoid of substantial surface irregularities) that facilitate directly fusing the components to one another. For example, it is desirable that the joint interface geometry is true and parallel with no substantial surface irregularities. In some examples, such as the example illustrated inFIGS.3and4A, the susceptor120acan be at least partially surrounded by or encapsulated (e.g., molded) in a weld material121ato form a susceptor grommet122adisposed between the coupling portions110a,110b. In this case, an outer interface surface123aof the susceptor grommet122acan be configured to interface with the coupling portion110bof the component101b, and an inner surface124aof the susceptor grommet122acan be configured to interface with the coupling portion110aof the component101a. In this example, therefore, the coupling portion110bis not configured to interface directly with the outer surface coupling portion110aof the cable101a. In one aspect, during assembly, the susceptor grommet122acontaining the susceptor120acan be disposed proximate a coupling portion, such as coupling portion110b, prior to inserting the coupling portion110ainto the opening111b. The components101b,101ccan also include features that can be utilized or configured to facilitate coupling with one another. For example, the component101b(in this example the end cap) can have a coupling portion114b. The component101c(e.g., a shell or tube in the illustrated example) can have a coupling portion110cconfigured to mate, interface, or otherwise facilitate coupling with the coupling portion114bof the component101bfor coupling the component101band the component101cto one another. The coupling portion110ccan include an opening115cformed in and defined by a flange116cof the component101c. In one aspect, the coupling portion114bof the component101bcan be configured to fit within the opening115c. Stated differently, the opening115ccan be configured to receive the coupling portion114bof the component101b. In the illustrated example, the coupling portions114b,110ceach have a cylindrical configuration, although this is not intended to be limiting, as any suitable configuration or geometry can be utilized. The component assembly100can also include one or more susceptors120bproximate the coupling portions114b,110c(e.g., embedded close to the joint interface). As described above, the susceptors120bcan be operable to convert electromagnetic energy (e.g., radio frequency (RF), magnetic fields, etc.) to heat sufficient to melt the coupling portions114b,110cat the joint interface, such that a solidified portion (indicated at104binFIG.3) of the coupling portions114b,110cabout the susceptor120bcouples the components101b,101cto one another. In some examples, such as the example illustrated inFIGS.3and4A, the susceptor120bcan be at least partially surrounded by or encapsulated (e.g., molded) in a weld material121bto form a susceptor grommet122bdisposed between the coupling portions114b,110c. In this case, an outer interface surface123bof the susceptor grommet122bcan be configured to interface with the coupling portion110cof component101c, and an inner surface124bof the susceptor grommet122bcan be configured to interface with the coupling portion114bof the component101b. In this example, therefore, the coupling portion110cis not configured to interface directly with the coupling portion114b. In one aspect, during assembly, the susceptor grommet122bcan be disposed proximate a coupling portion, such as coupling portion110c, prior to inserting the coupling portion114binto the opening115c. With reference to the exploded cross-section view ofFIG.4B, the components101a,101dinclude features that can be utilized or configured to facilitate coupling with one another. As mentioned above, the component101acan have the coupling portion110a, which in the case of a cable can be any suitable portion of the outer surface of the cable (e.g., a cable jacket). The component101d(e.g., an end cap in the illustrated example) can have a coupling portion110dconfigured to mate, interface, or otherwise facilitate coupling the component101dwith the outer surface coupling portion110aof the cable101a. The coupling portion110dcan include an opening111dformed in and defined by a flange112dof the component101d. In one aspect, the outer surface coupling portion110aof the component101acan be configured to fit within the opening111d. Stated differently, the opening111dcan be configured to receive the outer surface coupling portion110aof the component101a. In this case, the component101aextends through the component v101d. In the illustrated example, the coupling portions110a,110deach have a cylindrical configuration, although this is not intended to be limiting, as any suitable configuration or geometry can be utilized. The component assembly100can also include one or more susceptors120cproximate the coupling portions110a,110d(e.g., embedded close to the joint interface). As described above, the susceptors120ccan be operable to convert electromagnetic energy (e.g., radio frequency (RF), magnetic fields, etc.) to heat sufficient to melt the coupling portions110a,110dat the joint interface, such that a solidified portion (indicated at104cinFIG.3) of the coupling portions110a,110dabout the susceptor120ccouples the components101a,101dto one another. In some examples, such as the example illustrated inFIGS.3and4B, the susceptor120ccan be associated with a component, such as the component101din the illustrated example. For example, the susceptor120ccan be at least partially surrounded by or encapsulated (e.g., molded) in the material of the component101dproximate to the coupling portion110d. In this case, the coupling portion110dcan be configured to interface with the coupling portion110a, In this example, therefore, the coupling portion110dof the component101dcan be configured to interface directly with the outer surface coupling portion110aof the component101a. The components101c,101dcan also include features that can be utilized or configured to facilitate coupling with one another. For example, the component101dcan have a coupling portion114d. The component101c(e.g., shell) can have a coupling portion117cconfigured to mate, interface, or otherwise facilitate coupling with the coupling portion114dof the component101b(e.g., end cap) for coupling the component101dand the component101cto one another. The coupling portion117ccan include an opening118cformed in and defined by a flange119c. In one aspect, the coupling portion114dof the component101dcan be configured to fit within the opening118c. Stated differently, the opening118ccan be configured to receive the coupling portion114dof the component101d. In the illustrated example, the coupling portions114c,110deach have a cylindrical configuration, although this is not intended to be limiting, as any suitable configuration or geometry can be utilized. The component assembly100can also include one or more susceptors120dproximate the coupling portions114d,117c(e.g., embedded close to the joint interface). As described above, the susceptors120dcan be operable to convert electromagnetic energy (e.g., radio frequency (RF), magnetic fields, etc.) to heat sufficient to melt the coupling portions114d,117cat the joint interface, such that a solidified portion (indicated at104dinFIG.3) of the coupling portions114d,117cabout the susceptor120dcouples the components101c,101dto one another. In some examples, such as the example illustrated inFIGS.3and4B, the susceptor120dcan be associated with a component, such as the component101din the illustrated example. For example, the susceptor120dcan be at least partially surrounded by or encapsulated (e.g., molded) in the material of the component101dproximate to the coupling portion114d. In this case, the coupling portion114dcan be configured to interface with the coupling portion117c, In this example, therefore, the coupling portion114dof the component101dcan be configured to interface directly with the coupling portion117cof the component101c. In one aspect, mentioned above, the component101d, comprising an end cap in this example, can be configured to provide access for a feedthrough101e(e.g., for communication and/or power) through the protective housing or barrier formed by the components101b-dto the device103(e.g., an electronic device) located within the protective housing or barrier. The components101d,101einclude features that can be utilized or configured to facilitate coupling with one another. The feedthrough101ecan have any suitable configuration. In some examples, the feedthrough101ecan comprise a cable. The feedthrough101ecan have a coupling portion110e, which in the case of a cable can be any suitable portion of the outer surface of a cable (e.g., a cable jacket). The component101d(e.g., end cap) can have a coupling portion113das described herein configured to mate, interface, or otherwise facilitate coupling the component101dwith the outer surface coupling portion110eof the feedthrough101e, In this case, the feedthrough101eextends through the end cap101d. In the illustrated example, the coupling portions110d,110eeach have a cylindrical configuration, although this is not intended to be limiting, as any suitable configuration or geometry can be utilized. The component assembly100can also include one or more susceptors120eproximate the coupling portions113d,110e(e.g., embedded close to the joint interface). As described above, the susceptors120ecan be operable to convert electromagnetic energy (e.g., radio frequency (RF), magnetic fields, etc.) to heat sufficient to melt the coupling portions113d,110eat the joint interface, such that a solidified portion (indicated at104einFIG.3) of the coupling portions113d,110eabout the susceptor120ecouples the components101d,101eto one another. It should also be recognized that the susceptors120ecan optionally be included in a susceptor grommet122eas described herein to facilitate coupling the components101d,101eto one another. The components101a-e, and more particularly the coupling portions110a-e, can be formed or constructed in any suitable manner utilizing any suitable material for the intended purpose as described herein. For example, the components101a,101b(e.g., the coupling portions110a-e) can comprise a polymeric material, such as a thermoplastic material (e.g., polyethylene (PE), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyolefin, etc.). In some examples, the material of adjacent or mating components is the same. In other examples, the materials of adjacent or mating components can be different (e.g., different thermoplastic materials), which may be selected for their suitability in fusing or welding to one another, as described in more detail below. Typically, the susceptor120a-ewill be made of a metallic material, a ferromagnetic material, and/or a dielectric material. In one aspect, the susceptor120a-ccan have high resistivity, which may be advantageous for induction heating. Suitable susceptor materials can include steel (e.g., ferritic steel, stainless steel (e.g., ferritic stainless steel), etc.), copper, aluminum, molybdenum, niobium, silicon carbide, graphite, etc. In some cases where the component assembly100will be used in a water environment, stainless steel may be preferred as a susceptor material for its corrosion resistance properties in the event the susceptor is exposed to water. The susceptor(s)120a-ecan have any suitable configuration, geometry, or construction known in the art. In one aspect, the susceptor(s)120a-ecan comprise a ring or hoop configuration and/or a coil configuration, as shown inFIGS.3-4B. In another example, the susceptor(s)120a-ecan comprise a ball configuration. A cross-sectional shape of a ring, hoop, or coil can be of any suitable shape or geometry, such as a circular shape a rounded shape, a rectangular shape, a triangular shape, etc. In another aspect, the susceptor(s)120a-ecan be a particulate or a powder, which can be formed or molded into or otherwise supported by a polymeric material. FIG.3further illustrates a component coupling system105in accordance with an example of the present disclosure. For example, the coupling system105can include one or more electromagnetic energy sources130a-c, such as an inductor (e.g., PE welder), to generate an electromagnetic (e.g., RF or magnetic) field and apply this to or about select portions or regions of the component assembly100to produce a localized welded region. In one aspect, the electromagnetic energy sources130a-ccan be configured to radiate energy directed toward the susceptors120a-eto weld or fuse the adjacent components101a-eto one another by heating the susceptors120a-e. In a particular aspect, the electromagnetic energy sources130a,130bcan be configured to include an inductor coil, and the components101a-dcan fit within the coil without contacting the electromagnetic energy sources130a,130b, such that energy (e.g., a magnetic field or flux) is radiated radially inward to heat the susceptors120a-d. The electromagnetic energy source130ccan include an inductor coil configured to direct energy (e.g., a magnetic field or flux) longitudinally along the cable101eto heat the susceptor120ewithin the component101dwithout the electromagnetic energy source130ccontacting the component101eor the component101d. The intensity, duration, and/or location of the radiation or magnetic field can be tightly controlled to provide repeatable results. Each of the electromagnetic energy sources130a-ccan be configured to provide focused induction heating. In other words, the electromagnetic energy sources130a-ccan be configured to deliver localized, focused electromagnetic energy, meaning only the energy required to one or more specific locations or regions of the component assembly100in each of the radial and longitudinal directions (e.g., in the event of a circular component assembly, such as a cable or cable junction) to achieve one or more specific, localized fused or welded regions within the component assembly100, and to avoid undesirable interactions with other components that may be located in or around the assembly (e.g., metal components of an electronic device, pressure vessel, etc.). Indeed, the electromagnetic energy can be delivered so as to produce a welded or fused region confined to a specific boundary about the susceptors. For example, the electromagnetic energy source can be controlled to deliver electromagnetic energy to a specific radial depth (e.g., about 25 mm+/−1-2 mm) and along a specific axial length (e.g., about 25-50 mm+/−1-4 mm) about the susceptors120a-d, such that the component assembly100comprises one or more fused or welded regions having a specific depth and axial length sufficient to join the components of the component assembly100together. Material selections, thickness, and related composition, such as resistivity and conductivity, and/or other characteristics may also be taken into consideration. The joining structures and techniques disclosed herein can rapidly produce an assembly100that provides a high-pressure, watertight seal in much less time than standard injection molding technology. In one aspect, the principles disclosed herein can also be used for non-sealing, mechanical fastening purposes. In accordance with one embodiment of the present invention, a method of coupling polymeric components utilizing localized, focused electromagnetic energy is disclosed. The method can comprise obtaining a first component having a first coupling portion, a second component having a second coupling portion, and a susceptor. The method can also comprise mating the first and second components such that the susceptor is proximate the first and second coupling portions. Additionally, the method can comprise applying electromagnetic energy to the susceptor, wherein the susceptor converts the electromagnetic energy to heat, which melts portions of the first and second coupling portions about the susceptor to couple the first and second components to one another upon solidification. It is noted that no specific order is required in this method, though generally in one embodiment, these method steps can be carried out sequentially. In one aspect of the method, the first coupling portion comprises an opening and the second coupling portion is configured to fit within the opening. In one aspect of the method, the first coupling portion and the second coupling portion each have a cylindrical configuration. In one aspect of the method, the susceptor comprises at least one of a ring configuration, a coil configuration, a particulate, or a powder. In one aspect of the method, the susceptor comprises at least one of stainless steel, aluminum, molybdenum, niobium, silicon carbide, or graphite. In one aspect of the method; electromagnetic energy is applied by an inductor. In one aspect of the method, at least one of the first coupling portion or the second coupling portion is formed of a thermoplastic material. In one aspect of the method, the components form at least a portion of a data cable assembly. It is to be understood that the embodiments of the invention disclosed are not limited to the particular structures, process steps, or materials disclosed herein, but are extended to equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting. Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. In addition, various embodiments and example of the present invention may be referred to herein along with alternatives for the various components thereof. It is understood that such embodiments, examples, and alternatives are not to be construed as de facto equivalents of one another, but are to be considered as separate and autonomous representations of the present invention. Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a thorough understanding of embodiments of the invention, One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention. While the foregoing examples are illustrative of the principles of the present invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts of the invention. Accordingly, it is not intended that the invention be limited, except as by the claims set forth below. | 30,824 |
11858221 | It will be recognized by the person having ordinary skill in the art, given the benefit of this disclosure, that the dimensions of the various layers in the figures are not shown to scale. No particular layer thickness or dimensions are intended or implied unless made clear from the specific description in connection with that particular layer or other component. The exact dimensions will vary depending on the final configuration of the article and/or its intended use. DETAILED DESCRIPTION Certain features of multilayer assemblies with one or more surface depressions across a surface of the multi layer assembly are described. In some instances, the multilayer assembly may include a core layer and one or more additional layers disposed on a surface of the core layer. The surface depressions may be present on one or more surfaces of the core layer and any additional layer disposed on the core layer. For example, a surface depression can be formed by pushing the additional layer into the core layer so the recessed area or depression includes the additional layer. As noted in more detail below, pressing of the additional layer into the core layer can increase bonding and/or peel strength of the additional layer to the core layer. This increased bonding may result in less likelihood of delamination or peeling of the additional layer from the core layer. If desired, surface depressions may exist on two or more surfaces of the multilayer assembly. Different surface depressions need not have the same shape, width or depth. Further different surfaces of the multilayer assembly may have a different number of depressions, depressions of different shapes or geometries or otherwise not include the same number or type of depressions. In certain configurations, depressions may be spread out across a surface of the multilayer assembly, whereas in other instances, the depressions may be localized or present in a higher number at certain areas of the multilayer assembly, e.g., more depressions may be present at edges of the multilayer assembly to reduce peeling at the edges. In some configurations, a core layer with one or more surface depressions is shown inFIG.1A. The core layer110includes a depression115on a first surface112of the core layer110. The exact shape, width and depth of the depression115may vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. While the depression115is shown as being present on a first surface112, it could instead be present on the surface114or a depression may be present on a surface112and a surface114. In addition, the depression115can be positioned at many different sites along the surface112. As noted in more detail below, a skin layer or other layer may be present on the surface112(and/or surface114) and have a respective depression where some portion of the skin layer or additional layer is pressed into the depression115. In certain embodiments, a core layer120is shown inFIG.1Bthat comprises a first depression125on a first surface122and a second depression126on the first surface122. The depressions125,126need not be the same, and the exact shape, width and depth of the depressions125,126each may independently vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. In some instances, one of the depressions may instead be present on a second surface as shown inFIG.1C, where a second depression127is present on a second surface124of the core layer121. Where two depressions are present on different surfaces of the core layer121, the shape, width and depth of the depressions can be the same or can be different. As noted in more detail below, a skin layer or other layer may be present on the surface122. (and/or surface124) and have a respective depression(s) where some portion of the skin layer or additional layer is pressed into one or both of the depressions125,126. In other configurations, a core layer can include three or more depressions. Referring toFIG.1D, a core layer130is shown that comprises depressions135,136and137on a first surface132. The depressions135,136,137need not be the same, and the exact shape, width and depth of the depressions135,136,137each may independently vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. In some instances, one of the depressions may instead be present on a second surface as shown inFIG.1E, where a third depression138is present on a second surface134of the core layer131. If desired, two or more of the depressions may be present on the surface134of the core layer131. Where three depressions are present on different surfaces of the core layers130,131, the shape, width and depth of the depressions can be the same or can be different. As noted in more detail below, a skin layer or other layer may be present on the surface132(and/or surface134) and have a respective depression(s) where some portion of the skin layer or additional layer is pressed into the depressions135,136,137. If desired, however, the skin layer may be pressed into fewer than all of the depressions135,136,137. In some embodiments, a core layer can include four or more depressions. Referring toFIG.1F, a core layer140is shown that comprises depressions145,146,147and148on a first surface142. The depressions145,146,147,148need not be the same, and the exact shape, width and depth of the depressions145,146,147,148each may independently vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. In some instances, one of the depressions may instead be present on a second surface as shown inFIG.1G, where a fourth depression149is present on a second surface144of the core layer141. If desired, two or more of the depressions may be present on the surface144of the core layer141. Where four depressions are present on different surfaces of the core layers140,141, the shape, width and depth of the depressions can be the same or can be different. As noted in more detail below, a skin layer or other layer may be present on the surface142(and/or surface144) and have a respective depression(s) where some portion of the skin layer or additional layer is pressed into the depressions145,146,147,148. If desired, however, the skin layer may be pressed into fewer than all of the depressions145,146,147,148. In some embodiments, a core layer can include five or more depressions. Referring toFIG.1H, a core layer150is shown that comprises depressions155,156,157,158, and159on a first surface152. The depressions155,156,157,158,159need not be the same, and the exact shape, width and depth of the depressions155,156,157,158,159each may independently vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. In some instances, one of the depressions may instead be present on a second surface as shown inFIG.1I, where a fifth depression161is present on a second surface154of the core layer151. If desired, two or more of the depressions may be present on the surface154of the core layer150. Where five depressions are present on different surfaces of the core layer150, the shape, width and depth of the depressions can be the same or can be different. As noted in more detail below, a skin layer or other layer may be present on the surface152(and/or surface154) and have a respective depressions) where some portion of the skin layer or additional layer is pressed into the depressions155,156,157,158,159and160. If desired, however, the skin layer may be pressed into fewer than all of the depressions155,156,157,158,159. The core layers shown inFIGS.1A-1Imay each comprise a honeycomb core layer such as, for example, a paper honeycomb core layer, a polyurethane layer, an expanded foam, an extruded foam, a honeycomb structure produced from one or more polymeric materials including, but not limited to, polypropylene, polyethylene, polystyrene, a polyamide, a copolyamide, polyethylene terephthalate, a polyetherimide, a polyphenylene oxide, and other polymers, a honeycomb structure produced from one or more metals including, but not limited to, aluminum, iron, steel and other metals and metal alloys. In some embodiments, the core layer may be a honeycomb layer with a material other than cellulose. For example, the honeycomb layer may be porous and include significant open space within the core layer. The core layers shown inFIGS.1A-1Imay comprise a basis weight of about 200 grams per square meter (gsm) to about 4000 gsm. The overall thickness of the core layers shown inFIGS.1A-1Imay vary, for example, from about 0.5 cm to about 7.5 cm. The depth of the depressions shown in the core layersFIGS.1A-1Ican vary, for example, from about 0.125 inches (about 3 mm) to about 1 inch (about 2.5 cm), e.g., about 5 mm to about 1.25 mm, depending on the overall thickness of the core layer. As noted herein, different depressions can have different depths and/or geometries. In certain configurations, a plurality of depressions may be present across a surface of a core layer as shown inFIGS.2A-2C. Referring toFIG.2A, a core layer210is shown that comprises a plurality of depressions on a first surface212. The depressions may have the same or different shapes, widths or depths as desired. The depression distribution need not be uniform, and, if desired, more depressions may be positioned at one area of the core layer than other areas of the core layer. Referring toFIG.2B, a core layer220is shown with increased depressions positioned at edges223,225of the core layer220.FIG.2Cshows a depression distribution with the depressions positioned toward one side or edge233of a core layer230.FIG.21) shows a depression distribution with more depressions positioned toward a center area of a core layer240. As noted in more detail below, one or more skin layers or additional layers can be present on one or more surfaces of the core layers shown inFIGS.2A-2D. In certain embodiments, the core layers shown inFIGS.2A-2Dmay each comprise a honeycomb core layer such as, for example a paper honeycomb core layer, a polyurethane layer, an expanded foam, an extruded foam, a honeycomb structure produced from one or more polymeric materials including, but not limited to, polypropylene, polyethylene, polystyrene, a polyamide, a copolyamide, polyethylene terephthalate, a polyetherimide, a polyphenylene oxide, and other polymers, a honeycomb structure produced from one or more metals including, but not limited to, aluminum, iron, steel and other metals and metal alloys. In some embodiments, the core layer may be a honeycomb layer with a material other than cellulose. For example, the honeycomb layer may be porous and include significant open space within the core layer. The core layers shown inFIGS.2A-2Dmay comprise a basis weight of about 200 grams per square meter (gsm) to about 4000 gsm. The overall thickness of the core layers shown inFIGS.1A-1Imay vary from about 0.5 cm to about 7.5 cm. The depth of the depressions shown in the core layersFIGS.2A-2Dcan vary from about 0.125 inches (about 3 mm) to about 1 inch (about 2.5 cm), e.g., about 5 mm to about 1.25 mm, depending on the overall thickness of the core layer. As noted herein, different depressions can have different depths and/or geometries. In some embodiments, two or more surfaces of a core layer may comprise a plurality of depressions. Referring toFIG.3A, a core layer310is shown that comprises a plurality of depressions on a first surface312and on a second surface314. The depressions on any one surface may have the same or different shapes, widths or depths as desired. Further, depressions on the first surface312may all have a first shape (when viewed in cross-section) and depressions on the second surface314may all have a second shape (when viewed in cross-section). The first shape may be the same or different than the second shape. The depression distribution on each of the first surface312and the second surface314need not be uniform, and, if desired, more depressions may be positioned at one area of the core layer than other areas of the core layer. Further, the depression distribution need not be the same on each of the first surface312and the second surface314. Referring toFIG.3B, a core layer320is shown with increased depressions positioned at edges323,325on a first surface322of the core layer320.FIG.3Cshows a depression distribution with the depressions positioned toward one side or edge333of a first surface332of a core layer330.FIG.3Dshows a depression distribution with more depressions positioned toward a center area of a core layer340. While the depressions on the second surface of the core layers310,320,330,340are shown for illustration purposes as being uniform, the depression distribution could instead be non-uniform or asymmetric as described in connection with the depressions on the first surface of the core layers310,320,330and340. As noted in more detail below, one or more skin layers or additional layers can be present on one or more surfaces of the core layers shown inFIGS.3A-3D. In certain embodiments, the core layers shown inFIGS.3A-3Dmay each comprise a honeycomb core layer such as, for example, a paper honeycomb core layer, a polyurethane layer, an expanded foam, an extruded foam, a honeycomb structure produced from one or more polymeric materials including, but not limited to, polypropylene, polyethylene, polystyrene, a polyimide, a copolyamide, polyethylene terephthalate, a polyetherimide, a polyphenylene oxide, and other polymers, a honeycomb structure produced from one or more metals including, but not limited to, aluminum, iron, steel and other metals and metal alloys. In some embodiments, the core layer may be a honeycomb layer with a material other than cellulose. For example, the honeycomb layer may be porous and include significant open space within the core layer. The core layers shown inFIGS.3A-3Dmay comprise a basis weight of about 200 grams per square meter (gsm) to about 4000 gsm. The overall thickness of the core layers shown inFIGS.1A-1Imay vary from about 0.5 cm to about 7.5 cm. The depth of the depressions shown in the core layersFIGS.3A-3Dcan vary from about 0.125 inches (about 3 mm) to about 1 inch (about 2.5 cm), e.g., about 5 mm to about 1.25 mm, depending on the overall thickness of the core layer. As noted herein, different depressions can have different depths and/or geometries. In certain configurations, the core layers described herein can be used to provide a multilayer assembly that includes the core layer in combination with a skin layer or other layer. While the exact configuration of the skin layer may vary, the skin layer can be configured as a porous fiber reinforced thermoplastic layer disposed on a first surface of core layer. The porous fiber reinforced thermoplastic layer may include a web of open celled structures formed by a plurality of reinforcing materials, e.g., reinforcing fibers, held together with a thermoplastic material, e.g., a polyolefin material or other materials. The porous fiber reinforced thermoplastic layer can be bonded to surfaces of the plurality of depressions across a first surface of the core layer, e.g., the skin layer may have depressions that generally mirror the depressions in the core layer so each depression includes two layers, e.g., a core layer component and skin layer component. Various illustrations of multilayer assembly with a core layer and one or more skin layers are described in more detail below. In some configurations, the multilayer assembly may comprise a core layer and a single skin layer with one or more surface depressions on a surface of a multilayer assembly. Referring toFIG.4A, a multilayer assembly400comprises a core layer410, a skin layer411and a depression415on a first surface412of the multilayer assembly400. The exact shape, width and depth of the depression415may vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. While the depression415is shown as being present on a first surface412, it could instead be present on the surface414or a depression may be present on a surface412and a surface414. The depression415includes both the core layer410and the skin layer411. The presence of a depression415can enhance bonding of the skin layer411to the core layer410. In certain embodiments, a multilayer assembly420is shown inFIG.4Bas including a core layer421and a skin layer422. A first depression425on a first surface423and a second depression426on the first surface423are shown. The depressions425,426need not be the same, and the exact shape, width and depth of the depressions425,426each may independently vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. In some instances, one of the depressions may instead be present on a second surface as shown inFIG.4C, where a second depression427is present on a second surface424of a multilayer assembly. Where two depressions are present on different surfaces of a multilayer assembly, the shape, width and depth of the depressions can be the same or can be different. While not shown, a skin layer or other layer may be present on the surface424if desired. In other configurations, a multilayer assembly including at least one skin layer can include three or more depressions. Referring toFIG.4D, a multilayer assembly430, including a core layer431and a skin layer432, is shown that comprises depressions435,436and437on a first surface433. The depressions435,436,437need not be the same, and the exact shape, width and depth of the depressions435,436,437each may independently vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. In some instances, one of the depressions may instead be present on a second surface as shown inFIG.4E, where a third depression438is present on a second surface434of a multilayer assembly. If desired, two or more of the depressions may be present on the surface434of the multilayer assembly. Where three depressions are present on different surfaces of a multilayer assembly, the shape, width and depth of the depressions can be the same or can be different. While not shown, a skin layer or other layer may be present on the surface434if desired. In some embodiments, a multilayer assembly can include four or more depressions. Referring toFIG.4F, a multilayer assembly440including a core layer441and a skin layer442is shown that comprises depressions445,446,447and448on a first surface443. The depressions445,446,447,448need not be the same, and the exact shape, width and depth of the depressions445,446,447,448each may independently vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. In some instances, one of the depressions may instead be present on a second surface as shown inFIG.4G, where a fourth depression449is present on a second surface444of a multilayer assembly. If desired, two or more of the depressions may be present on the surface444of a multilayer assembly. Where four depressions are present on different surfaces of the multilayer assembly440, the shape, width and depth of the depressions can be the same or can be different. While not shown, a skin layer or other layer may be present on the surface444if desired. In some embodiments, a core layer can include five or more depressions. Referring toFIG.4H, a multilayer assembly450is shown that includes a core layer451and a skin layer452and depressions455,456,457,458, and459on a first surface453. The depressions455,456,457,458,459need not be the same, and the exact shape, width and depth of the depressions455,456,457,458,459each may independently vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. In some instances, one of the depressions may instead be present on a second surface as shown inFIG.4I, where a fifth depression461is present on a second surface454of a multilayer assembly. If desired, two or more of the depressions may be present on the surface454of a multilayer assembly. Where five depressions are present on different surfaces of a multilayer assembly, the shape, width and depth of the depressions can be the same or can be different. While not shown, a skin layer or other layer may be present on the surface454if desired. In certain embodiments, the core layers shown inFIGS.4A-4Imay each comprise a honeycomb core layer such as, for example, a paper honeycomb core layer, a polyurethane layer, an expanded foam, an extruded foam, a honeycomb structure produced from one or more polymeric materials including, but not limited to, polypropylene, polyethylene, polystyrene, a polyamide, a copolyamide, polyethylene terephthalate, a polyetherimide, a polyphenylene oxide, and other polymers, a honeycomb structure produced from one or more metals including, but not limited to, aluminum, iron, steel and other metals and metal alloys. In some embodiments, the core layer may be a honeycomb layer with a material other than cellulose. For example, the honeycomb layer may be porous and include significant open space within the core layer. The core layers shown inFIGS.4A-4Imay comprise a basis weight of about 200 grams per square meter (gsm) to about 4000 gsm. The overall thickness of the core layers shown inFIGS.4A-4Imay vary from about 0.5 cm to about 7.5 cm. The depth of the depressions shown in the core layersFIGS.4A-4Ican vary from about 0.125 inches (about 3 mm) to about 1 inch (about 2.5 cm), e.g., about 5 mm to about 1.25 mm, depending on the overall thickness of the core layer. As noted herein, different depressions can have different depths and/or geometries. In certain examples, the skin layers shown inFIGS.4A-4Imay each comprise a porous fiber reinforced thermoplastic layer. For example, the porous fiber reinforced thermoplastic layer may be configured as (or used in) a glass mat thermoplastic composite (GMT) or a light weight reinforced thermoplastic (LWRT). One such LWRT is prepared by FIANWHA AZDEL, Inc. and sold under the trademark SUPERLITE® material. The areal density of such a GMT or LWRT can range from about 300 grams per square meter (gsm) of the GMT or LWRT to about 4000 gsm, although the areal density may be less than 300 gsm or greater than 4000 gsm depending on the specific application needs. In some embodiments, the upper density can be less than about 4000 gsm. In certain instances, the GMT or the LWRT may comprise one or more lofting agent materials disposed in void space or pores of the GMT or the LWRT. Where two or more GMT or LWRT layers are present, the GMT or LWRT layers may be the same or may be different. In certain examples where an LWRT is used as a porous fiber reinforced thermoplastic skin layer, the LWRT typically includes a thermoplastic material and a plurality of reinforcing fibers which together form a web of open celled structures. The web can be formed from a random arrangement of reinforcing fibers that are held in place by the thermoplastic material. For example, the porous fiber reinforced thermoplastic layer typically comprises a substantial amount of open cell structure such that void space is present in the layers. In some instances, the porous fiber skin layers shown inFIGS.4A-4Imay comprise a void content or porosity of 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 70-80%, 70-90%, 70-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95% 70-80%, 70-90%, 70-95%, 80-90%, 80-95% or any illustrative value within these exemplary ranges. In some instances, the skin layers shown inFIGS.4A-4Icomprise a porosity or void content of greater than 0%, e.g., is not fully consolidated, up to about 95%. Unless otherwise stated, the reference to the skin layers shown inFIGS.4A-4Icomprising a certain void content or porosity is based on the total volume of that skin layer and not necessarily the total volume of the multilayer assembly. In certain examples, the skin layers shown inFIGS.4A-4Ican be produced in the form of a GMT or LWRT sheet. In certain instances, the sheet can be generally prepared using chopped glass fibers, a thermoplastic material, optionally a lofting agent and an optional thermoplastic polymer film or films and/or woven or non-woven fabrics made with glass fibers or thermoplastic resin fibers such as, for example, polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), a blend of PC/PBT, or a blend of PC/PET. In some embodiments, a PP, a PBT, a PET, a PC/PET blend or a PC/PBT blend can be used as a resin. To produce the sheet, a thermoplastic material and reinforcing materials can be added or metered into a dispersing foam contained in an open top mixing tank fitted with an impeller. Without wishing to be bound by any particular theory, the presence of trapped pockets of air of the foam can assist in dispersing the glass fibers, the thermoplastic material and the lofting agent. In some examples, the dispersed mixture of fibers and thermoplastic material can be pumped to a head-box located above a wire section of a paper machine via a distribution manifold. The foam, not the fibers and thermoplastic, can then be removed as the dispersed mixture is provided to a moving wire screen using a vacuum, continuously producing a uniform, fibrous wet web. The wet web can be passed through a dryer at a suitable temperature to reduce moisture content and to melt or soften the thermoplastic material. The resulting product may be pressed or compressed, e.g., using nip rollers or other techniques, to form a sheet which can then be coupled to a core layer or another layer. In certain embodiments, the high porosity present in the skin layers shown inFIGS.4A-4Ican reduce the overall weight of the multi layer assembly and can permit the inclusion of agents within the void space of the skin layers. For example, lofting agents can reside in the void space in a non-covalently bonded manner. Application of heat or other perturbations can act to increase the volume of the non-covalently bonded lofting agent which in turn increases the overall thickness of the layer, e.g., the layer increases as the size of the lofting agent increases and/or additional air becomes trapped in the layer. If desired, flame retardants, colorants, smoke suppressants and other materials may be included in the void space of the skin layers shown inFIGS.4A-4I. Prior to lofting, the multilayer assembly can be compressed to reduce its overall thickness, e.g., compressed before or after the layer is coupled to one or more other layers. In certain embodiments, the thermoplastic material of the skin layers shown inFIGS.4A-4Imay comprise, at least in part, a polyolefin or one or more of polyethylene, polypropylene, polystyrene, acrylonitrylstyrene, butadiene, polyethyleneterephthalate, polybutyleneterephthalate, polybutylenetetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, and blends of these materials with each other or other polymeric materials. Other suitable thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, co-polyamides, acrylonitrile-butylacrylate-styrene polymers, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystalline polymers, poly(1,4 phenyl ene) compounds commercially known as PARMAX®, high heat polycarbonate such as Bayer's APEC® PC, high temperature nylon, and silicones, as well as copolymers, alloys and blends of these materials with each other or other polymeric materials. The thermoplastic material used to form the skin layers shown inFIGS.4A-4Ican be used in powder form, resin form, rosin form, particle form, fiber form or other suitable forms. Illustrative thermoplastic materials in various forms are described herein and are also described, for example in U.S. Publication Nos, 20130244528 and US20120065283. The exact amount of thermoplastic material present in the skin layers shown inFIGS.4A-4Ican vary and illustrative amounts range from about 20% by weight to about 80% by weight, e.g., 30-70 percent by weight or 35-65 percent by weight. It will be recognized by the skilled person that the weight percentages of all materials used in any one of the skin layers shown inFIGS.4A-4Iwill add to 100 weight percent. In certain examples, the reinforcing fibers of the skin layers shown inFIGS.4A-4Imay comprise glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as, for example, para- and meta-aramid fibers, nylon fibers, polyester fibers, or high melt flow index resins that are suitable for use as fibers, mineral fibers such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metalized natural and/or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers can be chemically treated prior to use to provide desired functional groups or to impart other physical properties to the fibers, e.g., may be chemically treated so that they can react with the thermoplastic material, the lofting agent or both. The fiber content in the skin layers shown inFIGS.4A-4Imay independently be from about 20% to about 90% by weight of the layer, more particularly from about 30% to about 70%, by weight of the layer. Typically, the fiber content of a multilayer assembly comprising the skin layers shown inFIGS.4A-4Ivaries between about 20% to about 90% by weight, more particularly about 30% by weight to about 80% by weight, e.g., about 40% to about 70% by weight of the assembly. The particular size and/or orientation of the fibers used may depend, at least in part, on the thermoplastic polymer material used and/or the desired properties of the skin layers shown inFIGS.4A-4I. Suitable additional types of fibers, fiber sizes and amounts will be readily selected by the person of ordinary skill in the art; given the benefit of this disclosure. In one non-limiting illustration, fibers dispersed within a thermoplastic material and optionally a lofting agent to provide the skin layers shown inFIGS.4A-4Ican generally have a diameter of greater than about 5 microns, more particularly from about 5 microns to about 22 microns, and a length of from about 5 mm to about 200 mm; more particularly, the fiber diameter may be from about 2 microns to about 22 microns and the fiber length may be from about 5 mm to about 75 mm. In some embodiments, the lofting capacity of the skin layers shown inFIGS.4A-4Ican be further tuned by including one or more added lofting agents. The exact type of lofting agent used in the skin layers shown inFIGS.4A-4Ican depend on numerous factors including, for example, the desired lofting temperature, the desired degree of loft, etc. In some instances, microsphere lofting agents, e.g., expandable microspheres, which can increase their size upon exposure to convection heating may be used. Illustrative commercially available lofting agents are available from Kureha Corp, (Japan). In other instances, a first lofting agent with a first average particle size and a second lofting agent with a second average particle size, different from the first average particle size, may be used in the skin layers shown inFIGS.4A-4I. In other examples, the lofting agent may be an expandable graphite materials which can also impart some flame retardancy to the multilayer assembly. In some configurations, the skin layers shown inFIGS.4A-4Imay be a substantially, halogen free or halogen free layer to meet the restrictions on hazardous substances requirements for certain applications. In other instances, one or more of the layers may comprise a halogenated flame retardant agent such as, for example, a halogenated flame retardant that comprises one of more of F, Cl, Br, I, and At or compounds that including such halogens, e.g., tetrabromo bisphenol-A polycarbonate or monohalo-, dihalo-, trihalo- or tetrahalo-polycarbonates. In some instances, the thermoplastic material used in the skin layers shown inFIGS.4A-4Imay comprise one or more halogens to impart some flame retardancy without the addition of another flame retardant agent. Where halogenated flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the halogenated flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent. If desired, two different halogenated flame retardants may be added to the layers. In other instances, a non-halogenated flame retardant agent such as, for example, a flame retardant agent comprising one or more of N, P, As, Sb, Bi, S, Se, and Te can be added. In some embodiments, the non-halogenated flame retardant may comprise a phosphorated material so the layers may be more environmentally friendly. Where non-halogenated or substantially halogen free flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the substantially halogen free flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent based on the weight of the layer. If desired, two different substantially halogen free flame retardants may be added to one or more of the layers described herein. In certain instances, one or more of the skin layers shown inFIGS.4A-4Idescribed herein may comprise one or more halogenated flame retardants in combination with one or more substantially halogen free flame retardants. Where two different flame retardants are present, the combination of the two flame retardants may be present in a flame retardant amount, which can vary depending on the other components which are present. For example, the total weight of flame retardants present may be about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 15 weight percent, e.g., about 2 weight percent to about 14 weight percent based on the weight of the layer. The flame retardant agents used in the layers described herein can be added to the mixture comprising the thermoplastic material and fibers (prior to disposal of the mixture on a wire screen or other processing component) or can be added after the layer is formed. In some examples, the flame retardant material may comprise one or more of expandable graphite materials, magnesium hydroxide (MDH) and aluminum hydroxide (ATH). In certain embodiments, the skin layers shown inFIGS.4A-4Imay comprise one or more film layers in combination with a porous fiber reinforced thermoplastic layer. For example, the film of the skin layers shown inFIGS.4A-4Imay comprise or be a thermoplastic film, a polyolefin film, an elastomer film, etc. In certain configurations, the film comprises at least one of a polyolefin, e.g., polyethylene or polypropylene, at least one poly(ether imide), at least one poly(ether ketone), at least one poly(ether-ether ketone), at least one poly(phenylene sulfide), poly(arylene sulfone), at least one poly(ether sulfone), at least one poly(amide-imide), poly(1,4-phenylene), at least one polycarbonate, at least one nylon, and at least one silicone. In some embodiments, two or more films may be present in combination with a porous fiber reinforced thermoplastic layer for the skin layers shown inFIGS.4A-4I. In some embodiments, two or more surfaces of a multilayer assembly that includes a core layer and a skin layer may comprise a plurality of depressions. Referring toFIG.5A, a multilayer assembly510is shown that comprises a plurality of depressions on a first surface513and on a second surface514. In some instances, different surfaces may include a different number of depressions, depressions of different depth, depressions of different shape, etc. The first surface513comprises a skin layer512on a core layer511. The depressions on any one surface may have the same or different shapes, widths or depths as desired. Further, depressions on the first surface513may all have a first shape (when viewed in cross-section) and depressions on the second surface514may all have a second shape (when viewed in cross-section). The first shape may be the same or different than the second shape. The depression distribution on each of the first surface513and the second surface514need not be uniform, and, if desired, more depressions may be positioned at one area of the core layer than other areas of the core layer. Further, the depression distribution need not be the same on each of the first surface513and the second surface514. Referring toFIG.5B, a multilayer assembly520is shown with a core layer521and a skin layer522and with increased depressions positioned at edges524,525on a first surface523of the multilayer assembly520. The distribution of the depressions may also have other arrangements. For example, an increased number of depressions can be positioned toward one side or edge524on the first surface523. Alternatively, a depression distribution with more depressions positioned toward a center area of a multilayer assembly can be produced. While the depressions on the second surface of the multilayer assemblies510,520, are shown for illustration purposes as being uniform, the depression distribution could instead be non-uniform or asymmetric as described in connection with the depressions on the first surface of the multilayer assemblies510,520. In certain embodiments, the core layers shown inFIGS.5A,5Bmay each comprise a honeycomb core layer such as, for example, a paper honeycomb core layer, a polyurethane layer, an expanded foam, an extruded foam, a honeycomb structure produced from one or more polymeric materials including, but not limited to, polypropylene, polyethylene, polystyrene, a polyamide, a copolyamide, polyethylene terephthalate, a polyetherimide, a polyphenylene oxide, and other polymers, a honeycomb structure produced from one or more metals including, but not limited to, aluminum, iron, steel and other metals and metal alloys. In some embodiments, the core layer may be a honeycomb layer with a material other than cellulose. For example, the honeycomb layer may be porous and include significant open space within the core layer. The core layers shown inFIGS.5A,5Bmay comprise a basis weight of about 200 grams per square meter (gsm) to about 4000 gsm. The overall thickness of the core layers shown inFIGS.5A,5Bmay vary from about 0.5 cm to about 7.5 cm. The depth of the depressions shown in the core layers FIGS. SA,5B can vary from about 0.125 inches (about 3 mm) to about 1 inch (about 2.5 cm), e.g., about 5 mm to about 1.25 mm, depending on the overall thickness of the core layer. As noted herein, different depressions can have different depths and/or geometries. In certain examples, the skin layers shown inFIGS.5A,5Bmay each comprise a porous fiber reinforced thermoplastic layer. For example, the porous fiber reinforced thermoplastic layer may be configured as (or used in) a glass mat thermoplastic composite (GMT) or a light weight reinforced thermoplastic (LWRT). One such LWRT is prepared by HANWHA AZDEL, Inc. and sold under the trademark SUPERLITE® material. The areal density of such a GMT or LWRT can range from about 300 grams per square meter (gsm) of the GMT or LWRT to about 4000 gsm, although the areal density may be less than 300 gsm or greater than 4000 gsm depending on the specific application needs. In some embodiments, the upper density can be less than about 4000 gsm. In certain instances, the GMT or the LWRT may comprise one or more lofting agent materials disposed in void space or pores of the GMT or the LWRT. Where two or more GMT or LWRT layers are present, the GMT or LWRT layers may be the same or may be different. In certain examples where an LWRT is used as a porous fiber reinforced thermoplastic skin layer, the LWRT typically includes a thermoplastic material and a plurality of reinforcing fibers which together form a web of open celled structures. The web can be formed from a random arrangement of reinforcing fibers that are held in place by the thermoplastic material. For example, the porous fiber reinforced thermoplastic layer typically comprises a substantial amount of open cell structure such that void space is present in the layers. In some instances, the porous fiber skin layers shown inFIGS.5A,5Bmay comprise a void content or porosity of 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%, 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95% 70-80%, 70-90%, 70-95%, 80-90%, 80-95% or any illustrative value within these exemplary ranges. In some instances, the skin layers shown inFIGS.5A,5Bcomprise a porosity or void content of greater than 0%, e.g., is not fully consolidated, up to about 95%. Unless otherwise stated, the reference to the skin layers shown inFIGS.5A,5Bcomprising a certain void content or porosity is based on the total volume of that skin layer and not necessarily the total volume of the multilayer assembly. In certain examples, the skin layers shown inFIGS.5A,5Bcan be produced in the form of a GMT or LWRT sheet. In certain instances, the sheet can be generally prepared using chopped glass fibers, a thermoplastic material, optionally a lofting agent and an optional thermoplastic polymer film or films and/or woven or non-woven fabrics made with glass fibers or thermoplastic resin fibers such as, for example, polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), a blend of PC/PBT, or a blend of PC/PET. In some embodiments, a PP, a PBT, a PET, a PC/PET blend or a PC/PBT blend can be used as a resin. To produce the sheet, a thermoplastic material and reinforcing materials can be added or metered into a dispersing foam contained in an open top mixing tank fitted with an impeller. Without wishing to be bound by any particular theory, the presence of trapped pockets of air of the foam can assist in dispersing the glass fibers, the thermoplastic material and the lofting agent. In some examples, the dispersed mixture of fibers and thermoplastic material can be pumped to a head-box located above a wire section of a paper machine via a distribution manifold. The foam, not the fibers and thermoplastic, can then be removed as the dispersed mixture is provided to a moving wire screen using a vacuum, continuously producing a uniform, fibrous wet web. The wet web can be passed through a dryer at a suitable temperature to reduce moisture content and to melt or soften the thermoplastic material. The resulting product may be pressed or compressed, e.g., using nip rollers or other techniques, to form a sheet which can then be coupled to a core layer or another layer. In certain embodiments, the high porosity present in the skin layers shown inFIGS.5A,5Bcan reduce the overall weight of the multi layer assembly and can permit the inclusion of agents within the void space of the skin layers. For example, lofting agents can reside in the void space in a non-covalently bonded manner. Application of heat or other perturbations can act to increase the volume of the non-covalently bonded lofting agent which in turn increases the overall thickness of the layer, e.g., the layer increases as the size of the lofting agent increases and/or additional air becomes trapped in the layer. If desired, flame retardants, colorants, smoke suppressants and other materials may be included in the void space of the skin layers shown inFIGS.5A,5B. Prior to lofting, the multilayer assembly can be compressed to reduce its overall thickness, e.g., compressed before or after the layer is coupled to one or more other layers. In certain embodiments, the thermoplastic material of the skin layers shown inFIGS.5A,5Bmay comprise, at least in part, a polyolefin or one or more of polyethylene, polypropylene, polystyrene, acrylonitrylstyrene, butadiene, polyethyleneterephthalate, polybutyleneterephthalate, polybutylenetetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, and blends of these materials with each other or other polymeric materials. Other suitable thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, co-polyamides, acrylonitrile-butylacrylate-styrene polymers, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystalline polymers, poly(1,4 phenylene) compounds commercially known as PARMAX®, high heat polycarbonate such as Bayer's APEC® PC, high temperature nylon, and silicones, as well as copolymers, alloys and blends of these materials with each other or other polymeric materials. The thermoplastic material used to form the skin layers shown inFIGS.5A,5Bcan be used in powder form, resin form, rosin form, particle form, fiber form or other suitable forms. Illustrative thermoplastic materials in various forms are described herein and are also described, for example in U.S. Publication Nos. 20130244528 and US20120065283. The exact amount of thermoplastic material present in the skin layers shown inFIGS.5A,5Bcan vary and illustrative amounts range from about 20% by weight to about 80% by weight, e.g., 30-70 percent by weight or 35-65 percent by weight. It will be recognized by the skilled person that the weight percentages of all materials used in any one of the skin layers shown inFIGS.5A,5Bwill add to 100 weight percent. In certain examples, the reinforcing fibers of the skin layers shown inFIGS.5A,5Bmay comprise glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as, for example, para- and meta-aramid fibers, nylon fibers, polyester fibers, or high melt flow index resins that are suitable for use as fibers, mineral fibers such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metalized natural and/or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers can be chemically treated prior to use to provide desired functional groups or to impart other physical properties to the fibers, e.g., may be chemically treated so that they can react with the thermoplastic material, the lofting agent or both. The fiber content in the skin layers shown inFIGS.5A,5Bmay independently be from about 20% to about 90% by weight of the layer, more particularly from about 30% to about 70%, by weight of the layer. Typically, the fiber content of a multilayer assembly comprising the skin layers shown inFIGS.5A,5Bvaries between about 20% to about 90% by weight, more particularly about 30% by weight to about 80% by weight, e.g., about 40% to about 70% by weight of the assembly. The particular size and/or orientation of the fibers used may depend, at least in part, on the thermoplastic polymer material used and/or the desired properties of the skin layers shown inFIGS.5A,5B. Suitable additional types of fibers, fiber sizes and amounts will be readily selected by the person of ordinary skill in the art, given the benefit of this disclosure. In one non-limiting illustration, fibers dispersed within a thermoplastic material and optionally a lofting agent to provide the skin layers shown inFIGS.5A,5Bcan generally have a diameter of greater than about 5 microns, more particularly from about 5 microns to about 22 microns, and a length of from about 5 mm to about 200 mm; more particularly, the fiber diameter may be from about 2 microns to about 22 microns and the fiber length may be from about 5 mm to about 75 mm. In some embodiments, the lofting capacity of the skin layers shown inFIGS.5A,5Bcan be further tuned by including one or more added lofting agents. The exact type of lofting agent used in the skin layers shown inFIGS.5A,5Bcan depend on numerous factors including, for example, the desired lofting temperature, the desired degree of loft, etc. In some instances, microsphere lofting agents, e.g., expandable microspheres, which can increase their size upon exposure to convection heating may be used. Illustrative commercially available lofting agents are available from Kureha Corp. (Japan). In other instances, a first lofting agent with a first average particle size and a second lofting agent with a second average particle size, different from the first average particle size, may be used in the skin layers shown inFIGS.5A,5B. In other examples, the lofting agent may be an expandable graphite material which can also impart some flame retardancy to the multilayer assembly. In some configurations, the skin layers shown inFIGS.5A,5Bmay be a substantially halogen free or halogen free layer to meet the restrictions on hazardous substances requirements for certain applications. In other instances, one or more of the layers may comprise a halogenated flame retardant agent such as, for example, a halogenated flame retardant that comprises one of more of F, Cl, Br, I, and At or compounds that including such halogens, e.g., tetrabromo bisphenol-A polycarbonate or monohalo-, dihalo-, trihalo- or tetrahalo-polycarbonates. In some instances, the thermoplastic material used in the skin layers shown inFIGS.5A,5Bmay comprise one or more halogens to impart some flame retardancy without the addition of another flame retardant agent. Where halogenated flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the halogenated flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent. If desired, two different halogenated flame retardants may be added to the layers. In other instances, a non-halogenated flame retardant agent such as, for example, a flame retardant agent comprising one or more of N, P, As, Sb, Bi, S, Se, and Te can be added. In some embodiments, the non-halogenated flame retardant may comprise a phosphorated material so the layers may be more environmentally friendly. Where non-halogenated or substantially halogen free flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the substantially halogen free flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent based on the weight of the layer. If desired, two different substantially halogen free flame retardants may be added to one or more of the layers described herein. In certain instances, one or more of the skin layers shown inFIGS.5A,5Bdescribed herein may comprise one or more halogenated flame retardants in combination with one or more substantially halogen free flame retardants. Where two different flame retardants are present, the combination of the two flame retardants may be present in a flame retardant amount, which can vary depending on the other components which are present. For example, the total weight of flame retardants present may be about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 15 weight percent, e.g., about 2 weight percent to about 14 weight percent based on the weight of the layer. The flame retardant agents used in the layers described herein can be added to the mixture comprising the thermoplastic material and fibers (prior to disposal of the mixture on a wire screen or other processing component) or can be added after the layer is formed. In some examples, the flame retardant material may comprise one or more of expandable graphite materials, magnesium hydroxide (MDH) and aluminum hydroxide (ATH). In certain configurations, the skin layers shown inFIGS.5A,5Bmay comprise one or more film layers in combination with a porous fiber reinforced thermoplastic layer. For example, the film of the skin layers shown inFIGS.5A,5Bmay comprise or be a thermoplastic film, a polyolefin film, an elastomer film, etc. In certain configurations, the film comprises at least one of a polyolefin, e.g.; polyethylene or polypropylene, at least one poly(ether imide), at least one poly(ether ketone), at least one poly(ether-ether ketone), at least one poly(phenylene sulfide), poly(arylene sulfone), at least one poly(ether sulfone), at least one poly(amide-imide), poly(1,4-phenylene), at least one polycarbonate, at least one nylon, and at least one silicone. In some embodiments, two or more films may be present in combination with a porous fiber reinforced thermoplastic layer for the skin layers shown inFIGS.5A,5B. In certain configurations, the core layers described herein can be used to provide a multilayer assembly that includes the core layer in combination with two skin layers. While the exact configuration of the skin layers may vary, the skin layers each can be configured as a porous fiber reinforced thermoplastic layer disposed on a surface of a core layer. Each porous fiber reinforced thermoplastic layer may include a web of open celled structures formed by a plurality of reinforcing materials held together with a thermoplastic material. One or both of the porous fiber reinforced thermoplastic layer can be bonded to surfaces of the plurality of depressions across a first surface of the core layer, e.g., the skin layer may have depressions that generally mirror the depressions in the core layer so each depression includes two layers, e.g., a core layer component and skin layer component. Referring toFIG.6A, a multilayer assembly600comprises a core layer610, a first skin layer611and a second skin layer612. A depression616on a first surface615of the multilayer assembly600is shown. The exact shape, width and depth of the depression616may vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. While the depression616is shown as being present on a first surface615, it could instead be present on the surface617or a depression may be present on a surface616and a surface617. The depression617includes both the core layer610and the skin layer611. The presence of a depression616can enhance bonding of the skin layer611to the core layer610. InFIG.6A, no depressions are present on the second surface617of the multilayer assembly600. If desired, more than a single depression616may be present on the first surface615. For example, the first surface615may comprise one, two, three, four, five or more individual depressions across the surface615. In certain embodiments, a multilayer assembly620is shown inFIG.6Bas including a core layer621, a first skin layer622and a second skin layer623. A first depression626is present on a first surface624and a second depression628is present on a second surface627. The depressions626,628need not be the same, and the exact shape, width and depth of the depressions626,628each may independently vary and illustrative shapes (when viewed in cross-section) include triangular shapes, semi-circular shapes, elliptical shapes, symmetric shapes, asymmetric shapes and other shapes. In some instances, the surface624may comprise one, two, three, four, five or more depressions. Similarly, the surface627may comprise one, two, three, four, five or more depressions. The number of depressions on each of the surfaces624,627need not be the same. By including depressions on different surfaces of a multilayer assembly620including a core layer621and two skin layers622,623, enhanced bonding of the different skin layers622,623to the core layer621can be achieved. In certain embodiments, the core layers shown inFIGS.6A,6Bmay each comprise a honeycomb core layer such as, for example, a paper honeycomb core layer, a polyurethane layer, an expanded foam, an extruded foam, a honeycomb structure produced from one or more polymeric materials including, but not limited to, polypropylene, polyethylene, polystyrene, a polyamide, a copolyamide, polyethylene terephthalate, a polyetherimide, a polyphenylene oxide, and other polymers, a honeycomb structure produced from one or more metals including, but not limited to, aluminum, iron, steel and other metals and metal alloys. In some embodiments, the core layer may be a honeycomb layer with a material other than cellulose. For example, the honeycomb layer may be porous and include significant open space within the core layer. The core layers shown inFIGS.6A,6Bmay comprise a basis weight of about 200 grams per square meter (gsm) to about 4000 gsm. The overall thickness of the core layers shown inFIGS.6A,6Bmay vary from about 0.5 cm to about 7.5 cm. The depth of the depressions shown in the core layersFIGS.6A,6Bcan vary from about 0.125 inches (about 3 mm) to about 1 inch (about 2.5 cm), e.g., about 5 mm to about 1.25 mm, depending on the overall thickness of the core layer. As noted herein, different depressions can have different depths and/or geometries. In certain examples, the skin layers shown inFIGS.6A,6Bmay each comprise a porous fiber reinforced thermoplastic layer. For example, the porous fiber reinforced thermoplastic layer may be configured as (or used in) a glass mat thermoplastic composite (GMT) or a light weight reinforced thermoplastic (LWRT). One such LWRT is prepared by FIANWHA AZDEL, Inc. and sold under the trademark SUPERLITE® material. The areal density of such a GMT or LWRT can range from about 300 grams per square meter (gsm) of the GMT or LWRT to about 4000 gsm, although the areal density may be less than 300 gsm or greater than 4000 gsm depending on the specific application needs. In some embodiments, the upper density can be less than about 4000 gsm. In certain instances, the GMT or the LWRT may comprise one or more lofting agent materials disposed in void space or pores of the GMT or the LWRT. Where two or more GMT or LWRT layers are present, the GMT or LWRT layers may be the same or may be different. In certain examples where an LWRT is used as a porous fiber reinforced thermoplastic skin layer, the LWRT typically includes a thermoplastic material and a plurality of reinforcing fibers which together form a web of open celled structures. The web can be formed from a random arrangement of reinforcing fibers that are held in place by the thermoplastic material. For example, the porous fiber reinforced thermoplastic layer typically comprises a substantial amount of open cell structure such that void space is present in the layers. In some instances, the porous fiber skin layers shown inFIGS.6A,6Bmay comprise a void content or porosity of 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%, 70-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95% 70-80%, 70-90%, 70-95%, 80-90%, 80-95% or any illustrative value within these exemplary ranges. In some instances, the skin layers shown inFIGS.6A,6Bcomprise a porosity or void content of greater than 0%, e.g., is not fully consolidated, up to about 95%. Unless otherwise stated, the reference to the skin layers shown inFIGS.6A,6Bcomprising a certain void content or porosity is based on the total volume of that skin layer and not necessarily the total volume of the multilayer assembly. In certain examples, the skin layers shown inFIGS.6A,6Bcan be produced in the form of a GMT or LWRT sheet. In certain instances, the sheet can be generally prepared using chopped glass fibers, a thermoplastic material, optionally a lofting agent and an optional thermoplastic polymer film or films and/or woven or non-woven fabrics made with glass fibers or thermoplastic resin fibers such as, for example, polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), a blend of PC/PBT, or a blend of PC/PET. In some embodiments, a PP, a PBT, a PET, a PC/PET blend or a PC/PBT blend can be used as a resin. To produce the sheet, a thermoplastic material and reinforcing materials can be added or metered into a dispersing foam contained in an open top mixing tank fitted with an impeller. Without wishing to be bound by any particular theory, the presence of trapped pockets of air of the foam can assist in dispersing the glass fibers, the thermoplastic material and the lofting agent. In some examples, the dispersed mixture of fibers and thermoplastic material can be pumped to a head-box located above a wire section of a paper machine via a distribution manifold. The foam, not the fibers and thermoplastic, can then be removed as the dispersed mixture is provided to a moving wire screen using a vacuum, continuously producing a uniform, fibrous wet web. The wet web can be passed through a dryer at a suitable temperature to reduce moisture content and to melt or soften the thermoplastic material. The resulting product may be pressed or compressed, e.g., using nip rollers or other techniques, to form a sheet which can then be coupled to a core layer or another layer. In certain embodiments, the high porosity present in the skin layers shown inFIGS.6A,6Bcan reduce the overall weight of the multilayer assembly and can permit the inclusion of agents within the void space of the skin layers. For example, lofting agents can reside in the void space in a non-covalently bonded manner. Application of heat or other perturbations can act to increase the volume of the non-covalently bonded lolling agent which in turn increases the overall thickness of the layer, e.g., the layer increases as the size of the lofting agent increases and/or additional air becomes trapped in the layer. If desired, flame retardants, colorants, smoke suppressants and other materials may be included in the void space of the skin layers shown inFIGS.6A,6B. Prior to lofting, the multilayer assembly can be compressed to reduce its overall thickness, e.g., compressed before or after the layer is coupled to one or more other layers. In certain embodiments, the thermoplastic material of the skin layers shown inFIGS.6A,6Bmay comprise, at least in part, a polyolefin or one or more of polyethylene, polypropylene, polystyrene, acrylonitrylstyrene, butadiene, polyethyleneterephthalate, polybutyleneterephthalate, polybutylenetetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, and blends of these materials with each other or other polymeric materials. Other suitable thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, co-polyamides, acrylonitrile-butylacrylate-styrene polymers, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystalline polymers, poly(1,4 phenylene) compounds commercially known as PARMAX®, high heat polycarbonate such as Bayer's APEC® PC, high temperature nylon, and silicones, as well as copolymers, alloys and blends of these materials with each other or other polymeric materials. The thermoplastic material used to form the skin layers shown inFIGS.6A,6Bcan be used in powder form, resin form, rosin form, particle form, fiber form or other suitable forms. Illustrative thermoplastic materials in various forms are described herein and are also described, for example in U.S. Publication Nos. 20130244528 and US20120065283. The exact amount of thermoplastic material present in the skin layers shown inFIGS.6A,6Bcan vary and illustrative amounts range from about 20% by weight to about 80% by weight, e.g., 30-70 percent by weight or 35-65 percent by weight. It will be recognized by the skilled person that the weight percentages of all materials used in any one of the skin layers shown inFIGS.6A,6Bwill add to 100 weight percent. In certain examples, the reinforcing fibers of the skin layers shown inFIGS.6A,6Bmay comprise glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as, for example, para- and meta-aramid fibers, nylon fibers, polyester fibers, or high melt flow index resins that are suitable for use as fibers, mineral fibers such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metalized natural and/or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers can be chemically treated prior to use to provide desired functional groups or to impart other physical properties to the fibers, e.g., may be chemically treated so that they can react with the thermoplastic material, the lofting agent or both. The fiber content in the skin layers shown inFIGS.6A,6Bmay independently be from about 20% to about 90% by weight of the layer, more particularly from about 30% to about 70%, by weight of the layer. Typically, the fiber content of a multilayer assembly comprising the skin layers shown inFIGS.6A,6Bvaries between about 20% to about 90% by weight, more particularly about 30% by weight to about 80% by weight, e.g., about 40% to about 70% by weight of the assembly. The particular size and/or orientation of the fibers used may depend, at least in part, on the thermoplastic polymer material used and/or the desired properties of the skin layers shown inFIGS.6A,6B. Suitable additional types of fibers, fiber sizes and amounts will be readily selected by the person of ordinary skill in the art, given the benefit of this disclosure. In one non-limiting illustration, fibers dispersed within a thermoplastic material and optionally a lofting agent to provide the skin layers shown inFIGS.6A,6Bcan generally have a diameter of greater than about 5 microns, more particularly from about 5 microns to about 22 microns, and a length of from about 5 mm to about 200 mm; more particularly, the fiber diameter may be from about 2 microns to about 22 microns and the fiber length may be from about 5 mm to about 75 mm. In some embodiments, the lofting capacity of the skin layers shown inFIGS.6A,6Bcan be further tuned by including one or more added lofting agents. The exact type of lofting agent used in the skin layers shown inFIGS.6A,6Bcan depend on numerous factors including, for example, the desired lofting temperature, the desired degree of loft, etc. In some instances, microsphere lofting agents, e.g., expandable microspheres, which can increase their size upon exposure to convection heating may be used. Illustrative commercially available lofting agents are available from Kureha Corp. (Japan). In other instances, a first lofting agent with a first average particle size and a second lofting agent with a second average particle size, different from the first average particle size, may be used in the skin layers shown inFIGS.6A,6B. In other examples, the lofting agent may be an expandable graphite material which can also impart some flame retardancy to the multilayer assembly. In some configurations, the skin layers shown inFIGS.6A,6Bmay be a substantially halogen free or halogen free layer to meet the restrictions on hazardous substances requirements for certain applications. In other instances, one or more of the layers may comprise a halogenated flame retardant agent such as, for example, a halogenated flame retardant that comprises one of more of F, Cl, Br, I, and At or compounds that including such halogens, e.g., tetrabromo bisphenol-A polycarbonate or monohalo-, trihalo- or tetrahalo-polycarbonates. In some instances, the thermoplastic material used in the skin layers shown inFIGS.6A,6Bmay comprise one or more halogens to impart some flame retardancy without the addition of another flame retardant agent. Where halogenated flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the halogenated flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent. If desired, two different halogenated flame retardants may be added to the layers. In other instances, a non-halogenated flame retardant agent such as, for example, a flame retardant agent comprising one or more of N, P, As, Sb, Bi, S, Se, and Te can be added. In some embodiments, the non-halogenated flame retardant may comprise a phosphorated material so the layers may be more environmentally friendly. Where non-halogenated or substantially halogen free flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the substantially halogen free flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent based on the weight of the layer. If desired, two different substantially halogen free flame retardants may be added to one or more of the layers described herein. In certain instances, one or more of the skin layers shown inFIGS.6A,6Bdescribed herein may comprise one or more halogenated flame retardants in combination with one or more substantially halogen free flame retardants. Where two different flame retardants are present, the combination of the two flame retardants may be present in a flame retardant amount, which can vary depending on the other components which are present. For example, the total weight of flame retardants present may be about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 15 weight percent, e.g., about 2 weight percent to about 14 weight percent based on the weight of the layer. The flame retardant agents used in the layers described herein can be added to the mixture comprising the thermoplastic material and fibers (prior to disposal of the mixture on a wire screen or other processing component) or can be added after the layer is formed. In some examples, the flame retardant material may comprise one or more of expandable graphite materials, magnesium hydroxide (MDH) and aluminum hydroxide (ATM). In certain embodiments, the skin layers shown inFIGS.6A,6Bmay comprise one or more film layers in combination with a porous fiber reinforced thermoplastic layer. For example, the film of the skin layers shown inFIGS.6A,6Bmay comprise or be a thermoplastic film, a polyolefin film, an elastomer film, etc. In certain configurations, the film comprises at least one of a polyolefin, e.g., polyethylene or polypropylene, at least one poly(ether imide), at least one poly(ether ketone), at least one poly(ether-ether ketone), at least one poly(phenylene sulfide), poly(arylene sulfone), at least one poly(ether sulfone), at least one poly(amide-imide), poly(1,4-phenylene), at least one polycarbonate, at least one nylon, and at least one silicone. In some embodiments, two or more films may be present in combination with a porous fiber reinforced thermoplastic layer for the skin layers shown inFIGS.6A,6B. In some embodiments, a multilayer assembly may comprise a core layer, a skin layer and an additional layer. Referring toFIG.7A, a multilayer assembly700is shown that includes a core layer711, a skin layer712and an additional layer7B disposed on the skin layer712. InFIG.7A, the additional layer713conforms to the skin layer712such that a depression715includes the core layer711, the skin layer712and the additional layer713. In other instances, the additional layer may have sufficient structure so it spans any depressions on the skin layer.712For example and referring toFIG.7B, a multilayer assembly720is shown that comprises a core layer721, a skin layer722and an additional layer723disposed on the skin layer722. A depression725is shown that forms an air gap between the skin layer722and the additional layer723. For example, a projection or other device, as discussed in more detail below, can be pressed into the skin layer722and the core layer721to form the depression725. The layer723can then be deposited on the assembly so the layer723overlies the depression725. Outward viewing of the multilayer assembly720would not show any depressions in the surface of the multilayer assembly720as the additional layer723can generally be planar. The presence of a skin layer722with depressions into a core layer721in combination with an additional layer723can enhance bonding of the skin layer722to the core layer721while still providing a generally flat or planar surface for the multilayer assembly720. Where an additional layer is present on a skin layer as shown inFIGS.7A and7B, one or more surfaces of the multilayer assembly may comprise, two, three, four, five or more individual depressions each of which may include the core layer, the skin layer and optionally an additional layer. While not shown, one, two, three, four, five or more depressions can be present in any one surface of the assemblies shown inFIGS.7A,7B. In certain embodiments, the core layers shown inFIGS.7A,7Bmay each comprise a honeycomb core layer such as, for example, a paper honeycomb core layer, a polyurethane layer, an expanded foam, an extruded foam, a honeycomb structure produced from one or more polymeric materials including, but not limited to, polypropylene, polyethylene, polystyrene, a polyamide, a copolyamide, polyethylene terephthalate, a polyetherimide, a polyphenylene oxide, and other polymers, a honeycomb structure produced from one or more metals including, but not limited to, aluminum, iron, steel and other metals and metal alloys. In some embodiments, the core layer may be a honeycomb layer with a material other than cellulose. For example, the honeycomb layer may be porous and include significant open space within the core layer. The core layers shown inFIGS.7A,7Bmay comprise a basis weight of about 200 grams per square meter (gsm) to about 4000 gsm. The overall thickness of the core layers shown inFIGS.7A,7Bmay vary from about 0.5 cm to about 7.5 cm. The depth of the depressions shown in the core layersFIGS.7A,7Bcan vary from about 0.125 inches (about 3 mm) to about 1 inch (about 2.5 cm), e.g., about 5 mm to about 1.25 mm, depending on the overall thickness of the core layer. As noted herein, different depressions can have different depths and/or geometries. In certain examples, the skin layers shown inFIGS.7A,7Bmay each comprise a porous fiber reinforced thermoplastic layer. For example, the porous fiber reinforced thermoplastic layer may be configured as (or used in) a glass mat thermoplastic composite (GMT) or a light weight reinforced thermoplastic (LWRT). One such LWRT is prepared by HANWHA AZDEL, Inc. and sold under the trademark SUPERLITE® material. The areal density of such a. GMT or LWRT can range from about 300 grams per square meter (gsm) of the GMT or LWRT to about 4000 gsm, although the areal density may be less than 300 gsm or greater than 4000 gsm depending on the specific application needs. In some embodiments, the upper density can be less than about 4000 gsm. In certain instances, the GMT or the LWRT may comprise one or more lofting agent materials disposed in void space or pores of the GMT or the LWRT. Where two or more GMT or LWRT layers are present, the GMT or LWRT layers may be the same or may be different. In certain examples where an LWRT is used as a porous fiber reinforced thermoplastic skin layer, the LWRT typically includes a thermoplastic material and a plurality of reinforcing fibers which together form a web of open celled structures. The web can be formed from a random arrangement of reinforcing fibers that are held in place by the thermoplastic material. For example, the porous fiber reinforced thermoplastic layer typically comprises a substantial amount of open cell structure such that void space is present in the layers. In some instances, the porous fiber skin layers shown inFIGS.7A,7Bmay comprise a void content or porosity of 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%, 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95% 70-80%, 70-90%, 70-95%, 80-90%, 80-95% or any illustrative value within these exemplary ranges. In some instances, the skin layers shown inFIGS.7A,7Bcomprise a porosity or void content of greater than 0%, e.g., is not fully consolidated, up to about 95%. Unless otherwise stated, the reference to the skin layers shown inFIGS.7A,7Bcomprising a certain void content or porosity is based on the total volume of that skin layer and not necessarily the total volume of the multilayer assembly. In certain examples, the skin layers shown inFIGS.7A,7Bcan be produced in the form of a GMT or LWRT sheet. In certain instances, the sheet can be generally prepared using chopped glass fibers, a thermoplastic material, optionally a lofting agent and an optional thermoplastic polymer film or films and/or woven or non-woven fabrics made with glass fibers or thermoplastic resin fibers such as, for example, polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), a blend of PC/PBT, or a blend of PC/PET. In some embodiments, a PP, a PBT, a PET, a PC/PET blend or a PC/PBT blend can be used as a resin. To produce the sheet, a thermoplastic material and reinforcing materials can be added or metered into a dispersing foam contained in an open top mixing tank fitted with an impeller. Without wishing to be bound by any particular theory, the presence of trapped pockets of air of the foam can assist in dispersing the glass fibers, the thermoplastic material and the lofting agent. In some examples, the dispersed mixture of fibers and thermoplastic material can be pumped to a head-box located above a wire section of a paper machine via a distribution manifold. The foam, not the fibers and thermoplastic, can then be removed as the dispersed mixture is provided to a moving wire screen using a vacuum, continuously producing a uniform, fibrous wet web. The wet web can be passed through a dryer at a suitable temperature to reduce moisture content and to melt or soften the thermoplastic material. The resulting product may be pressed or compressed, e.g., using nip rollers or other techniques, to form a sheet which can then be coupled to a core layer or another layer. In certain embodiments, the high porosity present in the skin layers shown inFIGS.7A,7Bcan reduce the overall weight of the multilayer assembly and can permit the inclusion of agents within the void space of the skin layers. For example, lofting agents can reside in the void space in a non-covalently bonded manner. Application of heat or other perturbations can act to increase the volume of the non-covalently bonded lofting agent which in turn increases the overall thickness of the layer, e.g., the layer increases as the size of the lofting agent increases and/or additional air becomes trapped in the layer. If desired, flame retardants, colorants, smoke suppressants and other materials may be included in the void space of the skin layers shown inFIGS.7A,7B. Prior to lofting, the multilayer assembly can be compressed to reduce its overall thickness, e.g., compressed before or after the layer is coupled to one or more other layers. In certain embodiments, the thermoplastic material of the skin layers shown inFIGS.7A,7Bmay comprise, at least in part, a polyolefin or one or more of polyethylene, polypropylene, polystyrene, acrylonitrylstyrene, butadiene, polyethyleneterephthalate, polybutyleneterephthalate, polybutylenetetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, and blends of these materials with each other or other polymeric materials. Other suitable thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, co-polyamides, acrylonitrile-butylacrylate-styrene polymers, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystalline polymers, poly(1,4 phenylene) compounds commercially known as PARMAX®, high heat polycarbonate such as Bayer's APEC® PC, high temperature nylon, and silicones, as well as copolymers, alloys and blends of these materials with each other or other polymeric materials. The thermoplastic material used to form the skin layers shown inFIGS.7A,7Bcan be used in powder form, resin form, rosin form, particle form, fiber form or other suitable forms. Illustrative thermoplastic materials in various forms are described herein and are also described, for example in U.S. Publication Nos. 20130244528 and US20120065283. The exact amount of thermoplastic material present in the skin layers shown inFIGS.7A,7Bcan vary and illustrative amounts range from about 20% by weight to about 80% by weight, e.g., 30-70 percent by weight or 35-65 percent by weight. It will be recognized by the skilled person that the weight percentages of all materials used in any one of the skin layers shown inFIGS.7A,7Bwill add to 100 weight percent. In certain examples, the reinforcing fibers of the skin layers shown inFIGS.7A,7Bmay comprise glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as, for example, para- and meta-aramid fibers, nylon fibers, polyester fibers, or high melt flow index resins that are suitable for use as fibers, mineral fibers such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metalized natural and/or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers can be chemically treated prior to use to provide desired functional groups or to impart other physical properties to the fibers, e.g., may be chemically treated so that they can react with the thermoplastic material, the lofting agent or both. The fiber content in the skin layers shown inFIGS.7A,7Bmay independently be from about 20% to about 90% by weight of the layer, more particularly from about 30% to about 70%, by weight of the layer. Typically, the fiber content of a multilayer assembly comprising the skin layers shown inFIGS.7A,7Bvaries between about 20% to about 90% by weight, more particularly about 30% by weight to about 80% by weight, e.g., about 40% to about 70% by weight of the assembly. The particular size and/or orientation of the fibers used may depend, at least in part, on the thermoplastic polymer material used and/or the desired properties of the skin layers shown inFIGS.7A,7B. Suitable additional types of fibers, fiber sizes and amounts will be readily selected by the person of ordinary skill in the art, given the benefit of this disclosure. In one non-limiting illustration, fibers dispersed within a thermoplastic material and optionally a lofting agent to provide the skin layers shown inFIGS.7A,7Bcan generally have a diameter of greater than about 5 microns, more particularly from about 5 microns to about 22 microns, and a length of from about 5 mm to about 200 mm; more particularly, the fiber diameter may be from about 2 microns to about 22 microns and the fiber length may be from about 5 mm to about 75 mm. In some embodiments, the lofting capacity of the skin layers shown inFIGS.7A,7Bcan be further tuned by including one or more added lofting agents. The exact type of lofting agent used in the skin layers shown inFIGS.7A,7Bcan depend on numerous factors including, for example, the desired lofting temperature, the desired degree of loft, etc. In some instances, microsphere lofting agents, e.g., expandable microspheres, which can increase their size upon exposure to convection heating may be used. Illustrative commercially available lofting agents are available from Kureha Corp. (Japan). In other instances, a first lofting agent with a first average particle size and a second lofting agent with a second average particle size, different from the first average particle size, may be used in the skin layers shown inFIGS.7A,7B. In other examples, the lofting agent may be an expandable graphite material which can also impart some flame retardancy to the multilayer assembly. In some configurations, the skin layers shown inFIGS.7A,7Bmay be a substantially halogen free or halogen free layer to meet the restrictions on hazardous substances requirements for certain applications. In other instances, one or more of the layers may comprise a halogenated flame retardant agent such as, for example, a halogenated flame retardant that comprises one of more of F, Cl, Br, I, and At or compounds that including such halogens, e.g., tetrabromo bisphenol-A polycarbonate or monohalo-, trihalo- or tetrahalo-polycarbonates. In some instances, the thermoplastic material used in the skin layers shown inFIGS.7A,7Bmay comprise one or more halogens to impart some flame retardancy without the addition of another flame retardant agent. Where halogenated flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the halogenated flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent. If desired, two different halogenated flame retardants may be added to the layers. In other instances, a non-halogenated flame retardant agent such as, for example, a flame retardant agent comprising one or more of N, P, As, Sb, Bi, S, Se, and Te can be added. In some embodiments, the non-halogenated flame retardant may comprise a phosphorated material so the layers may be more environmentally friendly. Where non-halogenated or substantially halogen free flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the substantially halogen free flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent based on the weight of the layer. If desired, two different substantially halogen free flame retardants may be added to one or more of the layers described herein. In certain instances, one or more of the skin layers shown inFIGS.7A,7Bdescribed herein may comprise one or more halogenated flame retardants in combination with one or more substantially halogen free flame retardants. Where two different flame retardants are present, the combination of the two flame retardants may be present in a flame retardant amount, which can vary depending on the other components which are present. For example, the total weight of flame retardants present may be about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 15 weight percent, e.g., about 2 weight percent to about 14 weight percent based on the weight of the layer. The flame retardant agents used in the layers described herein can be added to the mixture comprising the thermoplastic material and fibers (prior to disposal of the mixture on a wire screen or other processing component) or can be added after the layer is formed. In some examples, the flame retardant material may comprise one or more of expandable graphite materials, magnesium hydroxide (MDH) and aluminum hydroxide (ATM). In certain embodiments, the skin layers shown inFIGS.7A,7Bmay comprise one or more film layers in combination with a porous fiber reinforced thermoplastic layer. For example, the film of the skin layers shown inFIGS.7A,7Bmay comprise or be a thermoplastic film, a polyolefin film, an elastomer film, etc. In certain configurations, the film comprises at least one of a polyolefin, e.g., polyethylene or polypropylene, at least one poly(ether imide), at least one poly(ether ketone), at least one poly(ether-ether ketone), at least one poly(phenylene sulfide), poly(arylene sulfone), at least one poly(ether sulfone), at least one poly(amide-imide), poly(1,4-phenylene), at least one polycarbonate, at least one nylon, and at least one silicone. In some embodiments, two or more films may be present in combination with a porous fiber reinforced thermoplastic layer for the skin layers shown inFIGS.7A,7B. In certain embodiments, the additional layers shown inFIGS.7A,7Bmay include a film (e.g., thermoplastic film or elastomeric film), a frim, a scrim (e.g., fiber based scrim or a scrim comprising hydrophilic fibers such as cellulose based fibers), a foil, a woven fabric, a non-woven fabric or be present as an inorganic coating, an organic coating, or a thermoset coating. In other instances, the additional layer shown inFIGS.7A,7Bmay comprise a limiting oxygen index greater than about 22, as measured per ISO 4589 dated1996. Where a thermoplastic film is present as (or as part of) the additional layer shown inFIGS.7A,7B, the thermoplastic film may comprise at least one of poly(ether imide), poly(ether ketone), poly(ether-ether ketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. Where a fiber based scrim is present as (or as part of) the additional layer shown inFIGS.7A,7B, the fiber based scrim may comprise at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metalized synthetic fibers, and metalized inorganic fibers. Where a thermoset coating is present as (or as part of) the additional layer shown inFIGS.7A,7B, the coating may comprise at least one of unsaturated polyurethanes, vinyl esters, phenolics and epoxies. Where an inorganic coating is present as (or as part of) the additional layer shown inFIGS.7A,7B, the inorganic coating may comprise minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti and Al or may comprise at least one of gypsum, calcium carbonate and mortar. Where a non-woven fabric is present as (or as part of) the additional layer shown inFIGS.7A,7B, the non-woven fabric may comprise a thermoplastic material, a thermal setting binder, inorganic fibers, metal fibers, metallized inorganic fibers and metallized synthetic fibers. If desired, the additional layer shown inFIGS.7A,7Bmay comprise an expandable graphite material, a flame retardant material, fibers, etc. In certain embodiments, an additional layer may be present on a second surface of a core layer as shown inFIGS.8A and8B.FIG.8Ashows a multilayer assembly800including a core layer811, skin layers812,814and an additional layer813. A depression815is present on one surface of the assembly800, though if desired two, three, four, five or more depressions may be present on one or more surfaces of the multilayer assembly. For example, a plurality of depressions may be present on the surface817and/or on the surface819. While not shown, an additional layer may also be present on the surface819if desired. In some examples, the additional layer may have sufficient structure so it spans any depressions on the skin layer. For example and referring toFIG.8B, a multilayer assembly820is shown that comprises a core layer821, skin layers822,824and an additional layer823disposed on the skin layer822. A depression825is shown that forms an air gap between the skin layer822and the additional layer823. For example, a projection or other device can be pressed into the skin layer822and the core layer821to form the depression825. The layer823can then be deposited on the assembly so the layer823overlies the depression825. Outward viewing of the multilayer assembly820would not show any depressions in the surface of the multilayer assembly820as the additional layer823can generally be planar. The presence of a skin layer822with depressions into a core layer821in combination with an additional layer823can enhance bonding of the skin layer822to the core layer821while still providing a generally flat or planar surface for the multilayer assembly820. If desired two, three, four, five or more depressions may be present on one or more surfaces of the multilayer assembly. For example, a plurality of depressions may be present on the surface827and/or on the surface829. While not shown, an additional layer may also be present on the surface829if desired. In certain embodiments, the core layers shown inFIGS.8A,8Bmay each comprise a honeycomb core layer such as, for example, a paper honeycomb core layer, a polyurethane layer, an expanded foam, an extruded foam, a honeycomb structure produced from one or more polymeric materials including, but not limited to, polypropylene, polyethylene, polystyrene, a polyamide, a copolyamide, polyethylene terephthalate, a polyetherimide, a polyphenylene oxide, and other polymers, a honeycomb structure produced from one or more metals including, but not limited to, aluminum, iron, steel and other metals and metal alloys. In some embodiments, the core layer may be a honeycomb layer with a material other than cellulose. For example, the honeycomb layer may be porous and include significant open space within the core layer. The core layers shown inFIGS.8A,8Bmay comprise a basis weight of about 200 grams per square meter (gsm) to about 4000 gsm. The overall thickness of the core layers shown inFIGS.8A,8Bmay vary from about 0.5 cm to about 7.5 cm. The depth of the depressions shown in the core layersFIGS.8A,8Bcan vary from about 0.125 inches (about 3 mm) to about 1 inch (about 2.5 cm), e.g., about 5 mm to about 1.25 mm, depending on the overall thickness of the core layer. As noted herein, different depressions can have different depths and/or geometries. In certain examples, the skin layers shown inFIGS.8A,8Bmay each comprise a porous fiber reinforced thermoplastic layer. For example, the porous fiber reinforced thermoplastic layer may be configured as (or used in) a glass mat thermoplastic composite (GMT) or a light weight reinforced thermoplastic (LWRT). One such LWRT is prepared by HANWHA AZDEL, Inc. and sold under the trademark SUPERLITE® material. The areal density of such a GMT or LWRT can range from about 300 grams per square meter (gsm) of the GMT or LWRT to about 4000 gsm, although the areal density may be less than 300 gsm or greater than 4000 gsm depending on the specific application needs. In some embodiments, the upper density can be less than about 4000 gsm. In certain instances, the GMT or the LWRT may comprise one or more lofting agent materials disposed in void space or pores of the GMT or the LWRT. Where two or more GMT or LWRT layers are present, the GMT or LWRT layers may be the same or may be different. In certain examples where an LWRT is used as a porous fiber reinforced thermoplastic skin layer, the LWRT typically includes a thermoplastic material and a plurality of reinforcing fibers which together form a web of open celled structures. The web can be formed from a random arrangement of reinforcing fibers that are held in place by the thermoplastic material. For example, the porous fiber reinforced thermoplastic layer typically comprises a substantial amount of open cell structure such that void space is present in the layers. In some instances, the porous fiber skin layers shown inFIGS.8A,8Bmay comprise a void content or porosity of 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%, 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95% 70-80%, 70-90%, 70-95%, 80-90%, 80-95% or any illustrative value within these exemplary ranges. In some instances, the skin layers shown inFIGS.8A,8Bcomprise a porosity or void content of greater than 0%, e.g., is not fully consolidated, up to about 95%. Unless otherwise stated, the reference to the skin layers shown inFIGS.8A,8Bcomprising a certain void content or porosity is based on the total volume of that skin layer and not necessarily the total volume of the multilayer assembly. In certain examples, the skin layers shown inFIGS.8A,8Bcan be produced in the form of a GMT or LWRT sheet. In certain instances, the sheet can be generally prepared using chopped glass fibers, a thermoplastic material, optionally a lofting agent and an optional thermoplastic polymer film or films and/or woven or non-woven fabrics made with glass fibers or thermoplastic resin fibers such as, for example, polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), a blend of PC/PBT, or a blend of PC/PET. In some embodiments, a PP, a PBT, a PET, a PC/PET blend or a PC/PBT blend can be used as a resin. To produce the sheet, a thermoplastic material and reinforcing materials can be added or metered into a dispersing foam contained in an open top mixing tank fitted with an impeller. Without wishing to be bound by any particular theory, the presence of trapped pockets of air of the foam can assist in dispersing the glass fibers, the thermoplastic material and the lofting agent. In some examples, the dispersed mixture of fibers and thermoplastic material can be pumped to a head-box located above a wire section of a paper machine via a distribution manifold. The foam, not the fibers and thermoplastic, can then be removed as the dispersed mixture is provided to a moving wire screen using a vacuum, continuously producing a uniform, fibrous wet web. The wet web can be passed through a dryer at a suitable temperature to reduce moisture content and to melt or soften the thermoplastic material. The resulting product may be pressed or compressed, e.g., using nip rollers or other techniques, to form a sheet which can then be coupled to a core layer or another layer. In certain embodiments, the high porosity present in the skin layers shown inFIGS.8A,8Bcan reduce the overall weight of the multilayer assembly and can permit the inclusion of agents within the void space of the skin layers. For example, lofting agents can reside in the void space in a non-covalently bonded manner. Application of heat or other perturbations can act to increase the volume of the non-covalently bonded lofting agent which in turn increases the overall thickness of the layer, e.g., the layer increases as the size of the lofting agent increases and/or additional air becomes trapped in the layer. If desired, flame retardants, colorants, smoke suppressants and other materials may be included in the void space of the skin layers shown inFIGS.8A,8B. Prior to lofting, the multilayer assembly can be compressed to reduce its overall thickness, e.g., compressed before or after the layer is coupled to one or more other layers. In certain embodiments, the thermoplastic material of the skin layers shown inFIGS.8A,8Bmay comprise, at least in part, a polyolefin or one or more of polyethylene, polypropylene, polystyrene, acrylonitiyistyrene, butadiene, polyethyleneterephthalate, polybutyleneterephthalate, polybutylenetetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, and blends of these materials with each other or other polymeric materials. Other suitable thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, co-polyamides, acrylonitrile-butylacrylate-styrene polymers, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystalline polymers, poly(1,4 phenylene) compounds commercially known as PARMAX®, high heat polycarbonate such as Bayer's AMC® PC, high temperature nylon, and silicones, as well as copolymers, alloys and blends of these materials with each other or other polymeric materials. The thermoplastic material used to form the skin layers shown inFIGS.8A,8Bcan be used in powder form, resin form, rosin form; particle form, fiber form or other suitable forms. Illustrative thermoplastic materials in various forms are described herein and are also described, for example in U.S. Publication Nos. 20130244528 and US20120065283. The exact amount of thermoplastic material present in the skin layers shown inFIGS.8A,8Bcan vary and illustrative amounts range from about 20% by weight to about 80% by weight, e.g., 30-70 percent by weight or 35-65 percent by weight. It will be recognized by the skilled person that the weight percentages of all materials used in any one of the skin layers shown inFIGS.8A,8Bwill add to 100 weight percent. In certain examples, the reinforcing fibers of the skin layers shown inFIGS.8A,8Bmay comprise glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly, high modulus organic fibers such as, for example, para- and meta-aramid fibers, nylon fibers, polyester fibers, or high melt flow index resins that are suitable for use as fibers, mineral fibers such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metalized natural and/or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers can be chemically treated prior to use to provide desired functional groups or to impart other physical properties to the fibers, e.g., may be chemically treated so that they can react with the thermoplastic material, the lofting agent or both. The fiber content in the skin layers shown inFIGS.8A,8Bmay independently be from about 20% to about 90% by weight of the layer, more particularly from about 30% to about 70%, by weight of the layer. Typically, the fiber content of a multilayer assembly comprising the skin layers shown inFIGS.8A,8Bvaries between about 20% to about 90% by weight, more particularly about 30% by weight to about 80% by weight, e.g., about 40% to about 70% by weight of the assembly. The particular size and/or orientation of the fibers used may depend, at least in part, on the thermoplastic polymer material used and/or the desired properties of the skin layers shown inFIGS.8A,8B. Suitable additional types of fibers, fiber sizes and amounts will be readily selected by the person of ordinary-skill in the art, given the benefit of this disclosure. In one non-limiting illustration, fibers dispersed within a thermoplastic material and optionally a lofting agent to provide the skin layers shown inFIGS.8A,8Bcan generally have a diameter of greater than about 5 microns, more particularly from about 5 microns to about 22 microns, and a length of from about 5 mm to about 200 ram; more particularly, the fiber diameter may be from about 2 microns to about 22 microns and the fiber length may be from about 5 mm to about 75 mm. In some embodiments, the lofting capacity of the skin layers shown inFIGS.8A,8Bcan be further tuned by including one or more added lofting agents. The exact type of lofting agent used in the skin layers shown inFIGS.8A,8Bcan depend on numerous factors including, for example, the desired lofting temperature, the desired degree of loft, etc. In some instances, microsphere lofting agents, e.g., expandable microspheres, which can increase their size upon exposure to convection heating may be used. Illustrative commercially available lofting agents are available from Kureha. Corp. (Japan). In other instances, a first lofting agent with a first average particle size and a second lofting agent with a second average particle size, different from the first average particle size, may be used in the skin layers shown inFIGS.8A,8B. In other examples, the lofting agent may be an expandable graphite material which can also impart some flame retardancy to the multilayer assembly. In some configurations, the skin layers shown inFIGS.8A,8Bmay be a substantially halogen free or halogen free layer to meet the restrictions on hazardous substances requirements for certain applications. In other instances, one or more of the layers may comprise a halogenated flame retardant agent such as, for example, a halogenated flame retardant that comprises one of more of F, Cl, Br, I, and At or compounds that including such halogens, e.g., tetrabromo bisphenol-A polycarbonate or monohalo-, dihalo-, trihalo- or tetrahalo-polycarbonates. In some instances, the thermoplastic material used in the skin layers shown inFIGS.8A,8Bmay comprise one or more halogens to impart some flame retardancy without the addition of another flame retardant agent. Where halogenated flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the halogenated flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent. If desired, two different halogenated flame retardants may be added to the layers. In other instances, a non-halogenated flame retardant agent such as, for example, a flame retardant agent comprising one or more of N, P, As, Sb. Bi, S, Se, and Te can be added. In some embodiments, the non-halogenated flame retardant may comprise a phosphorated material so the layers may be more environmentally friendly. Where non-halogenated or substantially halogen free flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the substantially halogen free flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent based on the weight of the layer. If desired, two different substantially halogen free flame retardants may be added to one or more of the layers described herein. In certain instances, one or more of the skin layers shown inFIGS.8A,8Bdescribed herein may comprise one or more halogenated flame retardants in combination with one or more substantially halogen free flame retardants. Where two different flame retardants are present, the combination of the two flame retardants may be present in a flame retardant amount, which can vary depending on the other components which are present. For example, the total weight of flame retardants present may be about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 15 weight percent, e.g., about 2 weight percent to about 14 weight percent based on the weight of the layer. The flame retardant agents used in the layers described herein can be added to the mixture comprising the thermoplastic material and fibers (prior to disposal of the mixture on a wire screen or other processing component) or can be added after the layer is formed. In some examples, the flame retardant material may comprise one or more of expandable graphite materials, magnesium hydroxide (NIDI) and aluminum hydroxide (ATH). In certain embodiments, the skin layers shown inFIGS.8A,8Bmay comprise one or more film layers in combination with a porous fiber reinforced thermoplastic layer. For example, the film of the skin layers shown inFIGS.8A,8Bmay comprise or be a thermoplastic film, a polyolefin film, an elastomer film, etc. In certain configurations, the film comprises at least one of a polyolefin, e.g., polyethylene or polypropylene, at least one poly(ether imide), at least one poly(ether ketone), at least one poly(ether-ether ketone), at least one poly(phenylene sulfide), poly(arylene sulfone), at least one poly(ether sulfone), at least one poly(amide-imide), poly(1,4-phenylene), at least one polycarbonate, at least one nylon, and at least one silicone. In some embodiments, two or more films may be present in combination with a porous fiber reinforced thermoplastic layer for the skin layers shown inFIGS.8A,8B. In certain embodiments, the additional layers shown inFIGS.8A,8Bmay include a film (e.g., thermoplastic film or elastomeric film), a frim, a scrim (e.g., fiber based scrim or a scrim comprising hydrophilic fibers such as cellulose based fibers), a foil, a woven fabric, a non-woven fabric or be present as an inorganic coating, an organic coating, or a thermoset coating. In other instances, the additional layer shown inFIGS.8A,8Bmay comprise a limiting oxygen index greater than about 22, as measured per ISO 4589 dated1996. Where a thermoplastic film is present as (or as part of) the additional layer shown inFIGS.8A,8B, the thermoplastic film may comprise at least one of poly(ether imide), poly(ether ketone), poly(ether-ether ketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. Where a fiber based scrim is present as (or as part of) the additional layer shown inFIGS.8A,8B, the fiber based scrim may comprise at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metalized synthetic fibers, and metalized inorganic fibers. Where a thermoset coating is present as (or as part of) the additional layer shown inFIGS.8A,8B, the coating may comprise at least one of unsaturated polyurethanes, vinyl esters, phenolics and epoxies. Where an inorganic coating is present as (or as part of) the additional layer shown inFIGS.8A,8B, the inorganic coating may comprise minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti and Al or may comprise at least one of gypsum, calcium carbonate and mortar. Where a non-woven fabric is present as (or as part of) the additional layer shown inFIGS.8A,8B, the non-woven fabric may comprise a thermoplastic material, a thermal setting binder, inorganic fibers, metal fibers, metallized inorganic fibers and metallized synthetic fibers. If desired, the additional layer shown inFIGS.8A,8Bmay comprise an expandable graphite material, a flame retardant material, fibers, etc. In some examples, one or more intervening layers may be present between a core layer and a skin layer. Referring toFIG.9, an intervening layer920is shown between a core layer910and a skin layer930. The intervening layer920may be for example, an adhesive layer, a powder coat layer, a film, or other materials. While not shown, one or more additional layers can also be present on a second surface904of the core layer910. Further, the second surface904may also comprise one, two, three, four, five or more depressions if desired. The core layer910and the skin layer930may comprise any of these materials described in reference, for example, toFIGS.8A and8B. In certain examples, it may be desirable to pre-form a skin layer with one or more depressions in the skin layer. The one or more depressions in the skin layer can mirror depressions in a core layer so the skin layer and core layer can be placed together. For example, a projection, press or other device, as discussed in more detail below, can be used to create depressions in a skin layer. These depressions can then be coupled to depressions in a core layer by matching up the various depressions. By mirroring the depressions in a skin layer and a core layer, the skin layer can be coupled to the core layer in a desired orientation. For example, where the skin layer has a specific arrangement of fibers, it may be desirable to orient the fibers in either the machine direction or the cross direction. By creating an asymmetric or unique arrangement of depressions in a skin layer and a core layer, the skin layer and the core layer can be coupled to each other in a specific direction. In certain embodiments, the depressions described herein can be produced in many different ways. For example and referring toFIG.10, a spike1010on a plate1000is shown. The spike1010can be pressed into the core layer, the skin layer or both to create a depression. The exact depth at which the spike is pressed into the layers may vary from about ⅛ inches (about 30 mm) to inches (about 1.25 cm). If desired, the depth can be adjusted either by pushing the spike1010further into the layers or by increasing a length of the spike1010. The spike1010may take many different forms and shapes and may have a sharp end or a rounded end, may be solid, may be hollow, may have two or more different projections or may take other forms. The spike1010typically comprises a material with a higher melting point than the materials used in the skin layer. For example, the spike1010may comprise a metal, high temperature polymer, rubber, carbon fiber, diamond or other materials with a melting point above 200 degrees Celsius, 250 degrees Celsius or above 300 degrees Celsius. If desired, the spike1010can be coated with materials such as, for example, an adhesive, a powder, a dye, a flame retardant, particles, a resin, a rosin, fibers or other materials. In some instances, the spike1010may comprise a non-stick coating, e.g., a fluoropolymer or other materials, so the core layer and skin layer do not stick to the spike during production of the multilayer assembly. In certain embodiments, the spike may be present in a plate along with one or more other spikes. For example and referring toFIG.11, a plate1100is shown that comprises a plurality of spikes (collectively1110) each of which has an independently adjustable depth. The depth of the spikes1110can be the same or can be different to provide depressions of different depths. Further, the dimensions and shapes of the spikes also need not be the same. The spikes1110may include any of those configurations and materials described in connection with spike1010. In some examples, a plate comprising a plurality of projections can be pressed into a surface of a multilayer assembly to provide a plurality of depressions. Referring toFIG.12, a plate1200is shown that comprises nine projections per row with nineteen individual rows totaling171individual projections. The exact number of projections per row may be one, two, three or more. Similarly, the number of rows present on a plate may be one, two, three or more. The individual projections in each row can be symmetrically or asymmetrically spaced apart from each other as desired. Further, the shape, size and/or depth of different projections need not be the same. In use of the plate1200, a skin layer can be placed on a core layer and heated to soften the skin layer and/or the core layer. The plate1200can then be pressed into the softened skin layer to create a plurality of depressions across the surface of the skin layer. In certain examples, while the projections are shown inFIG.12as being fixed, if desired, one or more of the projections can be actuated, e.g., hydraulically, pneumatically, etc. to push the projection into the skin layer. For example, the plate may be placed adjacent to a skin layer and remain stationary. One or more individual projections can be actuated to push that projection into the skin layer and/or core layer to create a depression. In certain configurations, a softened skin layer can be placed adjacent to a plurality of air jets to form depressions in a first surface of the multilayer assembly. For example, application of pneumatic pressure, e.g., either continuously or intermittently, from air jets can act to push the skin layer into the core layer and form one or more depressions. Different air pressures can be used if desired to form depressions with different depths and/or shapes. Ambient air, an inert gas such as nitrogen or helium or other gases may be used to form the depressions. In some instances, a reactive gas can be used so the fibers and/or thermoplastic materials present in the skin layer can react with the materials in the reactive gas. In certain examples, the core layers described herein can be produced by extruding or expanding foams or by producing honeycomb structures by joining multiple strips of material and/or cutting the material to a determined thickness and height. These strips can, for example, be attached glue/welded) at a determined spacing. When pulled open the cells can provide a honeycomb structure. For example, in one instance a paper roll can be used to provide a series of stacked sheets, which can be connected with an adhesive in certain areas. The stacked sheets can then be sliced. The slices can be expanded to provide a core with a plurality of cells or honeycombs. In the case of metal honeycomb structures, they can be printed, forged, cast or otherwise produced. In producing the skin layers described herein, it may be desirable to use a wet-laid process and one or more additional materials. For example, a liquid or fluid medium comprising dispersed material, e.g., thermoplastic material and one or more types of reinforcing materials such as fibers, etc., optionally with any one or more additives described herein (e.g., flame retardant agents, lofting agents, etc.), may be stirred or agitated in the presence of a gas, e.g., air or other gas. The dispersion may then be laid onto a moving support, e.g., a wire screen or other support material, to provide a substantially uniform distribution of the materials in the laid down material. To increase material dispersion and/or uniformity, the stirred dispersion may comprise one or more active agents, e.g., anionic, cationic, or non-ionic such as, for example, those sold under the name ACE liquid by Industrial Soaps Ltd., that sold as TEXOFOR® FN 15 material, by Glover Chemicals Ltd., and those sold as AMINE Fb 19 material by Float-Ore Ltd. These agents can assist in dispersal of air in the liquid dispersion. The components can be added to a mixing tank, flotation cell or other suitable devices in the presence of air to provide the dispersion. While an aqueous dispersion is desirably used, one or more non-aqueous fluids may also be present to assist in dispersion, alter the viscosity of the fluid or otherwise impart a desired physical or chemical property to the dispersion or the prepreg, core or article. In certain instances, after the dispersion has been mixed for a sufficient period, the fluid with the suspended materials can be disposed onto a screen, moving wire or other suitable support structure to provide a web of laid down material. Suction or reduced pressure may be provided to the web to remove any liquid from laid down material to leave behind the thermoplastic material, and any other materials that are present, e.g., fibers, additives, etc. The resulting web can be dried and optionally consolidated or pressed to a desired thickness prior to fully forming it to provide a desired skin layer. While wet laid processes may be used, depending on the nature of the thermoplastic material and reinforcing materials, it may be desirable to instead use an air laid process, a dry blend process, a carding and needle process, or other known process that are employed for making non-woven products. In certain embodiments, the skin layers described herein can be produced using an inline process and/or an inline system. For example, a system to produce a skin layer can include a head box that can be used to mix the materials and deposit a liquid comprising thermoplastic material (TP) and reinforcing materials (RM) on a moving support. The moving support can be moved using pulleys or rollers which can be coupled to a motor. A vacuum device can be present to remove liquid, but not the TP or RM, from the deposited materials on the moving support to form a web. The web can be permitted to solidify or be dried for at least some period before being provided to an optional set of rollers to compress the web. A moving belt can receive the dried web from the moving support. The gap between the moving support and the belt can be small so the dried web does not fall through. In certain examples, the web can then be placed on a core layer and heated to a desired temperature to soften the web, e.g., 170-240 degrees Celsius. The exact time used to heat the web may vary from a few seconds up to a few minutes depending on the overall thickness of the dried web. A plate, mold, etc. comprising projections can then be pressed into the heated web on the core layer to form one or more depressions to enhance bonding of the skin layer to the sidewalls of the core layer that are formed from pushing the projections into the multilayer assembly. In certain embodiments, the multilayer assembly can be placed in a mold optionally, with other layers that can be coupled to the multilayer assembly. The walls of the mold can include projections to provide depressions in the final assembly after molding. As the mold is heated, e.g., to 300 degrees Celsius or above, the assembly can be shaped into a desired final article while at the same time producing the depressions to enhance bonding of the skin layer to the core layer. In certain embodiments, an inflatable bladder with projections can be used with or without the mold to produce the depressions in the surface of the assemblies described herein. The inflatable bladder may be made of a high temperature material to soften one or more layers of the assembly to permit pressing of the dimples or depressions into the surface(s) of the assembly. In certain embodiments, an overall thickness, weight, etc. of the multilayer assemblies can vary. In some examples, a thickness of the multilayer assembly may vary. In some examples, for load floors in automotive applications, the load floor may have an effective basis weight so less than 4 mm deflection occurs when a load up to 125 lbs (˜57 kg) is placed on the floor. In other instances, the multilayer assembly may have an effective basis weight so less than 8 mm of deflection occurs when a load up to 500 lbs (˜227 kg) is placed on the floor. Applications with higher weight support requirements could have higher basis weights as desired. In certain embodiments, the multilayer assemblies described herein can be used in vehicles, e.g., automobiles, trucks, trains, planes, etc., in recreational vehicles, e.g., tow behind RV's, Class A RV's, Class B RV's, Class C's RVs, truck campers, toy haulers, RV trailers or other recreational vehicles, in building applications, e.g., siding, ceilings, wall cubicles, flooring, wall boards or in other applications. In certain embodiments, a load floor1300is shown inFIG.13A. A side view of a load floor that can be used as a vehicle load floor is shown. The load floor1300is typically, positioned in the rear portion of the vehicle, e.g., a rear storage portion of a sport utility vehicle or minivan, and is designed to receive components, gear, luggage, a spare tire, etc. for storage. A lid or covering (not shown) may also be present to enclose the components within the vehicle load floor1300and shield them from view. The load floor1300may comprise, for example, a multilayer assembly comprising one or more depression as described herein. In some instances, the load floor1300provides sufficient weight bearing capacity, e.g., about 50 pounds or more (about 22 kg or more or the ability to withstand at least 220 Newtons of force) so that no underlying support members from the vehicle need be present to support it. In certain examples, a load floor may have a layered construction as described herein in connection withFIGS.1A-8B. In some examples, the load floor may comprise a layered arrangement as shown inFIG.13B. The load floor1350includes a honeycomb layer1355. On a first surface of the layer1355is an optional adhesive layer1360. A first fiber reinforced thermoplastic layer1365can be present on the adhesive layer1360. A skin, decorative layer or scrim1370can be present on the layer1365. Another optional adhesive layer1375can be present on a second surface of the honeycomb layer1355. A second fiber reinforced thermoplastic layer1380can be present on the layer1375. A skin, scrim or decorative layer1385can be present on the layer1380. Depressions (not shown) can be present on or in one of more or the surfaces as noted herein. In other embodiments, the multilayer assemblies described herein can be present in a bulk head wall. For example, a bulk head wall configured to separate a passenger compartment of a vehicle from a cargo compartment of the vehicle may include one or more of the multilayer assemblies descried herein. The bulk head wall may comprise a core layer and a first porous fiber reinforced thermoplastic layer disposed on the first surface of core layer, wherein the first porous fiber reinforced thermoplastic layer is bonded to surfaces of a plurality of first depressions across a first surface of the core layer. An illustration is shown inFIG.14where a bulk head wall1410is shown as separating a passenger compartment1405and a sleeping area1420in a truck cab1400. Bulk head walls comprising the multilayer assemblies described herein may also be present in passenger vehicles, recreational vehicles, trains, subways, ships, planes, etc. In certain embodiments, the multilayer assemblies may comprise more than a single core or honeycomb layer. For example, one, two, three or more honeycomb layers can be present in any one multilayer assembly as desired. The honeycomb layers can be positioned adjacent to each other or separated by one or more other layers. The honeycomb layers described herein can be produced with dimples or depressions prior to coupling to other layers or after coupling to other layers. It will be recognized by the skilled person, given the benefit of this disclosure, that structures other than dimples or depressions could be provided in a similar manner. For example, a channel, slot or other structures could also be produced using methods and materials similar to those described herein. When introducing elements of the examples disclosed herein, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including” “with” and “having” are intended to be open-ended and mean that there may be additional elements other than the listed elements. It will be recognized by the person of ordinary skill in the art, given the benefit of this disclosure, that various components of the examples can be interchanged or substituted with various components in other examples. Although certain aspects, examples and embodiments have been described above, it will be recognized by the person of ordinary skill in the art, given the benefit of this disclosure, that additions, substitutions, modifications, and alterations of the disclosed illustrative aspects, examples and embodiments are possible. | 130,185 |
11858222 | InFIGS.1a-1d, a possible progression of the method according to the invention for applying a material is illustrated. For example, a fiber preform10is initially provided in the first step1a, said preform at least partially having the subsequent component form of the fiber composite component to be produced. The fiber preform10has in this case been formed from a fiber material11in that a plurality of layers of fiber materials were laid over one another. In the example ofFIG.1a, a very pronouncedly simplified component form is illustrated. It goes without saying that any desired complex component form can be produced here. Furthermore, pre-impregnated fiber materials11were used, such that the matrix material12in which the fiber material11is embedded is contained in the fiber preform10already during the production of the fiber preform10. Furthermore, a woven monofilament fabric20is provided which likewise already contains a matrix material21and thus is likewise pre-impregnated. The woven monofilament fabric20has a plurality of woven fabric threads22which are configured in the form of individual filaments. In the next method step1b, the woven monofilament fabric20is then arranged within an application region13of the fiber preform, wherein another material is intended to be applied within the application region13at a later stage. However, in step1b, the woven monofilament fabric20is then initially arranged in the application region13, wherein, in this case, the matrix material12of the fiber preform10and the matrix material21of the woven monofilament fabric20come into contact with one another and possibly mix with one another in the boundary region (boundary layer). The matrix material12of the fiber preform10and the matrix material21of the woven monofilament fabric20are subsequently at least partially cured, and this connects the woven monofilament fabric20to the fiber preform10or the fiber composite component in a materially bonded manner. As shown inFIG.1c, the woven monofilament fabric20is subsequently pulled off perpendicularly with respect to the fiber preform10or the fiber composite component, such that the materially bonded connection between the woven monofilament fabric20and the fiber composite component or the fiber preform10is cohesively fractured within the application region13. The resulting rough surface14within the application region13in this case has a high surface energy, wherein the use of a woven monofilament fabric in particular prevents reinforcing fibers of the fiber material11of the fiber preform10from also being ripped out and damaged. The proportion of the cohesively fractured surface within the application region13can in this case be set by the open areas or the mesh width of the woven monofilament fabric20, with it being necessary here to take account of the fact that the woven monofilament fabric20as woven pull-off fabric also has to be removed from the fiber preform10, after having been connected thereto in a materially bonded manner, without said fabric tearing in the process. In step1d, the actual material30is subsequently applied within the application region13, said application being able to be effected by means of an applicator31, for example. FIG.2shows a schematically pronouncedly simplified depiction of a detail of a woven monofilament fabric20in which the warp threads23and the weft thread(s)24are composed of an individual filament. This means that the warp threads23and the weft threads24are not multifilaments and thus do not have a plurality of filaments per se. It is rather the case that each warp thread23or weft thread24is composed of an individual filament. In this case, a mesh25is delimited by the respective warp thread and weft thread, wherein the open area26of a mesh25is in this case that region which is geometrically defined by the mesh width and mesh height. In this case, the materially bonded connection between the woven monofilament fabric20and the fiber preform or the fiber composite component10is cohesively fractured within said open area26, which leads to the desired surface energy. FIG.3schematically shows the operation for pulling off the woven monofilament fabric20from the fiber preform10. As can be seen, the materially bonded connection is in each case coherently fractured between the individual filaments22, such that a cohesive surface14is produced here. LIST OF REFERENCE DESIGNATIONS 10—Fiber preform11—Fiber material12—Matrix material13—Application region14—Cohesively fractured surface20—Woven monofilament fabric21—Matrix material of the woven monofilament fabric22—Woven fabric threads23—Warp threads24—Weft threads25—Meshes26—Open areas30—Material to be applied31—Applicator | 4,722 |
11858223 | DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. In order to overcome the problem of bonding both the 20% carbon fiber filled and 60% glass filled resins, we conceived the idea to overmold a strip of secondary resin molded locally on the part, where the IR welded bond is needed to take place. This secondary resin strip is typically be made of the same base resin as the structural resin used, but without fillers to disrupt the IR welding process. In the case of our nylon filled resins, we would use a nylon resin with no glass or carbon fiber fillers. These strips of secondary resin could be applied to one or both halves of the components being joined. The width and thickness of the strip would vary depending on the bond needed and the resins effectiveness to be joined. Other methods of joining besides IR welding may be applicable to using this secondary strip of resin to enable bonding such as hot plate welding, ultrasonic welding or vibration welding. In an alternate embodiment, the process is also used to allow dissimilar plastics to be joined together. The secondary strips made of compatible resins are added to one or both dissimilar plastics to enable their joining. In an additional embodiment, this method could be used with adhesives if the base resin in a part is unable to be dissolved by an adhesive to create a sufficient bond to another part. A secondary strip of resin can also be added to make a joint between them compatible if necessary. The process of adding this secondary strip of material to a primary plastic part is typically done through the process of two-shot injection molding or insert molding. The two-shot injection molding process enables the overmolding of the secondary strip resin because it is done immediately after the primary part resin is injected into the mold. While the primary part is still hot but sufficiently solid to manipulate, it can be presented to another cavity and injected with the secondary plastic resin, forming the strip of material to be bonded. Because this secondary injection of plastic occurs while the primary part is still very hot and is being done with plastics that have common base resin, a strong molecular bond occurs between the two resins. Once this occurs, the two parts can be bonded together by the joining process required. Referring now to the drawings, and in particular toFIG.8, there is provided a process for joining polymer molded parts, generally shown at10. The process involves the steps of providing a first part12and a second part14to be joined along cooperative joining portions16and18. The first part made from a first material and a second part made from a same or different material as the first material. Then an infrared bonding material is overmolded or otherwise bonded to at least one of the parts (12,14) in a place (16or18or both) for the parts12,14to be joined. The parts12and14are either already in the mold halves20,22that they were molded in, or they are placed in a mold cavity for joining them together. The molds are separated and an infrared heating element24is inserted between the parts12and14. This heats at least the surface with the infrared bonding material15, which can be on one side or both sides. Thereafter the mold is used for pressing the first part12into contact with the second part14at the joining surface15wherein a bond is formed. When two bonding materials are used the first infrared bonding material and second infrared bonding material are compatible for infrared melt bonding to each other and also to the respective surfaces16and18on the parts12and14. Preferably parts12and14comprise thermoplastic fiber filled thermoplastic resins. While Nylon and glass filled, or graphite filled polypropylene are preferred polymers. However, the present process is used with any filled resin with a high filler content that makes joining difficult. Generally, this process would be used with fiber filled materials having above about 20% fillers. Typically, the amount of fillers are about 40% and above fiber content, preferably the filler content is from about 40% to about 60% all fiber fillers are by weight. For carbon fiber filled resins it would be useful for amounts of 20% and above filler. This process when other fillers are present in a resin that makes joining difficult. The present process is also useful to bond two parts with differing levels of filler together, if one half needed some special properties or as a cost saving measure. As an example, the polymer is a 10-30% carbon fiber filled nylon composition and a nylon material is overmolded on the surfaces to be joined prior to infrared heat treatment for joining the parts. Highly filled 30-60% filled long glass fiber compositions are also joinable using the process of the present invention. Typically, the resin is a carbon fiber or glass filled fiber composition. The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the essence of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | 5,342 |
11858224 | DETAILED DESCRIPTION FIG.1shows a three-dimensional view of an aircraft10having a fuselage12and a fuselage section14.FIG.1furthermore contains an enlargement of a fragment of the fuselage section14. A fuselage shell16and the aft pressure bulkhead18are, inter alia, illustrated in the enlarged fragment. The fuselage shell16has the shape of a portion of a shell surface of a cylinder. By virtue of the design embodiment thereof having only one radius, the fuselage shell16, proceeding from a non-crimp fabric from carbon fibers, can be produced by a direct depositing method or with the aid of a double-belt press. In the direct depositing method, a tier from a bi-axial non-crimp fabric or NCF material of carbon fibers (“non-crimp fabric direct layup” or “NCF direct layup”) is placed directly on a male or convex consolidation tool and stapled to the tool and a preceding tier which is optionally present. A metallic conductive tier, for example in the form of an expanded copper foil, is disposed thereabove as a lightning strike protection (LPS) as uppermost tier. Tapes of the thermoplastic high-performance plastics material (90-150 mm) are subsequently cut into narrower tapes which by a flat ATL method are then applied as an overarching matrix material to the material tiers deposited on the cylinder surface (generation of a prepreg). Local reinforcements can be additionally produced by a flat ATL method and integrated in the consolidation tool. The composite material precursor is subsequently consolidated at an elevated pressure and at a temperature above the melting temperature of the high-performance plastics material. In summary, large-area reinforcement material tiers in the form of non-crimp fabrics can be used in a time-saving manner in this method. The matrix from a thermoplastic polymer in the form of narrow tapes is however still applied by an ATL method. In the method using a double-belt press, dry non-crimp fabrics of carbon fibers and films from thermoplastic high-perform plastics material are conjointly fed to a double-belt press. The thermoplastic polymer melts in the double-belt press and impregnates the dry non-crimp fabric of carbon fibers. A preliminary consolidation of the infed material tiers so as to form a flat continuous organic sheet takes place under the prevailing pressure. The sheet has a specific layup and the width b desired for the fuselage shell. The flat organic sheet is cut to size. The cut-to-size blank is cylindrically shaped with the desired radius by hot-rolling. The radius r can be 2000 mm for example. A discontinuous preform is obtained. The laminate forming the base for the external skin has a uniform thickness. In summary, large-area reinforcement material tiers in the form of non-crimp fabrics and large-area films from thermoplastic high-performance plastics material can be used in a time-saving manner in this method. However, the films have a high degree of stiffness. Therefore, the films can be processed in a double-belt press and with subsequent hot-rolling only so as to form cylindrical shapes with one radius. The two methods are however unsuitable for producing the aft pressure bulkhead18of the aircraft according toFIG.1. A pressure bulkhead of this type has a spherical shape. The spherical shape of a pressure bulkhead or of other complex curved components in the present description is also referred to as a shape with a double curvature, at least a double curvature, or as a shape or a component, respectively, with two or at least two curvature radii. In other words, the term spherical shape includes all shapes which have a curvature or contour that is more complex than a cylinder in which the curvature can be described by a single curvature radius. Components having a spherical shape, such as the aft pressure bulkhead18, can neither be produced by the direct depositing method nor with the aid of a double-belt press. The components to date are produced by an automated fiber placement (AFP) method. For example, the aft pressure bulkhead for the Airbus A380 with the aid of an AFP method can be produced by depositing tapes from thermoplastic CRP composite material on the shape-imparting surface and by consolidating (heating while impinged with pressure) of the blank. In very general terms, for the production of spherical components based on a thermoplastic fiber-composite material it has to date been necessary for tapes from a thermoplastic fiber-composite material to be deposited on the shape-imparting surface of a male or female molding tool. The layup herein comprises the base laminate having large-area reinforcement tiers disposed therebetween and, as a last tier, an expanded copper foil as a lightning strike protection. Local reinforcements and stringers32are integrated on the, optionally pre-consolidated, component such as an external skin laminate. The consolidation can be carried out in an autoclave or with the aid of a vacuum bag. Since this method is time-consuming and cost-intensive, there is a demand for improved materials and methods. In a preliminary test, the behavior of melted polyether ketone ketone (PEKK) was observed in a fiber-composite material precursor which in a layered manner was constructed from matrix precursor tiers A′ in the form of PEKK films and reinforcement tiers B in the form of non-crimp fabrics from carbon fibers at high pressure in a closed molding tool. FIG.2shows the sequence of the tiers A′ and the tiers B. The eight tiers B are joined so as to form four bi-axial non-crimp fabrics. The 12 tiers A′ are joined so as to form stacks from two or three PEKK films. The PEKK film has a thickness of approximately 40 μm, for example. The fiber-composite material precursor has the following sequence or stacking:A′A′A′ BB A′A′ BB A′A′ BB A′A′ BB A′A′A′. This composite material precursor is consolidated in a molding tool at a pressure of, for example, 40 bar and at a temperature which is above the melting temperature of PEKK, for example. FIG.3shows two microscopic photographs with an enlargement factor of 50 and 100, respectively, which have been recorded from micro-sections of the consolidated composite material precursor. The bi-axial non-crimp fabric (NCF material) is completely impregnated with PEKK during the consolidation. There are no pores or dry regions. Accordingly, PEKK above its melting temperature and under high pressure a suitable for completely impregnating carbon fibers in a bi-axial non-crimp fabric or NCF material. FIG.4shows the layer sequence of two textile composite material precursors20according to example I and example II. The precursor according to example I comprises 14 matrix precursor tiers A,22from a woven PEKK fabric22, and 12 reinforcement tiers B from a non-crimp fabric24,28from carbon fibers. The 14 matrix precursor tiers A are joined so as to form five units from two or three material precursor tiers A, respectively. The 12 reinforcement tiers B are joined so as to form four units in the form of tri-axial non-crimp fabric28from carbon fibers. This results in a sequence of tiers:AAA BBB AAA BBB AA BBB AAA BBB AAA. The composite material precursor20according to example II comprises 12 matrix tiers A,22from a woven PEKK fabric22, and eight reinforcement tiers from a non-crimp fabric24from carbon fibers. The 12 matrix tiers A,22are joined so as to form five units from two or three matrix tiers A, respectively. The eight reinforcement tiers B are joined so as to form four units in the form of a bi-axial non-crimp fabric26from carbon fibers. This results in a sequence of tiers:AAA BB AA BB AA BB AA BB AAA±45° 0°/90° 0°/90°±45° The angles indicated below BB reflect the orientation of the reinforcement fibers, preferably carbon fibers, in the fiber-composite material precursor. The textile composite material precursors20according to examples I and II from the tiers A and B can first be joined so as to form the composite material precursor20, the latter then being deposited on the shape-imparting surface36of the molding tool34. Alternatively, the textile composite material precursor20by depositing the individual tiers can also be joined directly on the shape-imparting surface36. The tiers A and B in these two alternatives can be deposited individually on top of one another. It is however also possible for a plurality of tiers A to first be joined so as to form units such as AA or AAA, and/or for a plurality of tiers B to be joined so as to form multi-axial units, such as BB to form a bi-axial non-crimp fabric26or BBB to form a tri-axial non-crimp fabric28. These units and/or multi-axial units can then be stacked on top of one another while forming the textile composite material precursor20. FIG.5in a heavily simplified manner shows the production of a component30, here an aft pressure bulkhead18, from the flexible textile fiber-composite material precursor20. The textile composite material precursor20is configured on the shape-imparting surface36. Due to the positive draping capability of the textile tiers A and B, the textile composite material precursor20assumes the contour of the surface. The component30, here the aft pressure bulkhead18, is obtained after the method described here has been carried out. The fiber-composite material is free of pores. Likewise, no spots which are free of the matrix are established. It is furthermore possible, as is illustrated inFIG.5, for local reinforcement elements such as stringers32to be placed on the pre-consolidated or the consolidated fiber composite material. When the fiber-composite material is used for the external skin, an upper final tier from an expanded copper film (ECF) can also be implemented as a lightning strike protection (LSP). The thermoplastic polymer material of the matrix precursor tiers A when in contact with the LSP material proves helpful herein. Various aspects of the disclosure herein will be summarized once again hereunder. In the context of the development of future aircraft fuselages, the use of thermoplastic materials (TP materials) for airframes and aircraft fuselage structures is one of the fundamental topics. The most technically mature solution is currently the AFP arrangement of tapes and cut-to-size tapes of TP materials for the external skin and parts of the casing. In the prior art, the most promising technology in terms of costs lies in thermoplastic NCF (non-crimp fabric) casings for the cylindrical regions. Since the standard NCF material having an enclosed TP matrix cannot be used in the spherical regions due to the restrictions in terms of the draping capability, the technology for regions with a double curvature still lies in an AFP method having cut-to-size tapes. The matrix in the TP/NCF approach is usually implemented by a resin foil (strong and stiff) or by powder on the NCF (sets the NCF). The following NCF methods are currently proposed for cylindrical regions:(A) NCF direct layup:NCF as a bi-axial material is placed directly in a male consolidation tool and stapled to the tool and the preceding tier;LSP is placed as the last tier and stapled to the preceding NCF tier;impregnating and consolidating are carried out in a pressurized cycle of a consolidating press;reinforcements (collective and local) are produced by a flat ATL and integrated in the consolidation tool. The NCF direct layup comprises: NCF+matrix→direct layup of NCF in a male consolidation tool (including LSP)→slitting the tape (90-150 mm)→producing the flat ATL reinforcement (prepreg)→integration of the reinforcement→consolidation method.(B) Double-belt press (casing with a single curvature)double-belt press technology using dry-fiber NCFs and thermoplastic resin films and foils;dry fibers and resin films are fed to a double-belt press, and NCF is impregnated and pre-consolidated so as to form a flat, continuous organic sheet with a special layup and a width for aircraft fuselage casings;the flat organic sheet is cut and hot-rolled to the desired radius (for example, r=2000 mm). This creates a discontinuous preform from a skin base laminate (of identical or constant thickness). The method using the double-belt press comprises: NCF+matrix→double-belt press for base skin (including LSP)→slitting the tape (90-150 mm)→producing the flat ATL reinforcement (prepreg)→integration of the reinforcement→consolidation method. Current method for regions with a double curvature:(C) Female/male AFP method (casing with a double curvature)automated fiber placement (AFP) method of thermoplastic tapes cut into narrower tapes in a female or male mold;use of pre-impregnated thermoplastic material;layup of the base laminate with interposed reinforcements;local reinforcements and stringers are integrated on the (pre-) consolidated skin laminate. The AFP method using a female/male shape-imparting surface comprises: Prepreg of cut-to-size tapes layup of the complete skin on the female or male shape-imparting surface LSP layup (AFP) consolidation method. The cost advantages by virtue of the high laying rates when using NCF are substantiated by the aft pressure bulkhead of the Airbus A380 and in the concepts of the “Wing of Tomorrow”. The latest NCF application lies in the use of NCF in the door frames of the Airbus A350, on account of which savings are achieved in terms of the reoccurring costs. The cost analysis for typical frames for aircraft fuselages have also demonstrated the great cost savings on account of the NCF concept, this however limited to the cylindrical casings. Preliminary tests with flat boards and resin films (thermoplastic) have shown promising results. The preliminary tests were used with two composite-material precursors with the following experimental layup:Variant 1: 14 tiers of PEKK foil (40 μm) (tiers A)four tiers from tri-axial NCF (350 g/m2) (tiers B) The stacking was AAA BBB AAA BBB AA BBB AAA BBB AAA.Variant 2: 12 tiers of PEKK foil (40 μm) (tiers A)four tiers from bi-axial NCF (tiers B) The stacking was AAA BB AA BB AA BB AA BB AAA. FIG.3shows microscopic photographs with the enlargement factor of 50 or 100, respectively, of micro-sections of the fiber-composite material obtained by the variant2. A complete impregnation of the NCF material could be achieved thereafter. No pores and dry regions could be observed. NCF technology and a method for thermoplastic matrix casings with a double curvature enables a short lead time and advantages in terms of the reoccurring costs for the regions with the double curvature. The disclosure herein relates to a concept for implementing the matrix in the NCF material in such a manner that the draping of the material is not blocked and draping is possible. The NCF concept can likewise be applied in the regions with the double curvature. The following advantages can be achieved:lower costs in the production of the external skin;use in other curved casing-type components, such as the aft pressure bulkhead;application in curved components of the frame. The following aspects are of importance:The matrix is used in intervening tiers. This is important because the viscosity is very high. The impregnation is thus guaranteed. The tiers are thin or of a medium thickness for aircraft external skins (the tiers may be thicker for other applications);homogenous distribution;the matrix remains positively distributed, also after draping;The matrix does not prevent the draping of the NCF. The NCF can otherwise not be impregnated or the matrix cannot be welded on the NCF;The matrix enables the required design features such as inclines (ramps), sloping tiers. By way of these characteristics it is possible for NCF to be used for a (spherical) fuselage skin with a double curvature or for other curved complex components. Real cost advantages can be achieved in comparison to the standard AFP method which is used for such parts. A thermoplastic matrix which is produced in the form of a woven fabric is used. The thermoplastic matrix is implemented in an NCF; the production of thermoplastic casings with a double curvature is possible by a high-pressure method. The PEKK matrix, as is used in aircraft fuselages, is available as a woven fabric. The PEKK matrix is used inter alia as an energy conductor for ultrasonic welding. A woven fabric which is able to be draped in a particularly positive manner is a woven fabric of twill/satin. This also enables a small volume when stacking. Preferred materials:bi-axial NCF or tri-axial NCF (the area weight per tier is a function of the matrix viscosity and is chosen such that the impregnation is still possible);matrix, for example PPS, PEEK, PEKK for (primary structure) in the format of a woven fabric (for example satin, twill). Method:male or female method;layup of NCF and matrix:1. matrix2. NCF tier3. matrix4 . . .use of a vacuum bag, or closing the molding tool;application of heat required for melting the matrix and for the impregnation of the material; pressure able to be applied in the range of 10 to 40 bar, but lower values are also possible;process window: Sequence temperature/pressure method. Method wind required for the matrix system. ADDITIONAL ADVANTAGES The woven matrix fabric can also be a trailblazer for implementing an LSP (lightning strike protection) material in casings with a double curvature. ECF nets which are capable of draping to a limited extent are currently available and can be combined with a concept of this type. While at least one example embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the example embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a”, “an” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority. LIST OF REFERENCE SIGNS 10Aircraft12Fuselage14Fuselage section16Fuselage shell18Aft pressure bulkhead20Textile composite material precursor22Woven fabric24Non-crimp fabric26Bi-axial non-crimp fabric28Tri-axial non-crimp fabric30Component32Stringer34Molding tool36Shape-imparting surfaceA Matrix precursor tierB Reinforcement tierC Metallic conductive tier | 18,813 |
11858225 | DETAILED DESCRIPTION FIG.1Aillustrates a prior art pultrusion process10for making pultruded strips12. In the process10, carbon fibres14are pulled from at least one continuous reel16. The fibres14are directed through a supply of liquid resin18, such as a resin bath, by rollers20which maintain tension in the fibres14. The resin-soaked fibres22are then pulled through a die24that forms the material into the final desired cross-sectional shape of the strip12. The resin18is then cured, for example by heating in an open chamber or by employing heated dies that cure the resin as the strip12is passed therethrough. FIG.1Bis a schematic cross-sectional view of a pultruded strip12formed by the known process10described above in relation toFIG.1A. The strip12includes a plurality of carbon fibres14extending along the length of the strip12throughout the cross-section thereof. The fibres14are suspended in cured resin18, which surrounds the fibres14and holds them together to form the profile shape of the strip12. The pultruded strip12has a generally rectangular cross-sectional shape having a width40and a thickness42, wherein the width40is greater than the thickness42. The strip12also has a length (not shown) extending perpendicular to the width40and thickness42directions. The length is greater than the width40. The pultruded strip12has a substantially constant cross-sectional shape along its entire length. The pultruded strip12comprises two opposing major surfaces44a,44bextending along the width40and length of the strip12. Each major surface44a,44bfunctions as an adherend surface for bonding to an adherend surface of a similar strip when multiple strips are stacked and bonded together to form a laminate structure, such as a spar cap for a wind turbine blade. Pultruded strips12(as shown inFIG.1Bor made by the process shown inFIG.1A) tend to have a very smooth and flat outer surface. The smooth outer surface, which forms the adherend surfaces44a,44b, can result in a poor bond forming between adjacent bonded strips12in the laminate structure. If the adjacent strips12are not properly bonded together there is a risk of delamination occurring, which may lead to failure of the laminate, e.g. the spar cap in use. In order to improve bonding between the strips12, the adherend surfaces need to be ‘activated’ prior to bonding in order to optimise the chemical and mechanical properties thereof. Activating the adherend surfaces may involve altering the surface topography, for example by surface roughening, to provide improved bonding between the adherend surfaces. One possible method of activating the adherend surfaces is by abrasion of the surfaces. However, it has been found that abrading the surfaces of pultruded strips12causes damage to the fibres14at or near the outer surface of the strip12. The damaged fibres may reduce the structural integrity of the strip, and consequently may compromise the structural integrity of the final composite structure. Referring toFIG.2A, another possible activation technique is the use of a peel ply26which may be formed onto the pultruded strip12, and which can be removed to form a roughened surface32as shown inFIG.2B. Such peel plies26are typically made of a woven fabric such as polyamide having the required surface topography for forming a sufficiently roughened surface32. During the pultrusion process, the peel ply26is drawn through the die24together with the fibres14and the resin18. The peel ply26is cured onto the surface of the strip12as the resin is cured and may subsequently be removed to create a roughened surface32. However, peel ply26presents challenges in both its application and removal. For example, when the peel ply26is held in tension on top of the strip12, it has a tendency to fold or crease at its edges which creates ripples on the surface of the strip12. The peel ply may cause fibre deviation in the strip12in the area around the ripples which compromises the mechanical properties of the strip12. Also, the peel ply26may become caught in the machinery, e.g. the die, used in the pultrusion process. As such peel ply26that is narrower than the strip12is used so that it does not extend to the longitudinal edges28of the surface. As shown inFIG.2A, this narrower peel ply26may be positioned such that the edges of the ply26are spaced from the longitudinal edges28of the strip12. A peripheral region30of the strip12is therefore left uncovered by the peel ply26, as shown inFIG.2A. This peripheral region30lies flush with the peel ply surface27, so that when the peel ply26is removed, the peripheral region30lies above the roughened surface32, as shown inFIG.2B. The absence of the peel ply26in the peripheral region30means that the peripheral region30is not roughened and therefore not activated or optimised for bonding. When the strips12are stacked, the peripheral regions30of neighbouring strips12contact one another. The mutually opposed smooth surfaces of the peripheral regions30of adjacent attached strips12means that poor bonding may occur between the peripheral regions30of the strips12which can lead to delamination. Moreover, consistency in the spacing at the edges of the strips12can be difficult to replicate in the process often resulting in variation in the size of peripheral regions30between the strips12and therefore inconsistency in bonding between strips12. The use of peel ply26also increases the risk that residues of the peel ply26may be left stuck on the strip after removal of the peel ply26, which may contaminate and compromise bonding between the strips12. The use of peel ply26also adds significant cost to the pultrusion process. FIG.3Ais a schematic cross-sectional view of a pultruded strip50according to an embodiment of the present invention As will be discussed in more detail below, the strip50is similar to the strip12described above, but further includes sacrificial layers52, which can be activated (e.g. by abrasion) without damaging the fibres14in the strip50. The pultruded strip50in this example has a generally rectangular cross-sectional shape having a width w and a thickness t, wherein the width w is greater than the thickness t. The strip50also has a length l (not shown) extending perpendicular to the width w and thickness t directions (e.g. perpendicular to the plane of the page showingFIG.3A). The length is greater than the width w. The pultruded strip50has a substantially constant cross-sectional shape along its entire length. The strip50has a core56, which includes a plurality of fibres58(e.g. carbon fibres), disposed in a hardened matrix material60(e.g. cured resin). The matrix60surrounds the fibres58and holds them together to form the profile shape of the core56. The core56has first and second major surfaces54a,54b, which in the orientation of the strip50shown inFIG.3Aare upper and lower surfaces respectively of the core56. The strip50further includes two sacrificial layers52, one on each of the opposing major surfaces54a,54bof the core56. In this example, the strip50has rounded or chamfered longitudinal edges46. It will be appreciated that the core56of the strip50in this example generally corresponds to the entire strip12described by way of background with reference toFIG.1B. In particular embodiments, the thickness t of the strip50is within the range of 1 mm to 10 mm, for example in the range of 3 mm to 7 mm or approximately 5 mm. The width w of the strip50may be in the range of 10 cm to 20 cm, for example. The length l of the strip50may be tens of metres. When the strip50is used to form a spar cap for a wind turbine blade it may have a length in excess of 50 metres, or in excess of 80 metres for some of the largest blades. Alternatively, the length l of the strip50may be much shorter such that a plurality of strips50are laid end to end to form a spar cap of the desired length. The fibres58in the core56are packed tightly together to provide the required fibre volume fraction within the core56. In some embodiments the core56may have a fibre volume fraction of at least 50%, for example at least 60% or 70%. The matrix60may comprise a resin material such as epoxy resin. The material forming the sacrificial layers52may comprise a resin material53such as vinylester or epoxy resin. The sacrificial layers52may comprise substantially the same resin as used for the matrix60forming the core56of the strip50or may be different. In embodiments where the sacrificial layers52comprise a different material to the matrix60, the sacrificial layers52may be chemically compatible with the matrix60of the core56such that an effective bond can be formed therebetween. In embodiments, the matrix60forming the core56of the strip50comprises an epoxy resin and the sacrificial layers52comprise a vinylester resin, which is chemically compatible with the epoxy resin of the matrix60such that an effective bond can be created therebetween. The use of epoxy resin for the matrix60may provide optimum structural properties of the strip50while the use of vinylester, which is typically cheaper than epoxy, for the sacrificial layer52may reduce the cost of the strip50in comparison to a strip having a sacrificial layer52made of epoxy. The sacrificial layers52are positioned on each of the mutually opposed major surfaces54a,54bof the core56, such that they each extend substantially the entire width and length of the strip50. The sacrificial layers52therefore extend over and cover the major surfaces54a,54band at least a portion of the rounded edges46of the strip50. Each of the two sacrificial layers52has a substantially uniform width and thickness across the length and width of the strip50. The two sacrificial layers52also have substantially the same thickness as each other in this example. In other embodiments, rather than forming two distinct layers52, the entire core56may be covered by a sacrificial layer. The sacrificial layer(s)52define adherend surfaces62a,62bof the strip50. When the strip50is produced, these adherend surfaces62a,62bmay initially be smooth and have a glass-like finish. It has been explained by way of background that such smooth surfaces are not optimal for forming strong bonds between stacked strips. In order to provide optimal adherend surfaces62a,62bthat result in strong bonding between strips50, the sacrificial layer(s)52may be activated by removing at least a portion of the layer52. For example, the adherend surfaces62a,62bof the sacrificial layer(s)52may be abraded to remove resin from these surfaces. Activation of the sacrificial layer(s)52serves to roughen the adherend surfaces62a,62b(at least on a microscopic or molecular level). Advantageously, the core56is not affected when the sacrificial layers52are activated, and hence no damage is caused to the fibres58in the strip50. Also, the sacrificial layers52may be abraded over the entire outer surfaces of the strip50, thus avoiding the problems described above associated with peel ply, where the edges of the strip are not activated. FIG.3Bshows an enlarged portion of the strip50shown inFIG.3Abefore (i) and after (ii) activation of the sacrificial layer52. Referring toFIG.3B(i), prior to activation, the sacrificial layer52has a thickness T1. At this stage, the adherend surface62adefined by the sacrificial layer52may have a smooth glass-like finish. Referring now toFIG.3B(ii), after activation of the sacrificial layer52, e.g. after some resin has been removed from the sacrificial layer52by abrasion of the adherend surface62a, the sacrificial layer52has a thickness T2. After activation, the adherend surface62amay have a rougher surface (at least on a microscopic level). The thickness of the sacrificial layer52removed during activation is indicated as T3inFIG.3B. The thickness T2of the sacrificial layer52after activation corresponds to the thickness T1of the sacrificial layer52before activation less the thickness T3that has been removed (i.e. T2=T1−T3). It can be seen from a comparison ofFIGS.3B and3Cthat activation of the sacrificial layer52causes a reduction in the thickness of the sacrificial layer (hence T2<T1). In embodiments, prior to activation the thickness T1of the sacrificial layer(s)52may be less than 2 mm, for example less than 1 mm or less than 0.5 mm thick. Preferably the thickness T1of the sacrificial layer(s)52prior to activation is in the range of 0.1 to 0.5 mm, for example 0.2 mm. Any suitable thickness T3of the sacrificial layer(s)52may be removed during activation. In order to avoid damaging the fibres58in the core56, it is preferable not to remove the entire sacrificial layers(s)52(hence T3should be less than T1). The thickness T2of the sacrificial layer(s)52after activation may be between 0.1 mm and 1 mm, for example. In embodiments where the sacrificial layer52has an initial thickness T1of about 0.2 mm, the thickness T2of the sacrificial layer52may be about 0.1 mm after activation thereof. In embodiments requiring a greater level of tolerance, for example when using manual activation methods, the initial thickness T1of the sacrificial layer52may be about 2 mm and the thickness T2of the sacrificial layer may be about 1 mm after activation. The sacrificial layer(s)52are therefore intended to be at least partially removed from the strip50(e.g. by abrasion or other suitable technique) prior to the incorporation of the strip50into a laminate composite, e.g. a spar cap or wind turbine blade. Referring now toFIG.3C, this shows (schematically) a plurality of pultruded strips50according to an embodiment of the invention arranged in a stack63and bonded together to form a spar cap64for a wind turbine blade. Each strip50in this example corresponds to the strip shown and described with reference toFIG.3Aafter activation of the sacrificial layers52(e.g. as shown inFIG.3B(ii)). Accordingly, part of the sacrificial layers52of each strip50has been removed, for example by abrasion or other technique to form activated adherend surfaces62a,62b. The stacked strips50are bonded together by an adhesive66, in this case a resin such as epoxy resin. The strips50are arranged in the stack63with their respective adherend surfaces62a,62bin mutually opposed relation. The adhesive66may be applied directly to the adherend surfaces62a,62bof the strips50, or via another technique such as a resin infusion process. In an infusion process, liquid resin is supplied to the stack63, and the resin infuses between the opposed adherend surfaces62a,62bof the strips50. Activation of the sacrificial layers52exposes more resin at the adherend surfaces62,62bof the strips50and results in an intimate molecular contact between the bonding adhesive66and adjacent adherend surfaces62a,62bof the stacked strips50. Once cured, the adhesive66therefore forms a strong bond between the strips50, which resists delamination. It will be appreciated thatFIG.3Cis not to scale, and in reality the sacrificial layers52and spaces between strips50would be smaller than they appear in the figure. For the avoidance of doubt, the other figures presented herein are also not intended to be to scale. The spar cap64shown inFIG.3Cmay be formed in situ with a wind turbine blade, for example by stacking the activated pultruded strips50in a wind turbine blade mould together with other blade materials and infusing the entire layup with a resin. Alternatively, the spar cap64could be formed as a separate component, and may subsequently be incorporated into a wind turbine blade layup. FIG.4shows an example apparatus70for manufacturing a pultruded strip50in accordance with the present invention. The apparatus70includes a plurality of endless reels72of carbon fibres58and a drawing device (not shown) pulling the fibres58from the reels72in a process direction81. The fibres58are directed by tension rollers76into a bath74containing liquid resin for forming a matrix60in the same way as described in relation toFIG.1above. The resin-soaked fibres78are then pulled through a die80. The cross section of the die80controls the cross-section of the strip core56that is formed by the pultrusion process. The die80may comprise lower and upper moulding surfaces that mould the major surfaces54a,54bof the core56. In embodiments, the die80may be rectangular to form a pultruded core56having a rectangular cross section. The die80may also be heated in order to partially cure the matrix material60. Additionally or alternatively the fibres58and matrix60forming the core56may then be directed into an oven for partial curing, for example an oven in line with the pultrusion die80. The core56comes out of the die80with the intended design shape and fibre count. From this point onwards the sacrificial layers52are added to the core56. After the first die80, the core56may not be fully cured but may be partially cured. The sacrificial layer52is then applied at an application station82. In the embodiment ofFIG.4, a second resin bath82containing a further resin is positioned downstream of the die for application of the sacrificial layer52. The second resin bath82may be similar to the first resin bath74containing the resin for the matrix60. A second die84may then be positioned downstream of the second resin bath82for shaping the strip50. In embodiments, the second bath82may be spaced a suitable distance from and/or below the output of the first die80to allow for bending of the core56into the second bath82. If required, the pultruded strip50, with the sacrificial layers52applied to its major surfaces54a,54b, may be subsequently moved to a curing oven, where the pultruded strip50is further heated to fully cure the strip50, thereby bonding the sacrificial layers52to the major surfaces54a,54bof the core56. The curing oven may form part of the pultrusion apparatus, for example it may be provided in line with the pultrusion die or may be integral with the pultrusion die. Once the resin in the core56and sacrificial layers52has cured, the strip50may then correspond to the strip50shown inFIG.3A. As just described, the core56is not fully cured but is partially cured before it enters the second resin bath82. By curing the matrix60only partially, rather than fully curing, a better bond may be achieved between the matrix60and the sacrificial layer52. However, it is also possible for the core56to be fully cured before it enters the second resin bath82. An activation station85for surface treatment of the strip50may be positioned downstream of the curing oven (if present). The exact activation method used will depend on the surface properties of the strips50and adhesive used. One particular activation technique is roughening of the surface of the strip50using abrasive materials to remove unwanted layers and generate a roughened surface texture. Such mechanical abrasion will remove weak boundary layers. It will also change the surface topography of the adherend surfaces62a,62bof the sacrificial layers52, increasing the bondable surface area of the strip50on a micro scale. Furthermore, mechanical abrasion may enhance the ability of the adhesive66(shown inFIG.3C) to ‘wet’ the adherend surfaces62a,62b, i.e. when the adhesive66readily and completely covers these surfaces62a,62b. In embodiments, the strip50may be abraded using silicon carbide paper or other abrasive materials. The resulting topography of the adherend surfaces62a,62bobtained with the abrasive can be controlled by modification of the grit size or by the time and/or pressure of the abrasive on the surfaces62a,62b, for example by automating the activation as opposed to manual sanding of the surfaces62a,62b. Another method of activation by surface roughening is by blasting the surfaces62a,62bfor example by grit blasting, cryoblast or sodablast. The type of blasting particle used, the particle size, pressure of blast, exposure time, angle of blast and distance between blast nozzle and adherend surfaces62a,62bcan be varied depending on the required surface finish. Alternatively or additionally, energetic surface pre-treatments may be used to activate the adherend surfaces62a,62bof the strips50. For example flame, corona discharge and plasma (FCDP) and excimer laser. Such procedures may cause a change in the surface texture of the adherend surfaces62a,62b. Activation of the sacrificial layer(s)52of the strips50may take place in line with the pultrusion process as an extension thereof. Alternatively, the strips50may be activated at a later stage and/or at a separate location to the pultrusion process. In particular embodiments, the strips50are activated immediately prior to bonding to each other. For example, the strips50may be activated less than 12 hours or less than 6 hours before bonding to avoid contamination of the adherend surfaces62a,62b. The pultruded strip50may be cut into individual elongate strips of the length required to form a spar cap or other elongate reinforcing structure. Cutting of the strip50may be performed before or after activation of the sacrificial layer52. The cutting may be performed in line with the pultrusion process or may be performed at a separate location. For example, the strips50may be assembled in large rolls for cutting and/or activation at a location remote from the pultrusion process. It will be appreciated that the sacrificial layer52need not be applied using a resin bath82as described above. Instead the sacrificial layer52could be applied downstream of the first die80by rollers (for example) which can give an accurate thickness of applied resin53. The sacrificial layer52could then cure without passing through a second die84. In embodiments, the application station comprises two roller systems, one arranged above the pultruded core56and one arranged below the pultruded core56. The roller systems store the sacrificial layer52, and apply the material53to the opposing major surfaces54a,54b(upper and lower surfaces) of the pultruded core56respectively. In alternative embodiments the application station comprises a resin sprayer. For example, two resin sprayers may be arranged such that one of the sprayers is above and the other below the pultruded core56or any other arrangement that allows the sacrificial layer52to be sprayed evenly onto the major surfaces54a,54bof the core56. In other embodiments, the application station may be integral with the core pultrusion die.FIG.5shows a cross-sectional view of a pultrusion die86incorporating an application station in accordance with an embodiment of the invention. The die86, which is positioned downstream of a resin bath, includes upper and lower surfaces88a,88b(which in this example are defined by plates) extending between a die inlet90and a die outlet92. A first portion94of the die86shapes the resin soaked fibres78to form the core56of the strip50. In the first portion94, the upper and lower surfaces88a,88bare spaced from each other by a first distance95perpendicular to the process direction and substantially equal to the desired thickness of the core56. A second portion96of the die86shapes the whole strip50, including the sacrificial layers52. In the second portion96, the upper and lower surfaces88a,88bform mutually opposed surfaces that are spaced from each other by a second distance97also perpendicular to the process direction. The second distance97is greater than the first distance95and substantially equal to the desired thickness t (seeFIG.3A) of the final strip50prior to activation of the sacrificial layers52. A resin inlet port98is arranged between the first and second portions94,96of the die86in order to apply the sacrificial layer52to the strip50downstream of the fibre inlet90. The die86further includes a transition portion91extending between the first portion94and the resin inlet port98in which the spacing between the upper and lower plates88a,88bgradually increases from the first distance95to the second distance97. As such, resin-soaked fibres78enter the die86at the inlet90and are shaped and partially or fully cured in the first portion94to form the core56. Additional resin53is applied to the core56from the resin inlet98and the sacrificial layers52are shaped and partially or fully cured onto the core56in the second portion96such that a strip50having sacrificial layers52as described in relation toFIG.3Aabove is produced at the outlet92. The die86may be heated such that the resin forming the matrix60of the core56is at least partially cured by the time it reaches the sacrificial resin inlet port98. Partially curing the matrix60in this way may improve the mechanical properties of the core56and therefore improve the mechanical properties of the resulting strip50. For example partial curing may help ensure the core56retains the requisite fibre density during application of the sacrificial layer52. By curing the matrix60only partially, rather than fully curing, a better bond may be achieved between the matrix60and the sacrificial layer52. The above described modification to the pultrusion process results in a strip50having a core56containing structural fibres58as well as sacrificial layers52on an outer surface of the core56, which enables subsequent surface activation of the strip50to be carried out without damaging the fibres58of the core56. Activation may result in a strip having a rough surface (at least on a microscopic or molecular level) which improves the bonding properties thereof. FIG.6shows a flow diagram of a process for making a strip50in accordance with an embodiment of the present invention. The process comprises a number of stages102,104,106,108,110,112during which a strip50according to the invention is formed. At stage102, dry fibres58, such as the carbon fibres of the embodiments described above, are combined with a material, such as a resin, suitable for forming a matrix to hold the fibres together. The fibres and matrix material are then shaped at stage104, for example in a die, to form a desired core profile. At stage106, the core may be at least partially cured by the addition of heat. The core56may be partially cured in the die, for example by providing a heated die, or may be cured in a curing oven positioned downstream of the die. At stage108, further material is added to at least one major surface of the core to form a sacrificial layer suitable for subsequent activation. The further material is added at an application station which could be a second resin bath, rollers, spray nozzles or could be integral with the first die as described in relation to any of the embodiments above. At stage110, the strip is then fully cured in order to bond the sacrificial layer52to the matrix material60thereby forming a strip50that can be effectively activated without damage to the core fibres. This may involve directing the strip50through a curing oven provided downstream of the pultrusion die, or the pultrusion die may be heated or otherwise configured to cure the matrix material60. At stage112the strip50is activated at an activation station in order to improve the bonding properties of the strip50. Activation may involve removal of at least some of the sacrificial layer52by any of the methods described above. The activation station may be provided in-line with the pultrusion die(s). After activation, the strip50is then cut into a plurality of smaller strips such that they can be bonded to one another to form a reinforcing structure for a wind turbine. The strip50may be cut before or after activation thereof. The strip50might be assembled in rolls for cutting at another location. Generally, the process includes pulling fibres through a number of stations relating to each of the stages mentioned above. A matrix material is added, shaped and at least partially cured in order to form a core. A sacrificial layer is added and cured onto the core to form a strip50according to the invention. As such the present invention provides a strip and a process for making such a strip that may be activated to improve its bonding properties. As activation can be performed on the sacrificial layer only, the activation equipment need not come into contact with the core containing the structural fibres. As such the strip may be activated over an entire major surface thereof without damage to the structural fibres therein, thereby overcoming the problems associated with existing pultruded strips as described above. Although the above described embodiments include carbon fibres, it will be appreciated that any reinforcing fibres might be incorporated into the core to provide the required structural properties thereof. Furthermore, it will be appreciated that the strip or core may have alternative shapes and dimensions to those shown or described in relation to the embodiments above. For example, the strip may or may not include rounded longitudinal edges or may have a curved cross-sectional profile that allows the stacking of multiple strips as described above. As such, other die shapes may be used depending on the geometry required for the spar cap or other load-bearing element. The sacrificial layer of the invention may be disposed on only one of the major surfaces of the strip, on both major surfaces of the strip or could completely surround the strip depending on the application method. The thickness of the sacrificial layer can be adjusted by specifying the design of the die, for example, and can be chosen to suit the surface activation method that may subsequently be adopted to abrade the layer and provide the required surface texture. Also the type of resin to be used for the sacrificial layer can be selected to be cheaper than the resin in the main core of the pultruded element. The sacrificial layers52may comprise a resin material such as those discussed in the embodiments above such that the sacrificial layers52may confer little or no load-bearing properties to the strip50. The sacrificial layer52is substantially devoid of continuous structural fibres such as the continuous carbon fibres58of the core56but may (if required) include other fibres or additives which may be added to the sacrificial layer52prior to application onto the core56. In embodiments, the sacrificial layers52have a fibre volume fraction of less than 5%. For example, in a preferred embodiment the sacrificial layer has a fibre volume fraction of 0%. Many resin types may be used in the pultrusion process of the invention, including but not restricted to vinylester and epoxy resins. The process may include using a different resin material to form the sacrificial layer than used in the initial pultrusion for forming the matrix. For example, epoxy resin could be used for the matrix material to provide optimum structural properties of the strip while vinylester could be used for the sacrificial layer to reduce the cost thereof. It will be appreciated that alternative materials, such as alternative resins, could also be used. The strip may be formed substantially entirely of resin and fibres however other additives may be present depending on the required properties of the strip. A spar cap or other elongate reinforcing structure may be made by stacking the strips50, as described above, and carrying out a resin infusion process in a mould tooling. The resulting spar cap or other elongate reinforcing structure may then be integrated into a wind turbine blade. In other embodiments, the strips may be stacked directly in a mould for a blade half with other structural components of the blade, and the resin infusion process may be applied to the entire blade half, such that the spar cap is both formed and integrated into the blade half simultaneously. FIG.7is a cross-sectional view of a wind turbine rotor blade200having a plurality of spar caps224,226,228,230. The blade200has an outer shell222, which is fabricated from two half shells214,216. The shells214,216are moulded from glass-fibre reinforced plastic (GRP). Parts of the outer shell222are of sandwich panel construction and comprise a blade core of lightweight foam (e.g. polyurethane), which is sandwiched between inner and outer GRP layers or ‘skins’. The blade comprises first and second pairs of spar caps224,226,228,230arranged between sandwich panel regions of the outer shell222. One spar cap of each pair is integrated with the windward shell and the other spar cap of each pair is integrated with the leeward shell. The spar caps224,226,228,230of the respective pairs are mutually opposed and extend longitudinally along the length of the blade200. A first longitudinally-extending shear web232bridges the first pair of spar caps224,226and a second longitudinally-extending shear web234bridges the second pair of spar caps228,230. The shear webs232,234in combination with the spar caps224,226,228,230form a pair of I-beam structures, which transfer loads effectively from the rotating blade200to the hub of the wind turbine (not shown). The spar caps224,226,228,230in particular transfer tensile and compressive bending loads, whilst the shear webs232.234transfer shear stresses in the blade200. Each spar cap224,226,228,230has a substantially rectangular cross section and is made up of a stack of pultruded strips50as described above. The number of strips50in the stack depends upon the thickness of the strips50and the required thickness of the shell, but typically there may be between four and twelve strips50in the stack. The wind turbine blade200shown inFIG.7is made using a resin-infusion (RI) process, whereby the various laminate layers of the shell are laid up in a mould cavity, and a vacuum is applied to the cavity. Resin is then introduced to the mould, and the vacuum pressure causes the resin to flow over and around the laminate layers and to infuse into the interstitial spaces between the layers. To complete the process, the resin-infused layup is cured to harden the resin and bond the various laminate layers together to form the blade200. The present invention is therefore not limited to the exemplary embodiments described above and many other variations or modifications will be apparent to the skilled person without departing from the scope of the present invention as defined by the following claims. | 34,215 |
11858226 | DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a method of manufacturing an electronic device according to an aspect of the present disclosure is described in detail based on embodiments shown in accompanying drawings. FIG.1is a perspective view schematically showing an electronic device.FIGS.2and3are cross-sectional views showing examples of electronic components, respectively.FIG.4is a diagram showing manufacturing steps of the electronic device shown inFIG.1.FIGS.5to10are views for illustrating the method of manufacturing the electronic device shown inFIG.1, respectively. For convenience of illustration, in each figure, three axes orthogonal to one another are shown as an X axis, a Y axis, and a Z axis. A direction parallel to the X axis is also referred to as an “X axis direction”, a direction parallel to the Y axis is also referred to as a “Y axis direction”, and a direction parallel to the Z axis is also referred to as a “Z axis direction”. Further, a tip end side of an arrow indicating each axis is also referred to as a “plus side”, and an opposite side is also referred to as a “minus side”. Further, a Z axis direction plus side is also referred to as “upper”, and a Z axis direction minus side is also referred to as “lower”. First, an electronic device1manufactured by the method of manufacturing the electronic device of one aspect of the present disclosure is briefly described. The electronic device1includes a lead group2that includes a plurality of leads, an electronic component3as a first electronic component coupled to the lead group2, an electronic component4as a second electronic component, electronic components5and6, and a mold cover7that molds these four electronic components3,4,5and6. The electronic components3,4,5and6are sensor components, respectively. Specifically, among the electronic components3,4,5and6, the electronic component3is an X-axis angular velocity sensor that detects an angular velocity around the X axis, the electronic component4is a Y-axis angular velocity sensor that detects an angular velocity around the Y axis, the electronic component5is a Z-axis angular velocity sensor that detects an angular velocity around the Z axis, and the electronic component6is a three-axis acceleration sensor that independently detects acceleration in the X axis direction, acceleration in the Y axis direction, and acceleration in the Z axis direction. That is, the electronic device1of this embodiment is a six-axis composite sensor. However, a configuration of the electronic device1is not limited to the above, and at least one of the electronic components3,4,5and6may be omitted, or another electronic component may be added. Further, the electronic components3,4,5and6are not limited to a sensor component. Next, the electronic components3,4and5are briefly described. These electronic components3,4and5have the same configuration, and are disposed to be inclined by 90° one another such that postures thereof correspond to respective detection axes. Therefore, hereinafter, the electronic component3is described as a representative, and a description of the electronic components4and5is omitted. As shown inFIG.2, the electronic component3includes a package31and a sensor element34housed in the package31. The package31includes, for example, a base32having a recess321and a lid33that closes an opening of the recess321and that is joined to the base32. A plurality of external terminals39are disposed at a lower surface of the base32, and these external terminals39are electrically coupled to the sensor element34, respectively. The sensor element34is, for example, a crystal vibrator having a drive arm and a detection arm. In this case, when an angular velocity is applied in a state where the drive arm is driven to vibrate, a detection vibration is excited in the detection arm by a Coriolis force, and the angular velocity can be obtained based on an electric charge generated in the detection arm by the detection vibration. As mentioned above, although the electronic component3was described, a structure of the electronic component3is not specifically limited as long as a function thereof can be exhibited. For example, the sensor element34is not limited to the crystal vibrator, and may be, for example, a silicon structure or a configuration that detects an angular velocity based on a change in capacitance. Further, in this embodiment, although the electronic components3,4and5have the same configuration, the present disclosure is not limited thereto and at least one may have a configuration different from others. Further, the electronic component3may be configured to detect not only the angular velocity around the X axis but also the angular velocity around other axes such as the Y axis and the Z axis in addition to the X axis. For example, when the electronic component3is configured to detect angular velocities around the X axis and the Y axis, the electronic component4can be omitted, and when the electronic component3is configured to detect angular velocities around the X axis, the Y axis and the Z axis, the electronic components4and5can be omitted. Next, the electronic component6is briefly described. As shown inFIG.3, the electronic component6includes a package61and three sensor elements64,65and66housed in the package61. The package61includes a base62and a lid63. The base62has three recesses624,625and626formed so as to overlap the sensor elements64,65and66. The lid63has a recess631that opens to the base62side, houses the sensor elements64,65and66in the recess631, and is joined to the base62. A plurality of external terminals69are disposed at a lower surface of the base62, and these external terminals69are electrically coupled to the sensor elements64,65and66, respectively. The sensor element64is an element that detects the acceleration in the X axis direction, the sensor element65is an element that detects the acceleration in the Y axis direction, and the sensor element66is an element that detects the acceleration in the Z axis direction. These sensor elements64,65and66have silicon structures, and the silicon structure includes a fixed electrode, and a movable electrode that forms a capacitance with the fixed electrode and that is displaced with respect to the fixed electrode when subjected to acceleration in a detection axis direction. In this case, the acceleration in the X axis direction can be detected based on a change in capacitance of the sensor element64, the acceleration in the Y axis direction can be detected based on a change in capacitance of the sensor element65, and the acceleration in the Z axis direction can be detected based on a change in capacitance of the sensor element66. As mentioned above, although the electronic component6was described, a configuration of the electronic component6is not specifically limited as long as a function thereof can be exhibited. For example, the sensor elements64,65and66are not limited to the silicon structure, and may be, for example, a quartz crystal vibrator or may be configured to detect acceleration based on a charge generated by a vibration. Next, the lead group2is described. As shown inFIG.1, the lead group2includes a first lead group230having a plurality of leads23coupled to the electronic component3, a second lead group240having a plurality of leads24coupled to the electronic component4, a third lead group250having a plurality of leads25coupled to the electronic component5, and a fourth lead group260having a plurality of leads26coupled to the electronic component6. The electronic component3and the respective leads23, the electronic component4and the respective leads24, the electronic component5and the respective leads25, and the electronic component6and the respective leads26are respectively coupled mechanically and electrically via a conductive joining member (not shown) such as solder. Further, one end of each lead23,24,25and26protrudes outward from the mold cover7. Hereinafter, a portion of each lead23,24,25and26that protrudes outward from the mold cover7is also referred to as an “outer portion”. The lead group2extends along an X-Y plane which includes the X axis and the Y axis. Further, in order to make the detection axis of the electronic component3coincide with the X axis, each lead23coupled to the electronic component3is bent, at a bending point P in the middle thereof, by 90° toward the Z axis direction. Similarly, in order to make the detection axis of the electronic component4coincide with the Y axis, each lead24coupled to the electronic component4is bent, at a bending point P in the middle thereof, by 90° toward the Z axis direction. On the other hand, each lead25coupled to the electronic component5and each lead26coupled to the electronic component6are not bent as the leads23and24respectively, and extend along the X-Y plane. The mold cover7molds the four electronic components3,4,5and6to protect the electronic components3,4,5and6from moisture, dust, impact, and the like. A molding material which composes the mold cover7is not specifically limited, and for example, a thermosetting epoxy resin can be used and the molding material can be molded by a transfer mold method. As mentioned above, the electronic device1was described. Next, the method of manufacturing the electronic device1is described. As shown inFIG.4, the manufacturing step of the electronic device1includes a coupling step of coupling the electronic components3,4,5and6to the leads23,24,25and26, a bending step of bending the leads23and24, a molding step of molding the electronic components3,4,5and6with the resin material, and a cutting step of cutting the leads23,24,25and26. Coupling Step First, as shown inFIG.5, a lead frame20is prepared. The lead frame20includes a frame-shaped frame21, a plurality of leads23,24,25and26that are located inward from the frame21and that are supported by the frame21, and a tie bar29that couples these leads23,24,25and26. The respective leads23,24,25and26are arranged along the X-Y plane. Next, as shown inFIG.6, the electronic component3is coupled to tip ends of the plurality of leads23(the first lead group230) via a joining member H, the electronic component4is coupled to tip ends of the plurality of leads24(the second lead group240) via a joining member H, the electronic component5is coupled to tip ends of the plurality of leads25(the third lead group250) via a joining member H, and the electronic component6is coupled to tip ends of the plurality of leads26(the fourth lead group260) via a joining member H. In this state, the detection axes of the electronic components3,4and5coincide with the Z axis. In addition, amounting order of the electronic components3,4,5and6is not particularly limited, and for example, the electronic components3,4,5and6may be mounted one by one or all at the same time. Thus, by coupling the electronic components3,4,5and6in a state where the lead frame20is flat, that is, before the leads23and24are bent, the electronic components3,4,5and6can be arranged in a plane along the X-Y plane. Therefore, each of the electronic components3,4,5and6can be mounted on the lead frame20from the Z axis direction, and mounting of the electronic components3,4,5and6onto the lead frame20is facilitated. In this embodiment, the electronic components3and4are coupled to the lead frame20from a Z axis direction minus side, and the electronic components5and6are coupled to the lead frame20from a Z axis direction plus side. When the electronic components3and4are coupled to the leads23and24after the bending of the leads23and24, at that time, a force may be applied to the leads23and24to cause unnecessary bending of the leads23and24. Therefore, even though the bending is performed with high accuracy, a bending angle of the leads23and24deviates from a target value. Therefore, by coupling the electronic components3and4to the leads23and24before the leads23and24are bent, a posture of the electronic components3and4can be controlled with higher accuracy. Bending Step Next, in order to adjust the posture of the electronic component3, the plurality of leads23are bent, at bending points P in the middle thereof, by 90° in the Z axis direction plus side, and the detection axis of the electronic component3coincides with the X axis. In addition, in order to adjust the posture of the electronic component4, the plurality of leads24are bent, at bending points P in the middle thereof, by 90° in the Z axis direction plus side, and the detection axis of the electronic component4coincides with the Y axis. Hereinafter, the bending of the leads23and24is specifically described. As shown inFIGS.7to9, in the bending step, a mounting table8on which the lead frame20is mounted and a pressing member9that presses and bends the lead frame20mounted on the mounting table8are used. A top surface of the mounting table8is a mounting surface81on which the lead frame20is mounted. Then, the lead frame20is mounted on the mounting surface81such that the bending points P of the leads23and24are positioned on an outer edge811of the mounting surface81. The outer edge811is rounded such that an inner edge at the bending points P has an ideal radius of curvature r1. That is, the outer edge811is a 90° arc having the radius of curvature r1. However, a configuration of the mounting surface81is not limited thereto. The pressing member9includes a first pressing member91, a second pressing member92, and a third pressing member93, and by pressing the leads23and24in order by the three first, second, and third pressing members91,92and93, the leads23and24are bent in three steps. In particular, a bending step of the leads23and24performed by the first and second pressing members91and92is a first step of bending the leads23and24by pressing the electronic components3and4, and a bending step of the leads23and24performed by the third pressing member93is a second step of bending the leads23and24by pressing the leads23and24without pressing the electronic components3and4. It is preferable that the first, second and third pressing members91,92and93are composed of hard materials, such as a metal, for example. First Step First, as shown inFIG.7, the lead frame20is mounted on the mounting surface81such that the bending point P of the lead23is positioned at the outer edge811. Next, the electronic component3is pressed by a part A of the first pressing member91from the Z axis direction minus side toward the plus side, and the lead23is bent by 30° with the bending point P as a fulcrum. The first pressing member91abuts against the mounting table8via the lead23at the same time as the lead23is bent by 30°, thereby restricting the bending of the leads23from exceeding 30°. Therefore, it is possible to prevent excessive bending of the lead23in this step. In particular, a contact surface911of the first pressing member91with the lead23is in contact with the bending point P of the lead23, and the outer edge at the bending point P is rounded so as to have an ideal radius of curvature r2. That is, the contact surface911is a 30° arc having the radius of curvature r2. According to such a configuration, since the lead23is deformed by pressing at a part B while sandwiching the bending point P of the lead23between the outer edge811of the mounting surface81and the contact surface911of the first pressing member91, the lead23can be bent with an ideal curvature at the bending point P. However, a configuration of the first pressing member91is not limited thereto and, for example a bending angle of the lead23may not be 30°. Next, as shown inFIG.8, the electronic component3is pressed by a part A of the second pressing member92from the Z axis direction minus side toward the plus side, and the lead23is further bent by 30°, that is bent by 60° in total, with the bending point P as a fulcrum. The second pressing member92abuts against the mounting table8via the lead23at the same time as the lead23is bent to 60°, thereby restricting the bending of the lead23from exceeding 60°. Therefore, it is possible to prevent excessive bending of the lead23in this step. In particular, a contact surface921of the second pressing member92with the lead23is in contact with the bending point P of the lead23, and the outer edge at the bending point P is rounded so as to have an ideal radius of curvature r2. That is, the contact surface921is a 60° arc having the radius of curvature r2. According to such a configuration, since the lead23is deformed by pressing at a part B while sandwiching the bending point P of the lead23between the outer edge811of the mounting surface81and the contact surface921of the second pressing member92, the lead23can be bent, at the bending point P, with an ideal curvature. However, a configuration of the second pressing member92is not limited thereto and, for example the bending angle of the lead23may not be 60°. In the first step, at least one of the first and second pressing members91and92may not have the part B that abuts against the lead23, and the electronic component3may be bent only by the part A. Second Step Next, as shown inFIG.9, the lead23is pressed by the third pressing member93from the Z axis direction minus side, and the lead23is further bent by 30°, that is, bent by a target angle of 90° in total, with the bending point P as a fulcrum. When the lead23is bent, the third pressing member93contacts only the lead23and is not in contact with the electronic component3. That is, a part B of the third pressing member93is in contact with the lead23, but a part A is not in contact with the electronic component3. The third pressing member93abuts against the mounting table8via the lead23at the same time as the lead23is bent to 90°, thereby restricting the bending of the lead23from exceeding 90°. Therefore, it is possible to prevent excessive bending of the lead23in this step. In particular, a pressing surface931of the third pressing member93that presses the lead23presses the bending point P of the lead23and a flat part at an electronic component3side from the bending point P, and the outer edge at the bending point P is rounded so as to have the ideal radius of curvature r2. That is, the pressing surface931is configured with a 90° arc portion having the radius of curvature r2and a flat portion continued thereto. According to such a configuration, the outer edge811of the mounting surface81and the pressing surface931of the third pressing member93sandwich the bending point P of the lead23and the flat portion at the electronic component3side from the bending point P, and the lead23can be bent in an ideal shape. However, a configuration of the third pressing member93is not limited thereto and, for example the bending angle of the lead23may not be 90°. According to the above steps, the posture of the electronic component3is adjusted by bending the lead23at the bending point P by 90°, and the detection axis of the electronic component3coincides with the X axis. It is preferable that the lead23is bent with an extremely small error with respect to 90°. Thereby, sensitivity of the electronic component3to the other axis, that is, sensitivity to the angular velocity around the Y axis and the angular velocity around the Z axis can be sufficiently lowered, and the angular velocity around the X axis can be detected more accurately. Further, by bending the lead23by 90° at the bending point P in a plurality of steps, in this embodiment, three steps, a return deformation after the bending of the lead23, that is, a deformation to return to a shape before a bending deformation can be effectively prevented. The return deformation after bending performed by the first pressing member91can be canceled by bending performed by the second pressing member92, and the return deformation after bending performed by the second pressing member92can be canceled by bending performed by the third pressing member93. Since the smaller an angle of bending in one bending step, the smaller an amount of return deformation, the final amount of return deformation of the lead23can be sufficiently reduced according to such a method. In particular, in the bending of the lead23performed by the third pressing member93, the lead23is bent by pressing the third pressing member93against the lead23without pressing the third pressing member93against the electronic component3. Therefore, the lead23can be bent without being affected by a dimensional error of the package31of the electronic component3or a thickness error of the joining member H. Therefore, the lead23can be bent by 90° with higher accuracy. In the bending of the lead23performed by the third pressing member93, the part B of the third pressing member93presses the flat part on the electronic component3side from the bending point P of the lead23, and a press mark is formed at the pressed portion of the lead23, but performance of the lead23and the electronic component3is not affected. In the bending step of the lead23performed by the first and second pressing members91and92, the lead23is bent by pressing the first and second pressing members91and92against the electronic component3at the part A. Therefore, a separation distance between the bending point P as the fulcrum and a contact point (part A) with the first and second pressing members91and92as a force point can be increased as much as possible, and the lead23can be appropriately bent with a smaller force. Therefore, stress applied to the lead frame20can be reduced. Next, in the similar manner as the bending of the lead23, by bending the lead24by 90° at the bending point P, the posture of the electronic component4is adjusted, and the detection axis of the electronic component4coincides with the Y axis. That is, first, the lead frame20is mounted on the mounting surface81such that the bending point P of the lead24is positioned at the outer edge811. Next, the electronic component4is pressed by the first pressing member91from the Z axis direction minus side, and the lead24is bent by 30° with the bending point P as a fulcrum. Next, the electronic component4is pressed by the second pressing member92from the Z axis direction minus side, the lead24is bent by 30° with the bending point P as a fulcrum, the lead24is pressed by the third pressing member93from the Z axis direction minus side, and the lead24is bent by 30° with the bending point P as a fulcrum. Therefore the lead24is bent by 90° at the bending point P. Thereby, an effect similar to the effect mentioned above can be exhibited. In this embodiment, the lead24is bent to 90° that is the target angle after the lead23is bent to 90° that is the target angle, but the processing order is not particularly limited. For example, the lead23may be bent to 90° after the lead24is bent to 90°, or the leads23and24may be bent to 90° at the same time. The same time means that the first pressing member91bends the leads23and24to 30° sequentially or at the same time, next, the second pressing member92bends the leads23and24to 60° sequentially or at the same time, and next, the third pressing member93bends the leads23and24to 90° sequentially or at the same time. Molding Step Next, a structure after bending is covered with a mold, and as shown inFIG.10, a mold cover7that covers the electronic components3,4,5and6is formed by transfer molding. Thereby, the electronic components3,4,5and6are resin-sealed. The molding material which composes the mold cover7is not specifically limited, and for example, the thermosetting epoxy resin can be used. Cutting Step Next, the frame21is cut and removed from the lead frame20, and outer portions of the leads23,24,25and26are bent into a predetermined shape. Next, the tie bar29that couples the leads23,24,25and26one another is cut and removed by a laser or the like. As described above, the electronic device1shown inFIG.1is manufactured. The method of manufacturing the electronic device1was described above. As described above, the method of manufacturing such an electronic device1in which the electronic components3,4,5and6coupled to the leads23,24,25and26are covered with the mold cover7includes a coupling step of coupling the electronic components3,4,5and6to the leads23,24,25and26, a bending step of bending the leads23and24to adjust the postures of the electronic components3and4, and a molding step of molding the electronic components3,4,5and6with the resin material to form the mold cover7. Further, the bending step includes a lead bending step of bending the leads23and24by pressing the pressing member9against the leads23and24without pressing the pressing member9against the electronic components3and4. By including such a lead bending step, the leads23and24can be bent without being affected by, for example, a package dimensional error of the electronic components3and4, a thickness error of the joining member H, and the like. Therefore, the leads23and24can be bent to the target angle with higher accuracy. Further, as described above, the bending step includes the first step of bending the leads23and24to the angle less than the target angle and the second step of bending the lead23to the target angle. Further, the second step is performed in the lead bending step of bending the leads23and24by pressing the pressing member9against the leads23and without pressing the pressing member9against the electronic components3and4. In this way, in the final bending step, by pressing the pressing member9against the leads23and24and bending the leads23and24, the leads23and24can be bent to the target angle with higher accuracy. Further, by performing the bending step a plurality of times, the leads23and24can be gradually bent, and a final amount of return deformation of the leads23and24can be sufficiently reduced. However, the first step may be omitted. The first step may be performed, similarly with the second step, in the lead bending step of bending the leads23and24by pressing the pressing member9against the leads23and24without pressing the pressing member9against the electronic components3and4. Further, as described above, in the first step, the leads23and24are bent to the angle less than the target angle by pressing the pressing member9against the electronic components3and4. High accuracy is not required for bending the leads23and24to the angle less than the target angle. Therefore, even if the bending angle of the leads23and24is affected by the package dimensional error of the electronic components3and4, the thickness error of the joining member H, and the like, there is no particular problem. Then, by pressing the electronic components3and4by the pressing member9, the force point can be sufficiently moved away from the bending point P, so that the leads23and24can be appropriately bent with a smaller force. Therefore, damage at the time of manufacturing the electronic device1can be effectively prevented. Further, as described above, the first step is performed a plurality of times. Thereby, the bending angle of the leads23and24in the first step performed one of the plurality of times can be further reduced. Therefore, the final amount of return deformation of the leads23and24can be further reduced. In this embodiment, the first step is performed twice, but the disclosure is not limited thereto, and the first step may be performed once or three times or more. As described above, the electronic device1includes, as electronic components, the electronic component3that is the first electronic component and the electronic component4that is the second electronic component, and includes, as leads, the lead23that is a first lead to which the electronic component3is coupled and the lead24that is a second lead to which the electronic component4is coupled. Further, in the coupling step, the electronic component3is coupled to the lead23, the electronic component4is coupled to the lead24, and the electronic component3and the electronic component4are arranged in a plane. In the bending step, the lead23is bent to set the electronic component3to the target posture, and the lead24is bent to set the electronic component4to the target posture. Thus, by arranging the electronic components3and4on the leads23and24in a plane, the electronic components3and4can be easily coupled to the leads23and24. However, the present disclosure is not limited to the above, and for example, any one of the electronic components3and4may be omitted. Further, as described above, the electronic component3is a sensor component that includes the package31and the sensor element34housed in the package31. Thus, when the electronic component3includes the package31, the package31was pressed by the pressing member9and the lead23was bent, the bending angle of the lead23may be deviated due to the dimensional error of the package31. Therefore, as in this embodiment, by pressing the lead23instead of the package31with the pressing member9and bending the lead23, the lead23can be bent to the target angle without being affected by the dimensional error of the package31. The same applies to the electronic component4. However, the present disclosure is not limited to the above, and the electronic components3and4may not respectively include the package. Further, the electronic components3and4may not respectively be the sensor component. In this embodiment, the electronic components3and4are sensor components, the detection target is the angular velocity, but the detection target is not limited thereto and may be, for example, acceleration, pressure, temperature, or the like. As mentioned above, although the method of manufacturing the electronic device according to this disclosure was described based on illustrated embodiments, the present disclosure is not limited thereto, and a configuration of each part can be replaced with any configuration having a similar function. In addition, any other component may be added to the present disclosure. | 29,953 |
11858227 | DETAILED DESCRIPTION OF THE INVENTION FIG.1illustrates a conventional modern upwind wind turbine2according to the so-called “Danish concept” with a tower4, a nacelle6and a rotor with a substantially horizontal rotor shaft. The rotor includes a hub8and three blades10extending radially from the hub8, each having a blade root16nearest the hub and a blade tip14furthest from the hub8. The rotor has a radius denoted R. The wind turbine blades10are manufactured as fibre-reinforced composite structures comprising a fibre-reinforcement material embedded in a polymer matrix. The individual blades10comprise an aerodynamic shell, and the suction side and the pressure side of the aerodynamic shell are often manufactured as separate parts in moulds20as shown inFIG.2. The blade shell parts11are manufactured separately by arranging the fibre-reinforcement material and typically also sandwich core material, such as foamed polymer or balsawood, on a mould surface22of the mould. The fibre reinforcement material is laid out as separate fibre mats24that are stacked overlapping on the mould surface22. The load bearing structure of the blade10may be manufactured as a spar cap integrated in the blade shell, also called a main laminate, with shear webs arranged between the spar caps of the pressure side shell part and the suction side shell part. Alternatively, the load bearing structure may be formed as a spar or a beam, and the aerodynamic shell is adhered to the load bearing structure. The two blade shell parts are also glued to each other, e.g. by use of internal flange parts. The fibre mats24may be laid up manually on the mould surface22or by use of a fibre mat layup system, in which case the fibre mats24may be laid up automatically or semi-automatically. FIG.3shows a cross-section of the mould20in a manufacturing setup, where a fibre mat layup system30is utilised to lay up the fibre mats24. The fibre mat layup system30is carried on a frame63and the fibre mats24are laid up by the fibre mat layup system30being moved along the mould20by use of a cart or portal60. The fibre mat material is delivered to the fibre mat layup system30from a fibre mat roll50that also is carried on the frame and thus is moved together with the fibre mat layup system30along the mould. The portal60comprises a first telescopic portion61and a second telescopic portion62so that the transverse position and the height of the frame63and thereby also the fibre mat layup system30may be varied. Further, the frame may be rotated about a pivot64m, whereby the layup angle of the fibre mats24may be varied. Thereby, the position and angle of the fibre mat layup system30can be varied in order to lay out the fibre mats at the desired position and to accommodate the shape of the mould surface22. The position and angle of the fibre mat layup system30may be pre-programmed so that the fibre mats24may be cut and laid up in an automated or semi-automated process. The portal may for instance be moved across the factory floor66by use of rails or wheels65. FIGS.4-10show side views of the fibre mat layup system30during a layup and cutting procedure according to the invention. As shown inFIG.4, the fibre mat24is supplied to the fibre mat layup system30from the fibre mat roll50. The fibre mat layup system30comprises a first drive roller32that advances the fibre mat24within the fibre mat layup system30. A cutting device34for cutting the fibre mat24is arranged downstream of the first drive roller32. The cutting device34may for instance be a sonic knife or a rotary cutter. A buffer roller38is arranged downstream of the cutting device34and provides for a buffer length39of the fibre mat. The buffer roller38is arranged in slots44so that the buffer roller38may be moved in a substantially horizontal direction so that the buffer length39may be varied, and the buffer roller is resiliently biased, e.g. by air pressure to provide the buffer length39. A first clamping device36is arranged between the cutting device34and the buffer roller38. A second drive roller40for advancing the fibre mat24within the fibre mat layup system30is arranged downstream of the buffer roller38and buffer length. The first drive roller32and the second drive roller40are arranged substantially vertically above each other. Thus, the buffer roller position is variable in a position substantially transverse to the general direction of fibre mat advancement, which in turn provides a simple solution for varying the buffer length39. The speed of the first and the second drive rollers32,40is generally aligned with the propagation speed of the fibre mat layup system30along the mould. This ensures that the fibre mats24can be arranged on the mould surface22without being dragged along the mould surface and without the fibre mats wrinkling. The fibre mat layup system30further comprises a tray42for arranging the fibre mats24on top of the mould surface22. The tray may be angled so that the tension of the fibre mat is relieved as it is arranged on top of the mould surface22. The fibre mat layup system30further comprises a draping device48. The draping device48may for instance comprise one or more compression rollers. Alternative or in addition thereto, the draping device may draping device comprises a number of brushes or pads. The brushes may for instance be flexible rubber pads that are dragged along with the fibre mat layup system, thus draping the fibres as they are moved along the fibre layers. The fibre mat24needs to be cut in order to provide the correct fibre mat length. The layout and cutting method according to the invention is thus carried out in two layup steps. In the first layup step, the fibre mat layup system30lays up a first length of the fibre mat onto the surface, in a sequence, where the fibre mat layup system30continues to advance the fibre mat24within the system and propagates along the mould. During the layup of the first length, the first drive roller and the second drive roller32,40continues to advance the fibre length, and the pulling forces thus applied to the buffer roller38is lower than the biasing of the roller. Thereby, the buffer roller38is kept stationary so as to provide the full buffer length39. Once the fibre mat has been laid up to the first length, the second layup step commences. The first clamping device36clamps the fibre mat, thereby immobilising a part of the fibre mat, and the cutting device34is activated and cuts the fibre mat as shown inFIG.5. The first drive means32may also be adapted to clamp the fibre mat in order to keep the fibre mat taut during the cutting procedure. Similarly, the first clamping device36may also be adapted to function as a drive roller, when the fibre mat is advanced internally in the fibre mat layup system30. The fibre mat layup system continues to lay up a second length of the fibre mat24during the cutting procedure. The second length corresponds to the length of the fibre mat within the system30from the cutting device34to the layup point at the tray42at the time of cutting. Thus, the total length of the fibre mat laid up corresponds to the first length plus the second length. During the cutting procedure, the second drive roller40continues to advance the fibre mat. Since the clamping device36still clamps the end of the cut fibre mat, the fibre mat will begin to apply a pulling force to the buffer roller38which is larger than the bias. Accordingly, the buffer roller begins to move along the slots44, thereby reducing the buffer length39. This continues until the buffer roller38is retracted to a storage or retracted position46, in which the buffer length39is minimised as shown inFIG.6. Then the clamping device36disengages the fibre mat so that the end of the fibre mat is pulled past the buffer roller as shown inFIG.7, while the fibre mat layup system30continues to move along the mould and lay up the fibre mat on the mould surface22as shown inFIG.9. The first drive roller32then starts to advance new fibre mat material from the fibre mat roll50. The new fibre mat material is guided from the first drive roller32to the second drive roller40. Since the buffer roller38is stored in the retracted position46, the fibre mat material may be advanced past the buffer roller as shown inFIG.9. When the new fibre mat material engages the second drive roller40, the buffer roller may be engaged again so that the buffer length39may again be provided to the system by bias force moving the buffer roller along the slots44as shown inFIG.10. The advancement of the fibre mat and the reengagement of the buffer roller38may be carried out while the fibre mat layup system is moved to the start position for the next fibre mat24to be laid up. Overall, the fibre mat layup system30and the layup procedure according to the invention provide a system and method, where the layup cycle time is only minimally affected by the cutting process time. The system is particularly suited for layup of fibre mats having a width of 20-80 cm. The fibre mats may comprise unidirectional, biaxial, triaxial or randomly oriented fibres. The reinforcement fibres are preferably glass fibres or carbon fibres. The layup of the first length of fibre mats may be carried out at a first movement speed, e.g. around 72 m/min. The layup of the second length of fibre mats, i.e. the layup during the cutting procedure, may be carried out at a lower speed. The speed may also be gradually reduced during the layup of the second length of the fibre mat. In the following, the preparation and layup of the root part of the wind turbine blade shell will be described. As shown inFIG.11, the layup procedure starts by arranging one or more outer fibre layers68on the mould surface22of the mould. The outer fibre layers68advantageously comprise biaxial fibre layers, e.g. with the fibres oriented −45 and 45 degrees compared to the longitudinal direction of the mould. The biaxial fibre layers provide a strong mechanical bonding to fastening members provided at the root end. The fastening members are in the final product, i.e. the wind turbine blade, used for mounting the root end of the blade to a wind turbine hub. The biaxial fibres provide strength both in the longitudinal direction and the transverse direction of the blade and thus help to ensure that the fastening members are not pulled out from the wind turbine blade root. FIGS.12and13show a mounting plate70that is used to prepare a root end insert comprising a number of fastening members in form of bushings74and retaining inserts in form of butterfly wedges76arranged between the bushings74. The mounting plate70together with the root end insert form a root end assembly. The mounting plate70may be used for arranging the root end insert on the mould surface22of the mould20and may be removed afterwards and at least prior to instalment of the blade on a wind turbine hub. The mounting plate70comprises a first side77and a second side79. The mounting plate70is provided with a plurality of recesses71provided on the first side77of the mounting plate70and a plurality of through-going bores72or holes. The bores72are centrally aligned with the recesses71. InFIGS.12and13only a few recesses71and bores72are shown. However, in practice they are arranged equidistantly along an entire semi-circle of the mounting plate70. The bushings74are mounted in the recesses71of the mounting plate70by inserting ends of the bushings74in the recesses. The bushings74are provided with central bores having inner threads75. The bushings74may thus be retained in the recesses by inserting stay bolts78from the second side of the mounting plate70and through the bores72of the mounting plate70. The bushings will then extend from the first side77of the mounting plate and be oriented substantially normal to a plane of the mounting plate70. In practice, the root end insert may be prepared by first mounting a first bushing74on the mounting plat and then arranging a first insert76next to and abutting the first bushing. Afterwards a second bushing74is arranged next to the first insert76and a second insert76next to the second bushing74. This procedure is then continued until bushings74and inserts76are arranged along the entire semi-circle on the mounting plate, e.g. by arranging bushings74and inserts76from left to right as illustrated inFIG.12. The inserts76need not be arranged in recesses on the first side77of the mounting plate, but may be retained between the bushings74due to the butterfly shape of the inserts76. The mounting plate70is provided with a number of protrusions73, such as pins or rods, which extend from the side of the mounting plate70. These protrusions73may used as connecting parts for providing a mating connection to corresponding parts on a frame of a lowering mechanism for arranging the root end insert on the surface22of the mould20. As shown inFIG.14, wedges80are arranged in longitudinal extension of the bushings74. The wedges may for instance be made of foamed polymer or balsawood, whereas the bushings are made of for instance cast iron or stainless steel. The wedges80are arranged so that the thick part of the wedge80is arranged proximal to the bushing74, and the thin, tapered part is arranged proximal to the bushing. This ensures that the fastening member has a gradual transition to the surrounding fibre layers of the final blade shell part, thereby ensuring that the blade root does not have a steep or discontinuous stiffness transition A fibre layer81may be wrapped around a bushing74and a wedge80. Advantageously, the fibre layer is relatively thin band that is wrapped in a helix shape around the two parts. Thereby, the fibre layer81, bushing74and wedge can be mounted together on the mounting plate70. The fibre layer81may advantageously comprise non-woven fibres or randomly oriented fibres, such as for instance glass wool. This facilitates a relative strong bonding in the polymer matrix after the later infusion and curing of the polymer. The inserts76preferably also has a profile that corresponds to the profile of bushings74and the wedges80. In other words, the inserts76preferably comprises a tapering part or wedge part at a proximal end thereof. The tapering part is advantageously integrally formed with the insert76. The inserts76may advantageously be made of a fibre-reinforced composite structure, e.g. a fibre pultrusion comprising pultruded glass fibres or carbon fibres. As shown inFIG.15the tapering part or wedge part of the inserts76may be aligned with the wedges81arranged in longitudinal extension of the bushings74. This may be carried out by weaving a fibre band under the tapering part of the inserts and over the wedges81of the fastening members or vice versa. Afterwards, an additional fibre layer83may be tightly wrapped and draped around the bushings74, wedges80and inserts76such that the root end insert has a cross-section as shown inFIG.16. The additional fibre layer83may for instance be a triaxial fibre layer comprising reinforcement fibres oriented −45 degrees, 0 degrees and 45 degrees compared to the longitudinal direction of the blade shell and mould. This provides strength in both the longitudinal direction and the transverse direction of the blade shell and increases the pull-out strength of the bushings74. Additionally, fibre bands (not shown) may be wrapped around the additional fibre layers83near the tapering parts of the wedges81and inserts76so as to ensure a smooth transition to the surrounding fibre layers in the layup. The root end insert has now been prepared and is ready to be arranged on top of the outer fibre layers68. This may be carried out as shown inFIGS.17-19by arranging the mounting plate70with the mounted root end insert (not shown) on a lowering mechanism85that may lower and arrange the root end insert on the mould surface22of the mould20. The lowering mechanism85may advantageously be attached to sides of the mould20. The lowering mechanism85comprises a frame86, which is provided with carrying means in form of hooks92that may matingly engage the protrusions73of the mounting plate70such that the mounting plate is connected to or resting on the frame86. The frame86comprises a front guiding slot89and a rear guiding slot90, which engage a front guiding roller87and a rear guiding roller88, respectively. The lowering mechanism further comprises a driving means in form of a telescopic piston cylinder91that is connected between a stationary part of the lowering mechanism85and the frame86. The telescopic piston cylinder91may advantageously be hingedly connected to the stationary part and the frame86. The guiding slots89,90are shaped so that the frame86and therefore also the mounting plate70with the root end insert are moved according to a desired motion. FIG.17shows the lowering mechanism85in the mounting position, where the mounting plate70together with the root end insert are arranged on the frame86of the lowering mechanism85. The mounting plate70is mounted on the frame86in a substantially vertical orientation. When the telescopic piston cylinder91begins to retract the piston, the frame86is moved on the guiding rollers87,88via the guiding slots89,90. As seen, the guiding slots each comprise a horizontal slot part and an angled slot part. The horizontal slot part of the front guiding slot89is longer than the horizontal slot part of the rear guiding slot90, and the angled part of the front guiding89slot is angled more compared to a horizontal plane than the angled part of the rear guiding slot90. Thereby, the frame86will in a first motion (fromFIG.17toFIG.18) be lowered down towards the moulding surface22of the mould, while the frame86and mounting plate70are tilted so that the root end insert is angled upwards in the longitudinal direction of the mould. The lowering a tilting motion continues until the root end insert substantially contacts the moulding surface22of mould20, after which a second motion step (fromFIG.18toFIG.19) is carried out. In the second motion step, the frame86with mounting plate70and root end insert are pivoted until the mounting plate86is oriented arranged substantially vertically and the root end insert rests on the mould surface22of the mould20. This motion ensures that the fibre material68that has already been arranged on the mould surface22is not distorted or otherwise wrinkled. Afterwards, a number of inner fibre layers95are as shown inFIG.20arranged on top of the root end insert. The inner fibre layers95may for instance be triaxial fibre layers comprising reinforcement fibres oriented −45 degrees, 0 degrees and 45 degrees compared to the longitudinal direction of the blade shell and mould. This provides strength in both the longitudinal direction and the transverse direction of the blade shell and increases the pull-out strength of the bushings74. FIG.21shows a cross-section of the final layup at the root part of the mould. As seen, the layup comprises bushings74and inserts76wrapped in a fibre layer83and sandwiched between outer fibre layers68and inner fibre layers95. Finally, a vacuum bag is sealed against the mould20, and the mould cavity formed between the vacuum bag and the mould20is evacuated, after which a liquid resin is drawn into the mould cavity and impregnates the fibre material. Finally, the resin is cured so as form the shell part. This shell part may then be adhered to another shell part, e.g. along leading and trailing edge thereof, so as to form the aerodynamic shell of the wind turbine blade. The mounting plates may be removed prior to this process. Alternatively, the mounting plates may be left on and first be removed prior to the wind turbine blade being mounted on a wind turbine hub. Embodiments of products, systems and methods are set out in the following items: Item 1. A fibre mat layup system for laying up and cutting fibre mats in a mould for the manufacture of a fibre-reinforced composite part, in particular a part for a wind turbine blade, such as an aerodynamic shell part, wherein the system is adapted to laying up the fibre mat as it is moved in a longitudinal direction along the mould, and wherein the system comprises:a first drive roller for advancing the fibre mat,a cutting device for cutting the fibre mat,a first clamping device for clamping the fibre mat, while the fibre mat is being cut by the cutting device,a buffer roller providing a buffer length for the fibre mat and being arranged downstream of the first drive roller, the first clamping device and the cutting device, the buffer roller being movable so as to vary the buffer length of the fibre mat, anda second drive roller for advancing the fibre mat and being arranged downstream of the buffer roller. Item 2. A fibre mat layup system according to item 1, wherein the fibre mat is supplied from a fibre mat roll. Item 3. A fibre mat layup system according to item 1 or 2, wherein the system further comprises a draping device arranged downstream of the second drive roller. Item 4. A fibre mat layup system according to item 3, wherein the draping device comprises one or more rollers, such as a compression roller. Item 5. A fibre mat layup system according to item 3 or 4, wherein the draping device comprises a number of brushes. Item 6. A fibre mat layup system according to any of the preceding items, wherein the cutting device is a sonic knife. Item 7. A fibre mat layup system according to any of the preceding items, wherein the cutting device is a rotary cutter. Item 8. A fibre mat layup system according to any of the preceding items, wherein the system is adapted to lay out fibre mats having a width of at least 20 cm. Item 9. A fibre mat layup system according to any of the preceding items, wherein the system is adapted to lay up fibre mats with a speed of between 25 m/minute and 100 m/minute. Item 10. A fibre mat layup system according to any of the preceding items, wherein the system is adapted slow down its movement speed along the movement during cutting of the fibre mat. Item 11. A fibre mat layup system according to any of the preceding items, wherein the first drive roller is arranged substantially vertical above the second drive roller, and preferably also substantially vertical above the first clamping device. Item 12. A fibre mat layup system according to any of the preceding items, wherein the buffer roller is arranged so as to be movable in a substantially horizontal direction. Item 13. A fibre mat layup system according to any of the preceding items, wherein the buffer roller is resiliently biased. Item 14. A fibre mat layup system according to item 13, wherein the buffer roller is biased by use of gas pressure. Item 15. A fibre mat layup system according to item 13, wherein the buffer roller is biased by use of a spring. Item 16. A fibre mat layup system according to any of the preceding items, wherein the buffer roller may be locked in a disengaged position, where the buffer length is minimised. Item 17. A method of manufacturing a composite part, in particular a part for a wind turbine blade, such as an aerodynamic shell part, wherein fibre mats are laid up in a mould part in a layup procedure by use of an automated fibre mat layup system, wherein the layup procedure comprises the steps of:a) delivering a supply of one or more fibre mats to the fibre mat layup system,b) laying up a first length of a fibre mat onto a surface of the mould along a first longitudinal part of the mould by moving the fibre mat layup system in a longitudinal direction of the mould,c) clamping a first part of the fibre mat,d) cutting the fibre mat at a cutting position, and while step d) is carried oute) laying up a second length of the fibre mat by continuing to move the fibre mat layup system along the mould, while a buffer length arranged downstream of the first part of the fibre mat is being reduced, andf) repeating steps a)-e) to define a plurality of laid out fibre mats defining the composite part. Item 18. A method according to 17, wherein the buffer length in step f) is reduced by varying the position of a buffer roller, the buffer roller providing a buffer length for the fibre mat. Item 19. A method according to item 17 or 18, wherein the delivery of the one or more fibre mats in step a) involves advancing the one or more fibre mats to a position, where they extend from a first drive roller to the buffer roller arranged downstream of the first drive roller and further onto a second drive roller arranged downstream of the buffer roller. Item 20. A method according to item 19, wherein the delivery is carried out while the buffer roller is in a retracted position, and wherein the first drive roller advances the fibre mat until it engages the second drive roller. Item 21. A method according to item 20, wherein the buffer roller subsequently is moved to an engaged position, wherein the drive roller provides the buffer length of the fibre mat. Item 22. A method according to item 20 or 21, wherein the fibre mat layup system after step e) is moved to a new start position for laying out a fibre mat, while a subsequent delivery of a supply of one or more fibre mats to the fibre mat layup system fibre mat is carried out. Item 23. A method according to any of items 17-22, wherein the fibre mat layup system during step b) is moved along the mould at a first speed, and wherein the fibre mat layup system in step e) is moved along the mould at a second speed being lower than the first speed. Item 24. A method of manufacturing a wind turbine blade shell part made of a composite structure comprising a fibre-reinforcement material embedded in a polymer matrix, wherein the method comprises the steps of:a) arranging one or more outer fibre layers on a mould surface, the one or more outer fibre layers defining an outer surface of the wind turbine blade shell part,b) mounting a plurality of fastening devices on a mounting plate so as to form a root end assembly,c) arranging the root end assembly on top of the one or more outer fibre layers at a root end section of the mould,d) arranging one or more inner fibre layers on top of the root end assembly,e) supplying a polymer to the outer and inner fibre layers,f) allowing the polymer to cure so as to form the composite structure, andg) removing the mounting plate. Item 25. A method according to item 24, wherein the fastening members are bushings. Item 26. A method according to item 25, wherein the bushings are mounted on the mounting plate by use of stay bolts. Item 27. A method according to any of items 24-26, wherein the mounting plate is provided with guiding recesses for insertion of one end of the fastening members. Item 28. A method according to any of items 24-27, wherein the preparation of the root end assembly further comprises the step of mounting inserts between the fastening members. Item 29. A method according to any of items 24-28, wherein fibre material, advantageously non-woven fibre material, such as glass wool, is wrapped around the fastening members. Item 30. A method according to any of items 24-29, wherein a wedge is arranged in longitudinal extension of the fastening member. Item 31. A method according to any of items 24-30, wherein the inserts comprises a tapered part or wedge part. Item 32. A method according to item 30 or item 31, wherein a fibre material is weaved between the wedges of the fastening members and the wedge part of the inserts. Item 33. A method according to any of items 24-32, wherein a fibre layer, such as a fibre mat, is wrapped around the plurality of fastening members and the optional inserts prior to the root end assembly being arranged in the mould. Item 34. A method according to any of items 24-33, wherein the outer fibre layer(s) comprise biaxial fibre mats. Item 35. A method according to any of items 24-34, wherein the inner fibre layers(s) comprise triaxial fibre mats. Item 36. A root end assembly comprising:a mounting plate comprising a first side and a second side, anda plurality of fastening members, such as bushing, mounted to the first side of the mounting plate so that the fastening members extend substantially normal to first side of the mounting plate, whereinthe mounting plate is adapted to be removed, when the root end assembly has been mounted in a wind turbine blade shell part. Item 37. A root end assembly according to item 36, wherein the assembly further comprises a number of inserts arranged between the fastening members. Item 38. A root end assembly according to item 36 or 37, wherein the fastening members are made of metal, such as cast iron or stainless steel. Item 39. A root end assembly according to any of items 36-37, wherein the assembly further comprise wedges arranged in longitudinal extension of the fastening members, alternatively the wedges being provided with a tapering part proximal to the mounting plate. Item 40. A root end assembly according to any of items 36-39, wherein the inserts comprise a tapering part proximal to the mounting plate. Item 41. A root end assembly according to any of items 36-40, wherein the mounting plate on the first side comprises recesses or notches, and wherein a proximal end of the fastening members are arranged in said recesses or notches. Item 42. A root end assembly according to any of items 36-41, wherein the mounting plate further comprises a number of holes, and wherein the fastening members are attached to the mounting plate by stay bolts that have been inserted from the second side of the mounting plate and through the holes. Item 43. A root end assembly according to any of items 36-42, wherein the mounting plate is provided with attachment devices for attaching the mounting plate to the lowering device. Item 44. A root end assembly according to item 43, wherein the attachment devices are pins or rods that may mate or rest on hooks provided on the lowering device. Item 45. A mould for manufacturing a wind turbine blade shell part, the mould being provided with a moulding surface that defines the outer shape of the wind turbine shell part, wherein the mould has a longitudinal direction and comprises a root end mould part at a longitudinal end thereof, and wherein the mould is provided with a lowering mechanism, which is adapted to carry and lower a root end insert onto the moulding surface of the mould. Item 46. A mould according to item 45, wherein the lowering mechanism is attached to the mould, preferably on the sides of the mould. Item 47. A mould according to item 45 or 46, wherein the lowering mechanism is adapted to lower the root end insert in a two-step motion, where the root end insert in a first motion step is lowered onto the moulding surface while the root end insert is angled upwards in the longitudinal direction until a first end of the root end insert contacts a part of the moulding surface at the root end, and where the root end insert in a second motion step is tilted until the root end insert rests on the moulding surface. Item 48. A mould according to any of items 45-47, wherein the lowering mechanism comprises a frame for carrying the root end insert and a driving means for lowering the frame together with root end insert. Item 49. A mould according to item 48, wherein the lowering mechanism comprises at least a pair of guiding pins or rollers and mating guiding slots provided on the frame. Item 50. A mould according to item 49, wherein the guiding slots comprises a front guiding slot and a rear guiding slot, wherein the slots are shaped so that rear guide in the first motion lowers a rear part of the frame faster than the a front guiding slot lowers a front part of the frame. Item 51. A mould according to item 50, wherein the slots are shaped so that the front guide in the second motion lowers the front part of the frame faster than the rear guiding slot lowers the rear part of the frame. Item 52. A mould according to any of items 48-51, wherein the driving means comprises a telescopic piston cylinder, such as a hydraulic or pneumatic piston. Item 53. A mould according to any of items 48-52, wherein the frame is provided carrying means for carrying the root end insert. Item 54. A mould according to item 53, wherein the carrying means are hooks that are adapted to receive pins from the root end insert. Item 55. A method of manufacturing a wind turbine blade shell part, wherein the wind turbine blade shell part is manufactured as a composite structure comprising a fibre-reinforcement material embedded in a polymer matrix, and wherein the wind turbine blade shell part is provided with a root end insert that, when manufactured, is accessible from a root end of the wind turbine shell part, and wherein the wind turbine blade shell part is manufactured in a mould provided with a moulding surface that defined an outer shape of the wind turbine blade shell part, wherein the method comprises the steps of:a) arranging the root end insert on a lowering device of the mould, andb) lowering the root end insert onto the moulding surface of the mould via the lowering device. Item 56. A method according to item 55, wherein the step b) is carried out in two motions steps, whereinb1) the root end insert in a first motion step is lowered onto the moulding surface while the root end insert is angled upwards in the longitudinal direction until a first end of the root end insert contacts a part of the moulding surface at the root end, andb2) the root end insert in a second motion step is tilted until the root end insert rests on the moulding surface. Item 57. A method according to item 55 or 56, wherein the root end insert prior to stepa) is arranged on a mounting plate, and wherein the root end insert is arranged on the lowering mechanism via the mounting plate. Item 58. A method according to any of items 55-57, wherein the root end insert comprises a plurality of fastening members, such as bushings. Item 59. A method according to item 58, wherein the root end insert further comprises a number of inserts arranged between fastening members. Item 60. A method according to any of items 55-59, wherein the lowering mechanism comprises a frame for carrying the root end insert and a driving means for lowering the frame together with root end insert. Item 61. A method according to any of items 55-60, wherein the frame and the root end insert is lowered onto the moulding surface of the mould via guiding slots and guiding pins or rollers. Item 62. A method according to any of items 55-61, wherein the method prior to step a) comprises the step of arranging one or more outer fibre layers on the moulding surface, the one or more outer fibre layers defining an outer surface of the wind turbine blade shell part. Item 63. A method according to item 62, wherein the method additionally comprises the step of arranging one or more inner fibre layers on top of the root end insert. Item 64. A method according to item 62 or 63, wherein the method after step b) comprises the steps of supplying a polymer to the outer and inner fibre layers, and allowing the polymer to cure so as to form the composite structure. LIST OF REFERENCE NUMERALS 2wind turbine4tower6nacelle8hub10blade11blade shell14blade tip16blade root20mould22mould surface23blade shell24fibre mats30fibre mat layup system32first drive roller34cutting device36first clamping device38buffer roller39buffer length40second drive roller42tray44slots46storage position/retracted position48draping device50fibre mat roll60cart/portal61telescopic portion62telescopic portion63frame64pivot65wheel/track66floor68outer fibre layer(s)70mounting plate71recess72bore/hole73protrusions/pins/rods74bushings/fastening means75central bore with inner thread76insert/butterfly wedge77first side of mounting plate78stay bolt79second side of mounting plate80wedge81fibre layer with non-woven fibres or randomly oriented fibres82fibre band83fibre layer wrapped around bushings and inserts85lowering mechanism/lowering device86frame87front guiding roller88rear guiding roller89front guiding slot90rear guiding slot91driving means/telescopic piston cylinder95inner fibre layer(s) | 36,230 |
11858228 | DETAILED DESCRIPTION The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in the respective testing measurements. Also, as used herein, the term “about” generally means within 10%, 5%, 1%, or 0.5% of a given value or range. Alternatively, the term “about” means within an acceptable standard error of the mean when considered by one of ordinary skill in the art. Other than in the operating/working examples, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for quantities of materials, durations of times, temperatures, operating conditions, ratios of amounts, and the likes thereof disclosed herein should be understood as modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the present disclosure and attached claims are approximations that can vary as desired. At the very least, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Ranges can be expressed herein as from one endpoint to another endpoint or between two endpoints. All ranges disclosed herein are inclusive of the endpoints, unless specified otherwise. FIG.1AthroughFIG.8illustrate a molding method for manufacturing an article according to some embodiments of the present disclosure. In some embodiments, the method is for manufacturing the article6shown inFIG.8. Referring toFIG.1AandFIG.1B, a molding device1is provided.FIG.1Ais a schematic perspective view of a molding device1at a first manufacturing stage according to some embodiments of the present invention.FIG.1Bis a side view of the molding device1ofFIG.1A. The molding device1may include an upper mold2, a lower mold3, a middle mold4and a position control mechanism5. In some embodiments, the upper mold2may correspond to the lower mold3in some configurations such as dimension, shape or the like. The upper mold2may be placed on and engaged with the lower mold3. In some embodiments, the provision of the molding device1may include conveying the lower mold3towards the upper mold2. As such, the lower mold3would be disposed under the upper mold2for subsequent steps. In some embodiments, the upper mold2may be aligned with the lower mold3. In the embodiment illustrated inFIG.1AandFIG.1B, the molding device1is in an open configuration. The upper mold2may have a top surface21and a bottom surface22opposite to the top surface21. The upper mold2may define a recess portion23and a passage24. The bottom surface22of the upper mold2may face the lower mold3and the middle mold4. The recess portion23of the upper mold2may be recessed from the bottom surface22of the upper mold2. A configuration (e.g., dimension or shape) of the recess portion23of the upper mold2may correspond to a configuration (e.g., dimension or shape) of the middle mold4. The recess portion23of the upper mold2may include a first inner surface231and a second inner face232. The second inner face232may extend between the first inner surface231and the bottom surface22of the upper mold2. The first inner surface231and the second inner face232may be substantially conformal with the middle mold4. In some embodiments, the passage24may extend through the upper mold2, and may have an opening241on the top surface21of the upper mold2. In some embodiments, the passage24may be communicable with the recess portion23of the upper mold2or the mold cavity14when the molding device1is in the closed configuration as shown inFIG.3AandFIG.3B. Alternatively, the passage24may be in communication with the recess portion23of the upper mold2. Thus, the recess portion23of the upper mold2may be accessible through the passage24. For simplicity and clarity, only one passage24is illustrated, however, it can be understood that any suitable numbers of the passage24can be configured at the upper mold2. In some embodiments, the number of the passage24is identical to the number of the recess portion23of the upper mold2. In some embodiments, the number of the recess portion23of the upper mold2is more than the number of the passage24. In some embodiments, the number of the passage24is more than the number of the recess portion23of the upper mold2. In some embodiments, instead of configuring the passage24at the upper mold2, the passage24may be configured at the lower mold3for accessing a recess portion3of the lower mold3or the mold cavity14when the molding device1is in the closed configuration as shown inFIG.3AandFIG.3B. In some embodiments, the passage24may be configured at a sidewall of the lower mold3, a bottom portion of the lower mold3, or any other suitable positions as long as the passage24is communicable with the mold cavity14when the molding device1is in the closed configuration as shown inFIG.3AandFIG.3B. The lower mold3may be disposed below the upper mold2. The lower mold3may have a top surface31and a bottom surface32opposite to the top surface31. The lower mold3may define a recess portion33and a hole structure34. The top surface31of the lower mold3may face the upper mold2and the middle mold4. The recess portion33of the lower mold3may be recessed from the top surface31of the lower mold3. A configuration (e.g., dimension or shape) of the recess portion33of the lower mold3may correspond to a configuration (e.g., dimension or shape) of a bottom surface of the middle mold4. A position of the recess portion33of the lower mold3may be right under the middle mold4. The recess portion33of the lower mold3may be a portion of the mold cavity14when the molding device1is in the closed configuration as shown inFIG.3AandFIG.3B. In some embodiments, the hole structure34may be disposed outside the recess portion33of the lower mold3. Thus, the hole structure34may not be in communication with the recess portion33of the lower mold3. Thus, recess portion33of the lower mold3may not be accessible through the hole structure34. In some embodiments, the hole structure34may or may not extend through the lower mold3. The hole structure34may include a first hole341and a second hole342in communication with each other. The first hole341may have an opening on the top surface31of the lower mold3. The second hole342is under the first hole341. A size (e.g., width or diameter) of the second hole342is smaller than a size (e.g., width or diameter) of the first hole341, so as to form a step structure343. For simplicity and clarity, only one hole structure34is illustrated, however, it can be understood that any suitable numbers of the hole structure34can be configured at the lower mold3. In some embodiments, the hole structure34may be used for accommodating at a portion of the position control mechanism5. Thus, the number of the hole structure34may be equal to the number of the position control mechanism5. In some embodiments, the number of the hole structure34may be two or three, which can balance or substantially uniformly support a downward press force applied on the position control mechanism5and the middle mold4from the upper mold2. The middle mold4may be disposed between the upper mold2and the lower mold3, and may be moveably attached to the lower mold3through the position control mechanism5. The middle mold4may be moveable between the upper mold2and the lower mold3. In some embodiments, the middle mold4can move between the upper mold2and the lower mold3due to the operation of the position control mechanism5. In some embodiments, the position control mechanism5can drive or actuate the middle mold4to move along a direction between the upper mold2and the lower mold3, or along a height of the molding device1. It can be understood that a maximum displacement of the middle mold4is limited by the position control mechanism5. That is, the gap or distance between the middle mold4and the lower mold3is controlled by the position control mechanism5. Further, the gap or distance between the middle mold4and the upper mold2is not controlled by the position control mechanism5. As shown inFIG.1AandFIG.1B, the middle mold4may include a main portion41and a shoe last42. The main portion41may be connected to a back end of the shoe last42. In some embodiments, the main portion41and the shoe last42may be formed integrally as a monolithic structure. The main portion41may have a top surface411and a bottom surface412opposite to the top surface411. The shoe last42may have a top surface421, a bottom surface422opposite to the top surface421, and an outer surface423extending between the top surface421and the bottom surface422. In addition, the shoe last42may define at least one recess43recessed from the outer surface423. The recess43of the middle mold4may be a portion of the mold cavity14when the molding device1is in the closed configuration as shown inFIG.3AandFIG.3B. In some embodiments, the at least one recess43may include a plurality of recesses43in communication with each other and extending to the bottom surface422of the shoe last42. In some embodiments, the shoe last42may further define at least one bottom recess (not shown) recessed from the bottom surface422of the shoe last42. The top surface421of the shoe last42may be substantially aligned with or coplanar with the top surface411of the main portion41. Thus, a top surface of the middle mold4may include the top surface421of the shoe last42and the top surface411of the main portion41. Further, the bottom surface422of the shoe last42may be substantially aligned with or coplanar with the bottom surface412of the main portion41. Thus, a bottom surface of the middle mold4may include the bottom surface422of the shoe last42and the bottom surface412of the main portion41. As a result, a maximum thickness of the shoe last42may be substantially equal to a maximum thickness of the main portion41and a maximum thickness of the middle mold4. The position control mechanism5may be connected or attached to the bottom surface412of the main portion41of the middle mold4. The position control mechanism5may drive or actuate the middle mold4to move upward so as to generate a gap G between the top surface31of the lower mold3and a bottom surface of the middle mold4(including the bottom surface422of the shoe last42and the bottom surface412of the main portion41) when the molding device1is in an open configuration. That is, the position control mechanism5may generate the relative movement between the middle mold4and the lower mold3. As shown inFIG.1AandFIG.1B, the molding device1is in an open configuration, and the gap G reaches its maximum value. In some embodiments, a portion of the position control mechanism5may be accommodated in the hole structure34of the lower mold3. Thus, when the molding device1is in a closed configuration, the whole position control mechanism5may be accommodated in the hole structure34of the lower mold3, and the bottom surface412of the main portion41may contact the top surface31of the lower mold3. As shown inFIG.1AandFIG.1B, the position control mechanism5may include at least one ejector51and an elastic mechanism52. The ejector51may be a pin, a pillar, a post or a column, and may be used for guiding the moving direction of the middle mold4. An upper end of the ejector51may be connected or attached to the bottom surface412of the main portion41of the middle mold4, and a lower end of the ejector51may extend through the first hole341of the hole structure34and extend into the second hole342of the hole structure34. The elastic mechanism52may be used for controlling a movement of the ejector51or driving the ejector51. For example, the elastic mechanism52may be a spring or an elastic body that surrounds the ejector51. An upper end of the elastic mechanism52may be connected or attached to the bottom surface412of the main portion41of the middle mold4, and a lower end of the elastic mechanism52may be connected or attached to the step structure343of the hole structure34of the lower mold3. When a downward force is applied on the middle mold4to drive the middle mold4to move downward to press the elastic mechanism52, an elastic potential energy is stored in the pressed elastic mechanism52. Once the downward force is released, the elastic potential energy will push the middle mold4to move upward. It can be understood that the position control mechanism5may be a piston or other suitable mechanism that has a compression phase and a springback phase. In some embodiments, the elastic mechanism52may be omitted, and the lower end of the ejector51may be connected to a suitable actuator. Thus, the movement of the ejector51may not controlled by the elastic potential energy. In some embodiments, the middle mold4may be detachable from the lower mold3and the position control mechanism5. It can be understood that the size or appearance of the article6(FIG.8) may correspond to the size or appearance of the middle mold4. Thus, in order to manufacture different articles6(FIG.8) having different sizes or different appearances, different middle mold4having different sizes or different appearances may be adopted and changed. When the middle mold4is changed, the recess portion33of the lower mold3and the recess portion23of the upper mold2may be changed accordingly. Referring toFIG.2AandFIG.2B, a distance between the upper mold2and the lower mold3is reduced gradually.FIG.2Ais a schematic perspective view of the molding device1at a second manufacturing stage according to some embodiments of the present invention.FIG.2Bis a side view of the molding device1ofFIG.2A. As shown inFIG.2AandFIG.2B, a relative movement between the upper mold2and the lower mold3occurs. In some embodiments, the position of the upper mold2may be fixed, and the lower mold3and the middle mold4may move together toward the upper mold2. In some embodiments, the positions of the lower mold3and the middle mold4may be fixed, and the upper mold2may move toward the lower mold3and the middle mold4. In some embodiments, the lower mold3and the upper mold2may move toward each other. At the stage illustrated inFIG.2AandFIG.2B, the middle mold4has contacted the upper mold2, but the lower mold3has not contacted the upper mold2yet. That is, the middle mold4contacts the upper mold2before the lower mold3contacts the upper mold2. For example, the middle mold4may be accommodated in the recess portion23of the upper mold2. The first inner surface231of the upper mold2may contact the top surface of the middle mold4(including the top surface421of the shoe last42and the top surface411of the main portion41). The second inner face232of the upper mold2may contact the outer surface423of the middle mold4. In some embodiments, the bottom surface of the middle mold4(including the bottom surface422of the shoe last42and the bottom surface412of the main portion41) may be substantially coplanar with the bottom surface22of the upper mold2. Meanwhile, the gap G between the top surface31of the lower mold3and the bottom surface of the middle mold4has not changed. Referring toFIG.3AandFIG.3B, the relative movement between the upper mold2and the lower mold3continues until the distance between the upper mold2and the lower mold3is reduced to zero.FIG.3Ais a schematic perspective view of the molding device1at a third manufacturing stage according to some embodiments of the present invention.FIG.3Bis a side view of the molding device1ofFIG.3A. In some embodiments, the position of the upper mold2may be fixed, the middle mold4may sustain the upper mold2, and the lower mold3may move toward the upper mold2. In some embodiments, the position of the lower mold3may be fixed, and the upper mold2and the middle mold4may move together toward the lower mold3. In some embodiments, the lower mold3and the upper mold2may move toward each other. Thus, the gap G between the top surface31of the lower mold3and the bottom surface of the middle mold4has reduced to zero. The upper mold2may apply a downward force on the middle mold4to drive the middle mold4to move downward to press the elastic mechanism52. Therefore, an elastic potential energy is stored in the pressed elastic mechanism52. As shown inFIG.3AandFIG.3B, the molding device1is in a closed configuration, and the upper mold2is engaged with the lower mold3. The bottom surface22of the upper mold2and the bottom surface412of the main portion41may contact the top surface31of the lower mold3. Thus, the upper mold2and the lower mold3may jointly define an accommodating space12for accommodating the middle mold4. It can be understood that the accommodating space12may be substantially same as the recess portion23of the upper mold2. The whole middle mold4is disposed and accommodated in the accommodating space12. In addition, the upper mold2, the middle mold4and the lower mold3may jointly define a mold cavity14. The mold cavity14is configured to accommodate a material and allows the material to be made into a molded article having predetermined shape by mold forming. The passage24of the upper mold2is in communication with the mold cavity14. In some embodiments, the opening241of the passage24may be coupled with an injection molding machine or extrusion molding machine, so that the material may be injected/extruded into the mold cavity14from the injection molding machine or extrusion molding machine and formed the predetermined shape therein. As shown inFIG.3AandFIG.3B, the mold cavity14may include a first portion141and a second portion142in communication with each other. The first portion141may be defined by the second inner face232of the upper mold2and the sidewalls of the recess43of the shoe last42. It can be understood that the first portion141of the mold cavity14may be substantially same as the recess43of the shoe last42. Further, the second portion142may be defined by the sidewalls of the recess portion33of the lower mold3, the bottom surface of the middle mold4(including the bottom surface422of the shoe last42and the bottom surface412of the main portion41) and the bottom surface22of the upper mold2. It can be understood that the second portion142of the mold cavity14may be substantially same as the recess portion33of the lower mold3. Referring toFIG.4AandFIG.4B, a material60may be injected into the mold cavity14through the opening241of the passage24. The material60may at least partially surround the middle mold4.FIG.4Ais a schematic perspective view of the molding device1at a fourth manufacturing stage according to some embodiments of the present invention.FIG.4Bis a side view of the molding device1ofFIG.4A. In some embodiments, the material60is injected into the mold cavity14when the molding device1is in a closed configuration or when the upper mold2and the lower mold3are engaged with each other. In some embodiments, the material60may include thermoplastic polyurethane (TPU), polyurethane (PU), plastics or any other suitable materials. In some embodiments, the material60may be foamable material or less foamable material. In some embodiments, the material60may be non-foamable material. In some embodiments, the material60may fill up the mold cavity14(including the first portion141and the second portion142). Then, an article6is integrally formed from the material60. The article6may be a shoe such as a slipper, flip-flop, or a sandal. The article6may include a base portion62(e.g., a sole portion) and at least one upper portion61(e.g., a strap portion). The upper portion61of the article6may be formed from a first portion of the material60disposed in the first portion141of the mold cavity14. The base portion62of the article6may be formed from a second portion of the material60disposed in the second portion142of the mold cavity14. In addition, an additional pin63may be formed from a third portion of the material60disposed in the passage24. The additional pin63may be connected to the upper portion61of the article6. Referring toFIG.5AandFIG.5B, the lower mold3is disengaged from the upper mold2.FIG.5Ais a schematic perspective view of the molding device1at a fifth manufacturing stage according to some embodiments of the present invention.FIG.5Bis a side view of the molding device1ofFIG.5A. The relative movement between the upper mold2and the lower mold3occurs, and the distance between the upper mold2and the lower mold3increases gradually. Meanwhile, the article6may be held or attached on the middle mold4, and the additional pin63may be still attached on the article6. In some embodiments, the position of the upper mold2may be fixed, and only the lower mold3may move away from the upper mold2. Meanwhile, the middle mold4may sustain the upper mold2and may not move. The relative movement between the middle mold4and the lower mold3may be achieved by a pushing force applied to the middle mold4by the position control mechanism5. Such pushing force is converted from the elastic potential energy stored in the pressed elastic mechanism52ofFIG.3AandFIG.3B. In some embodiments, the position of the lower mold3may be fixed, and the upper mold2and the middle mold4may move away from the lower mold3simultaneously. Meanwhile, the middle mold4may sustain the upper mold2and may move with the upper mold2. The relative movement between the middle mold4and the lower mold3may be achieved by a pushing force applied to the middle mold4by the position control mechanism5. Such pushing force is converted from the elastic potential energy stored in the pressed elastic mechanism52ofFIG.3AandFIG.3B. Referring toFIG.6AandFIG.6B, the relative movement between the upper mold2and the lower mold3continues so as to separate the upper mold2from the middle mold4.FIG.6Ais a schematic perspective view of the molding device1at a sixth manufacturing stage according to some embodiments of the present invention.FIG.6Bis a side view of the molding device1ofFIG.6A. Meanwhile, the article6may remain on the middle mold4. In some embodiments, the position of the upper mold2may be fixed, and the lower mold3and the middle mold4move together away from the upper mold2since a maximum displacement of the middle mold4is limited by the position control mechanism5attached to the lower mold3. In some embodiments, the position of the lower mold3may be fixed, and the upper mold2may move away from the lower mold3and the middle mold4. As shown inFIG.6B, a distance between the middle mold4and the upper mold2may be greater than a distance between the middle mold4the lower mold3. Referring toFIG.7, the article6may be detached from an upper side of the middle mold4.FIG.7is a schematic side view of the molding device1at a seventh manufacturing stage according to some embodiments of the present invention. As shown inFIG.7, the article6may be detached from the middle mold4through a space between the middle mold4and the upper mold2. It can be understood that the gap G between the top surface31of the lower mold3and the bottom surface of the middle mold4can facilitate the detachment of the article6. Then, the additional pin63may be removed from the article6so as to obtain the article6as shown inFIG.8. FIG.8is a schematic perspective view of the article6according to some embodiments of the present invention. The article6may include a base portion62and at least one upper portion61connected to base portion62. The base portion62and the upper portion61may be formed integrally and concurrently. Thus, there may be no interface between the base portion62and the upper portion61. FIG.9throughFIG.15illustrate a molding method for manufacturing an article according to some embodiments of the present disclosure. In some embodiments, the method is for manufacturing the article6shown inFIG.8. Referring toFIG.9, a molding device1ais provided. The molding device1aofFIG.9is similar to the molding device1ofFIG.1AandFIG.1B, except that the middle mold4ais upside down. The molding device1amay include an upper mold2a, a lower mold3a, a middle mold4aand a position control mechanism5a. In the embodiment illustrated inFIG.9, the molding device1ais in an open configuration. The upper mold2amay have a top surface21and a bottom surface22opposite to the top surface21. The upper mold2amay define a recess portion23aand at least one passage24. The bottom surface22of the upper mold2amay face the lower mold3aand the middle mold4a. The recess portion23aof the upper mold2amay be recessed from the bottom surface22of the upper mold2. A configuration (e.g., dimension or shape) of the recess portion23aof the upper mold2amay correspond to a configuration (e.g., dimension or shape) of a top surface421of the middle mold4a. A position of the recess portion23aof the upper mold2amay be right above the middle mold4a. The recess portion23aof the upper mold2aofFIG.9may be similar to the recess portion33of the lower mold3ofFIG.1AandFIG.1B. In some embodiments, the passage24may extend through the upper mold2a, and may have an opening241on the top surface21of the upper mold2a. In some embodiments, the passage24may be communicable with the recess portion23aof the upper mold2aor the mold cavity14awhen the molding device1ais in the closed configuration as shown inFIG.11. Alternatively, the passage24may be in communication with the recess portion23aof the upper mold2a. Thus, the recess portion23aof the upper mold2amay be accessible through the passage24. The lower mold3amay be disposed below the upper mold2a. The lower mold3amay have a top surface31and a bottom surface (not shown) opposite to the top surface31. The lower mold3amay define a recess portion33aand a hole structure34a. The top surface31of the lower mold3amay face the upper mold2aand the middle mold4a. The recess portion33aof the lower mold3amay be recessed from the top surface31aof the lower mold3a. A configuration (e.g., dimension or shape) of recess portion33aof the lower mold3amay correspond to a configuration (e.g., dimension or shape) of the middle mold4a. The recess portion33aof the lower mold3amay be a portion of the mold cavity14awhen the molding device1ais in the closed configuration as shown inFIG.11. The recess portion33aof the lower mold3amay include a first inner surface331aand a second inner face332a. The second inner face332amay extend between the first inner surface331aand the top surface31of the lower mold3a. The first inner surface331aand the second inner face332amay be substantially conformal with the middle mold4a. The recess portion33aof the lower mold3aofFIG.9may be similar to the recess portion23of the upper mold2ofFIG.1AandFIG.1B. In some embodiments, the hole structure34amay be disposed under the recess portion33aof the lower mold3a, and in communication with the recess portion33aof the lower mold3a. In some embodiments, the hole structure34amay be used for accommodating at least a portion of the position control mechanism5a. The middle mold4amay be disposed between the upper mold2aand the lower mold3a, and may be moveably attached to the lower mold3athrough the position control mechanism5a. The middle mold4amay be moveable between the upper mold2aand the lower mold3adue to the operation of the position control mechanism5a. In some embodiments, the position control mechanism5acan drive or actuate the middle mold4ato move along a direction between the upper mold2aand the lower mold3a, or along a height of the molding device1a. It can be understood that a maximum displacement of the middle mold4ais limited by the position control mechanism5a. That is, the gap or distance between the middle mold4aand the lower mold3ais controlled by the position control mechanism5a. Further, the gap or distance between the middle mold4aand the upper mold2ais not controlled by the position control mechanism5a. The middle mold4aofFIG.9may be similar to the middle mold4ofFIG.1AandFIG.1B, except that the main portion41ofFIG.1AandFIG.1Bmay be omitted, and the middle mold4aofFIG.9is upside down. As shown inFIG.9, the middle mold4amay include a shoe last42. The shoe last42may have a top surface421, a bottom surface422opposite to the top surface421, and an outer surface423extending between the top surface421and the bottom surface422. In addition, the shoe last42may define at least one recess43recessed from the outer surface423. The recess43of the middle mold4amay be a portion of the mold cavity14awhen the molding device1ais in the closed configuration as shown inFIG.11. The position control mechanism5amay be connected or attached to the bottom surface422of the shoe last42of the middle mold4a. The position control mechanism5amay drive or actuate the middle mold4ato move upward so as to generate a gap G between the top surface31of the lower mold3aand the bottom surface422of the shoe last42when the molding device1ais in an open configuration. That is, the position control mechanism5amay generate the relative movement between the middle mold4aand the lower mold3a. As shown inFIG.9, the molding device1ais in an open configuration, and the gap G reaches its maximum value. In some embodiments, a portion of the position control mechanism5amay be accommodated in the hole structure34aof the lower mold3a. Thus, when the molding device1ais in a closed configuration, the whole position control mechanism5amay be accommodated in the hole structure34aof the lower mold3a. As shown inFIG.9, the position control mechanism5amay an ejector51, an elastic mechanism52and a fixed support53. The ejector51may be a pin, a pillar, a post or a column, and may be used for guiding the moving direction of the middle mold4a. An upper end of the ejector51may be connected or attached to the bottom surface422of the shoe last42of the middle mold4a, and a lower end of the ejector51may extend into the hole structure34aand may slide in the hole structure34a. The elastic mechanism52may be used for controlling a movement of the ejector51or driving the ejector51. For example, the elastic mechanism52may be a spring or an elastic body that disposed in a center hollow of the ejector51. An upper end of the elastic mechanism52may be connected or attached to the bottom surface422of the shoe last42of the middle mold4a, and a lower end of the elastic mechanism52may be connected or attached to the fixed support53. When a downward force is applied on the middle mold4ato drive the middle mold4ato move downward to press the elastic mechanism52, an elastic potential energy is stored in the pressed elastic mechanism52. Once the downward force is released, the elastic potential energy will push the middle mold4ato move upward. It can be understood that the position control mechanism5amay be a piston or other suitable mechanism that has a compression phase and a springback phase. In some embodiments, the elastic mechanism52may be omitted, and the lower end of the ejector51may be connected to a suitable actuator. Thus, the movement of the ejector51may not controlled by the elastic potential energy. Referring toFIG.10, a distance between the upper mold2aand the lower mold3ais reduced gradually. A relative movement between the upper mold2aand the lower mold3aoccurs. In some embodiments, the position of the upper mold2amay be fixed, and the lower mold3aand the middle mold4amay move together toward the upper mold2a. In some embodiments, the positions of the lower mold3aand the middle mold4amay be fixed, and the upper mold2amay move toward the lower mold3aand the middle mold4a. In some embodiments, the lower mold3aand the upper mold2amay move toward each other. At the stage illustrated inFIG.10, the middle mold4ahas contacted the upper mold2a, but the lower mold3ahas not contacted the upper mold2ayet. Meanwhile, the gap G between the top surface31of the lower mold3aand the bottom surface422of the middle mold4ahas not changed. Referring toFIG.11, the relative movement between the upper mold2aand the lower mold3acontinues until the distance between the upper mold2aand the lower mold3ais reduced to zero. In some embodiments, the position of the upper mold2amay be fixed, the middle mold4amay sustain the upper mold2a, and the lower mold3amay move toward the upper mold2a. In some embodiments, the position of the lower mold3amay be fixed, and the upper mold2aand the middle mold4amay move together toward the lower mold3a. In some embodiments, the lower mold3aand the upper mold2amay move toward each other. Thus, the gap G between the top surface31of the lower mold3aand the bottom surface422of the middle mold4ahas reduced to zero. The upper mold2amay apply a downward force on the middle mold4ato drive the middle mold4ato move downward to press the elastic mechanism52. Therefore, an elastic potential energy is stored in the pressed elastic mechanism52. As shown in11, the molding device1is in a closed configuration, and the upper mold2ais engaged with the lower mold3a. The bottom surface22of the upper mold2amay contact the top surface31of the lower mold3a. Thus, the upper mold2aand the lower mold3amay jointly define an accommodating space12afor accommodating the middle mold4a. It can be understood that the accommodating space12amay be substantially same as the recess portion33aof the lower mold3a. For example, the middle mold4amay be accommodated in the recess portion33aof the lower mold3a. The first inner surface331aof the lower mold3amay contact the bottom surface422of the shoe last42of the middle mold4a. The second inner face332aof the lower mold3amay contact the outer surface423of the middle mold4a. In some embodiments, the top surface421of the shoe last42of the middle mold4amay be substantially coplanar with the top surface31of the lower mold3a. In addition, the upper mold2a, the middle mold4aand the lower mold3amay jointly define a mold cavity14a. The mold cavity14ais configured to accommodate a material and allows the material to be made into a molded article having predetermined shape by mold forming. The passage24of the upper mold2ais in communication with the mold cavity14a. In some embodiments, the opening241of the passage24may be coupled with an injection molding machine or extrusion molding machine, so that the material may be injected/extruded into the mold cavity14afrom the injection molding machine or extrusion molding machine and formed the predetermined shape therein. The mold cavity14aofFIG.11may be similar to the mold cavity14ofFIG.1AandFIG.1B, and may include a first portion141aand a second portion142ain communication with each other. The first portion141amay be defined by the second inner face332aof the lower mold3aand the sidewalls of the recess43of the shoe last42. It can be understood that the first portion141aof the mold cavity14amay be substantially same as the recess43of the shoe last42. Further, the second portion142amay be defined by the sidewalls of the recess portion23aof the upper mold2a, the top surface421of the shoe last42of the middle mold4aand the top surface31of the lower mold3a. It can be understood that the second portion142aof the mold cavity14amay be substantially same as the recess portion23aof the upper mold2a. Referring toFIG.12, a material60may be injected into the mold cavity14athrough the opening241of the passage24. The material60may at least partially surround the middle mold4a. In some embodiments, the material60may fill up the mold cavity14a(including the first portion141aand the second portion142a). Then, an article6is integrally formed from the material60. The article6may be a shoe such as a slipper, flip-flop, or a sandal. The article6may include a base portion62(e.g., a sole portion) and at least one upper portion61(e.g., a strap portion). The upper portion61of the article6may be formed from a first portion of the material60disposed in the first portion141aof the mold cavity14a. The base portion62of the article6may be formed from a second portion of the material60disposed in the second portion142aof the mold cavity14a. In addition, at least one additional pin63may be formed from a third portion of the material60disposed in the passage24. The additional pin63may be connected to the base portion62of the article6. Referring toFIG.13, the lower mold3ais disengaged from the upper mold2a. The relative movement between the upper mold2aand the lower mold3aoccurs, and the distance between the upper mold2aand the lower mold3aincreases gradually. Meanwhile, the article6may be held or attached on the middle mold4a, and the additional pin(s)63may be still attached on the article6. In some embodiments, the position of the upper mold2amay be fixed, and only the lower mold3amay move away from the upper mold2a. Meanwhile, the middle mold4amay sustain the upper mold2aand may not move. The relative movement between the middle mold4aand the lower mold3amay be achieved by a pushing force applied to the middle mold4aby the position control mechanism5a. Such pushing force is converted from the elastic potential energy stored in the pressed elastic mechanism52ofFIG.11. In some embodiments, the position of the lower mold3amay be fixed, and the upper mold2aand the middle mold4amay move away from the lower mold3asimultaneously. Meanwhile, the middle mold4amay sustain the upper mold2aand may move with the upper mold2a. The relative movement between the middle mold4aand the lower mold3amay be achieved by a pushing force applied to the middle mold4aby the position control mechanism5a. Such pushing force is converted from the elastic potential energy stored in the pressed elastic mechanism52of11. Referring toFIG.14, the relative movement between the upper mold2aand the lower mold3acontinues so as to separate the upper mold2afrom the middle mold4a. Meanwhile, the article6may remain on the middle mold4a. In some embodiments, the position of the upper mold2amay be fixed, and the lower mold3aand the middle mold4amove together away from the upper mold2asince a maximum displacement of the middle mold4ais limited by the position control mechanism5aattached to the lower mold3a. In some embodiments, the position of the lower mold3amay be fixed, and the upper mold2amay move away from the lower mold3aand the middle mold4a. As shown inFIG.14, a distance between the middle mold4aand the upper mold2amay be greater than a distance between the middle mold4athe lower mold3a. Referring toFIG.15, the article6may be detached from an upper side of the middle mold4a. As shown inFIG.15, the article6may be detached from the middle mold4athrough a space between the middle mold4aand the upper mold2a. It can be understood that the gap G between the top surface31of the lower mold3aand the bottom surface422of the middle mold4acan facilitate the detachment of the article6. Then, the additional pin63may be removed from the article6so as to obtain the article6as shown inFIG.8. FIG.16AthroughFIG.20illustrate a molding method for manufacturing an article according to some embodiments of the present disclosure. In some embodiments, the method is for manufacturing the article6shown inFIG.8. Referring toFIG.16AandFIG.16B, a molding device1bis provided. The molding device1bofFIG.16AandFIG.16Bis similar to the molding device1ofFIG.1AandFIG.1B, except that the shoe last42of the middle mold4bmay further define at least one notch44and an opening45recessed from the outer surface423and in communication with the recess43. The location of the passage24of the upper mold2may correspond to the opening45. A depth of the notch44may be less than a depth of the recess43. A depth of the opening45may be greater than the depth of the notch44and the depth of the recess43. Referring toFIG.17AandFIG.17B, the molding device1bis in a closed configuration. The notch44, the opening45and the recess43of the middle mold4bmay be a portion of the mold cavity14. Referring toFIG.18AandFIG.18B, a material60may be injected into the mold cavity14through the opening241of the passage24. Then, an article6is integrally formed from the material60. The article6may include a base portion62(e.g., a sole portion), at least one upper portion61(e.g., a strap portion), at least one strip64and protrusion65. In addition, at least one additional pin63may be formed on the protrusion65. That is, the protrusion65may be below the additional pin63. Further, the base portion62, the upper portion61, the strip64, the protrusion65and the additional pin63may be formed integrally and concurrently. The upper portion61may be connected to the base portion62. The additional pin63may be connected to the strip64, and the strip64may be connected to the upper portion61. A thickness of the protrusion65may be greater than a thickness of the strip64and a thickness of the upper portion61. A thickness of the strip64may be less than the thickness of the upper portion61. Referring toFIG.19AandFIG.19B, the lower mold3is disengaged from the upper mold2. Referring toFIG.20, the article6may be detached from an upper side of the middle mold4b. Then, the additional pin63, the protrusion65and the strip64may be removed from the article6so as to obtain the article6as shown inFIG.8. In some embodiments, the additional pin63, the protrusion65and the strip64are removed from the article6by cutting or shearing the strip64. FIG.21is a flow chart illustrating a molding method according to some embodiments of the present invention. As shown inFIG.21, the molding method70may include the following steps. In some embodiments, the method70may include a step S71: providing a lower mold and a middle mold moveably attached to the lower mold. For example, as shown inFIG.1AandFIG.1B, a molding device1is provided. The molding device1may include an upper mold2, a lower mold3, a middle mold4and a position control mechanism5. The middle mold4may be moveably attached to the lower mold3though the position control mechanism5. In some embodiments, the method70may include a step S72: engaging an upper mold with the lower mold to define an accommodating space and dispose the middle mold within the accommodating space, wherein the upper mold, the middle mold and the lower mold jointly define a mold cavity. For example, as shown inFIG.3AandFIG.3B, the upper mold2is engaged with the lower mold3to define an accommodating space12, and the middle mold4is disposed within the accommodating space12. The upper mold2, the middle mold4and the lower mold3jointly define a mold cavity14. In some embodiments, the method70may include a step S73: injecting a material into the mold cavity and at least partially surrounding the middle mold. For example, as shown inFIG.4AandFIG.4B, a material60is injected into the mold cavity14, and the material60at least partially surrounds the middle mold4. In some embodiments, the method70may include a step S74: forming an article from the material. For example, as shown inFIG.4AandFIG.4B, an article6is formed from the material60. The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein, may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods and steps. | 46,138 |
11858229 | DETAILED DESCRIPTION FIG.1schematically illustrates a tooling solution currently used in the aircraft industry, along with a top view of an example of a multi-spar torsion box (100). In particular, the tooling (101) comprises several fixed height mandrels (102) for manufacturing a single configuration of a multi-spar torsion box (100). The tooling (101) shown is used to produce a multi-spar torsion box (100) by a hot forming method. The tooling (101) comprises a base plate (103) which performs the functions of sustaining and transporting the rest of the elements which are part of the tooling (101) required for applying a thermodynamic process to the multi-spar torsion box (100) made of composite material, while ensuring fulfilment of the restrictive structural and dimensional tolerances. Different layers of composite material are provided along part of the external surface of the mandrels (102), obtaining the desired distribution of composite material which will undergo the curing process. In particular, in FIG.1the composite material is distributed following a C-shape pattern, such that the mandrels (102) can be distributed by alternating the orientation of the C-shape pattern for producing the spars (100.1) by bringing together two walls completely covered with composite material; and for producing several stringers or stiffening elements (100.2) by connecting the walls which are only partially covered with composite material. In this sense, several mandrels (102) are shown assembled together with fresh composite laminates layered so as to provide the structure with its final shape, prior to said curing process, to build the complete multi-spar torsion box (100). Additionally, external Caul plates (103) are used to secure aerodynamic tolerances. Regarding the fixed height mandrels (102) used in the prior art, as shown inFIG.1, they are built by welding two C-shape aluminum beams and are assembled and coordinated among themselves by means of longitudinal rods (105) with hippodrome shape. Using this tooling (101), it is possible to manufacture a multi-spar torsion box (100) combining skins (100.3,100.4), stringers (100.2) and spars (101.1). As every mandrel (102) has a predefined fixed shape, in case of any multi-spar torsion box (100) height change, new mandrels (102) should be implemented for producing the required structure (100). FIG.2schematically illustrates the principle of the invention using a set of modular lifting surfaces as an example. In this example, the multi-spar torsion box (100) is modified only by varying the web height of the front and rear spars (101.11,101.12) while maintaining common upper (100.3) and lower skins (100.4). Then, the addition of different leading edges (LE) (106) and different trailing edges (TE) (107) enables the modification of the lifting surface planform and therefore allows tailoring the size of the lifting surface to the sizing requirements of a particular member of the aircraft family. It is to be noted thatFIG.2is simply a schematic representation of the concept and the implied increase in relative thickness (t/c, thickness-to-chord ratio) has not be taken into account. It is assumed that the different multi-spar torsion boxes (100) with different heights corresponding to each embodiment compensate the increase in loads due to the longer chords for the leading and trailing edges (LE and TE) due to the increased web height. Further, for the sake of simplicity,FIG.2does not show an increase in trailing edge chord. FIG.3shows a schematic representation of a front view of two different configurations of modular tooling (10) for manufacturing multi-spar torsion boxes (100) with different web heights (z1, z2) according to an embodiment of the present invention. In particular, the Figure to the left shows one mandrel module (11) coupled to a spacer module (12A), and the Figure to the right shows the same mandrel module (11) coupled to a bigger spacer module (12A′), thus allowing to produce a higher multi-spar torsion box (100) for a different structure of an aircraft (1000) of the family. Accordingly, the same modular tooling (10) allows providing different web heights to a set of multi-spar torsion boxes (100), thus tailoring the size of said multi-spar torsion boxes (100) to the sizing requirements of a particular member of an aircraft (1000) family. The spacer modules (12A,12A′) shown comprise a hollow beam geometry, with a first flat bottom base (12A.1,12A.1′), substantially parallel to a second flat top base (12A.2,12A.2′), which is spaced apart from the first flat bottom base (12A.1,12A.1′) a distance determined by two parallel walls (12A.3,12A.4;12A.3′,12A.4′) which extend substantially perpendicularly between the first flat bottom base (12A.1,12A.1′) and the second flat top base (12A.2,12A.2′). Similarly, the mandrel module (11) comprises a hollow beam geometry, with a first flat bottom base (11.1), substantially parallel to a second flat top base (11.2), which is spaced apart from the first flat bottom base (11.1) a distance determined by two parallel walls (11.3,11.4) which extend substantially perpendicularly between the first flat bottom base (11.1) and the second flat top base (11.2). In both left and right stacks of mandrel and spacer modules shown inFIG.3, the mandrel module (11) and the spacer module (12A,12A′) are stacked one on the other to form a vertical column. The mandrel module (11) being supported on top of a respective spacer module (12A,12A′), such that the first flat bottom base (11.1) of the mandrel module (11) is supported on the second flat top base (12A.2,12A.2′) of the respective spacer module (12A,12A′). The width of the mandrel module (11) is the distance between the walls (11.3,11.4) and is equal to the width of each spacer modules (12A,12A′). Thus, the stacking (15) of the mandrel module (11) and each spacer module (12A,12A′) forms a substantially rectangular geometry comprising two closed cells. FIG.4shows a front view of two different configurations of modular tooling (10) for manufacturing multi-spar torsion boxes (100) with different web heights (z1, z2) according to an embodiment of the present invention. InFIG.4, the stack on the left shows a mandrel module (11) coupled to a spacer module (12A), and the stack to the right shows the same mandrel module (11) coupled to the same spacer module (12A) and to an additional spacer module (12D) in the form of a plank-shaped structure, for reaching a height (z2) greater than the height (z1) reached without the plank-shaped structure (12D), thus allowing to produce a higher multi-spar torsion box (100) for a different structure of an aircraft (1000) of the family. The shared spacer module (12A) shown comprise a hollow beam geometry, with a first flat bottom base (12A.1), parallel to a second flat top base (12A.2), which is spaced apart from the first flat bottom base (12A.1) a distance determined by two parallel walls (12A.3,12A.4) which extend perpendicularly between the first flat bottom base (12A.1) and the second flat top base (12A.2). In the stack to the left inFIG.4, the mandrel module (11) and the spacer module (12A) are stacked in the same manner than the embodiments shown inFIG.3. This is, the mandrel module (11) is supported on top of the spacer module (12A), such that the first flat bottom base (11.1) of the mandrel module (11) is supported on the second flat top base (12A.2) of the spacer module (12A). Further, the width of the mandrel module (11), this is, the distance between the walls (11.3,11.4) is equal to the width of the spacer modules (12A). Thus, the stacking (15) of the mandrel module (11) and the spacer module (12A) has a substantially rectangular geometry, comprising two closed cells. However, in the stack to the right inFIG.4, the plank-shaped structure (12D) is interposed between the mandrel module (11) and the spacer module (12A), such that the first flat bottom base (11.1) of the mandrel module (11) is supported on a top surface of the plank-shaped structure (12D), and the plank-shaped structure (12D) is supported on the second flat top base (12A.2) of the spacer module (12A). Additionally, both stacks inFIG.4with and without the plank-shaped structure (12D) interposed therebetween comprise complementary fastening means for guiding the coupling process and for fixing said coupling once it has been completed. In particular, in the stack to the left inFIG.4, the mandrel module (11) and the spacer module (12A) comprise a blind hole drilled in the contact surfaces (11.1,12A.2) of the stacking using a numerical control (NC) machine for achieving tight tolerances and allowing precise coordination between both holes, so that a pin (13) can penetrate both holes, substantially perpendicularly to both contact surfaces (11.1,12.2), thus securing the coupling. In the same manner, in the figure to the right, the plank shaped structure (12D) stacked between the mandrel module (11) and the spacer module (12A) has been drilled in coordination with the holes of the contact surfaces (11.1,12A.2) so that a longer pin (13′) can pass through the whole stacking (15), thus fixing the stacking among the mandrel module (11), the plank-shaped structure (12D) and the spacer module (12A). FIG.5shows a front view of a configuration of a mandrel module (11) coupled to a spacer module (12B) of modular tooling (10) for manufacturing multi-spar torsion boxes (100) according to another embodiment of the invention, wherein the mandrel module (11) is split in a first (16) and second (17) mandrel module members. In particular, the first mandrel module member (16) comprises a first base (16.1), a first wall (16.2) and a second wall (16.3) extending from said first base (16.1); and the second mandrel module member (17) comprises a second base (17.1), a first wall (17.2) and a second wall (17.3) extending from said second base (17.1). On one side, the first wall (16.2) of the first mandrel module member (16) is shown abutting the first wall (17.2) of the second mandrel module member (17) along a portion of their lengths. Both first walls (16.2,17.2) are configured for sliding on each other, such that, when the spacer module (12B) is replaced, or is set to couple with the mandrel module members (16,17) in a different position, the defined web height (z) of the coupling changes thereby, said walls (16.2,17.2) sliding on each other in order to adapt to the new configuration. In this sense, said first walls (16.2,17.2) are illustrated comprising a thickness reduction along the portion of their lengths configured for mechanically connecting the other respective first wall (16.2,17.2). This way, the length of the portion in contact is maximized, such that both first walls (16.2,17.2) can slide on each other along a plurality of configurations for defining different web heights for a multi-spar torsion box (100) to be manufactured. In particular, upon a change in the defined web height of the coupling due to a replacement or a change in the position of the spacer module (12B) interposed between both mandrel module members (16,17), said first walls (16.2,17.2) slide on each other in order to adapt to the new configuration, while remaining in mechanical contact, thus preventing the inner hollow volume from any vacuum leakage. On the other side, the spacer module (12B) is shown interposed between the distal ends (16.4,17.4) of the second walls (16.3,17.3). In this sense, the distal end (16.4,17.4) portions of both mandrel module members (16,17) slope obliquely towards the joint interfaces (19.1,19.2). In a similar manner, the spacer module (12B) shown has a portion substantially shaped as a trapezium, comprising two sloping surfaces configured for abutting the distal ends (16.4,17.4) along said joint interfaces (19.1,19.2). This particular configuration with oblique surfaces in mechanical contact along the joint interfaces (19.1,19.2) provides the modular tooling (10) with continuous height adjustment as a result of the potential coupling options for the mandrel module members (16,17) and the spacer module (12B) along the joint interfaces (19.1,19.2). FIG.6shows an alternative embodiment for replacing the oblique surfaces in mechanical contact at the joint interfaces (19.1,19.2) shown inFIG.5. In particular, the figure shows a particular embodiment of a coupling between the distal ends (16.4,17.4) of the mandrel module members (16,17) and the spacer module (12B) achieved by means of two rectangular projections (16.5,17.5) which are provided only on a portion of the contact surfaces of distal ends (16.4,17.4), since the rest of the surface is configured for matching with the spacer module (12B), which, in this particular embodiment, is in the form of a z-shaped body. Therefore, said z-shaped body (12B) is configured for matching with the projections (16.5,17.5) of each respective distal end (16.4,17.4), thus being interposed between them. Further, since securing inner tightness along the composite curing cycle is necessary to ensure that the cycle is performed in proper conditions which prevents defects due to vacuum leakage, such as porosity, the joint interfaces (19.1,1.2) have been provided with flat rubber sealants (18.1) which are interposed between the contact surfaces of both the rectangular projections (16.5,17.5) and the z-shaped body (12B). Apart from the addition of flat rubber sealants (18.1), in order to improve the sealant effect, as well as the stability of the coupling, an encapsulated anchor nut (18.2) along with a sealant ring has been provided at each joint interface (19.1,19.2). FIG.7shows a front view of two different configurations of modular tooling (10) for manufacturing multi-spar torsion boxes (100) with different web heights (z1, z2) according to an embodiment of the present invention. The modular tooling to the left inFIG.7shows one mandrel module (11) coupled to a spacer module (12C). The modular tooling to the right inFIG.7shows the same mandrel module (11) coupled to a bigger spacer module (12C′), thus allowing to produce a higher multi-spar torsion box (100) for a different structure of an aircraft (1000) of the family. In particular, the spacer module (12C,12C′) is provided directly on the mandrel module (11) by an additive layer manufacturing process. More in particular, the modular tooling to the left inFIG.7shows a mandrel module (11) made of aluminum, wherein the two opposed bases (11.1,11.2) and the walls (11.3,11.4) have been completely surrounded by a composite laminate which has been provided directly on the outer surface of the mandrel module (11), thus wrapping said mandrel module (11), by braiding technology. Thus, the length of the walls (11.3,11.4) of the mandrel module (11), along with the thickness of the spacer module (12C) coupled thereto, resulting from the amount of composite material provided on the mandrel module (11), define a total height (z1) corresponding to the web height of a multi-spar torsion box (100) to be manufactured. Regarding the modular tooling shown to the right inFIG.7, additional composite material has been deposited surrounding the mandrel module (11), thus reaching a greater height (z2) which allows producing a higher multi-spar torsion box (100) FIG.8shows modular tooling (10) comprising several configurations of a coupling between a mandrel module (11) and a spacer module (12A), arranged in combination for manufacturing a multi-spar torsion box (100), according to the steps of a method for manufacturing multi-spar torsion boxes (100) with different web heights according to the present invention. In particular, a distance z1has been determined as the web height of a multi-spar torsion box (100) to be manufactured. Then, two mandrel modules (11,11′) have been coupled to respective spacer modules (12A,12A′) tailored for achieving the web height determined (z1), according to the embodiments shown inFIG.3. Later on, the mandrel modules (11,11′) and the spacer modules (12A,12A′) coupled thereto have been provided with composite material distributed according to a C-shape pattern. Then, the two mandrel modules (11,11′) coupled to respective spacer modules (12A,12A′) have been arranged and coordinated among themselves by means of a longitudinal rod with hippodrome shape (24), such that two stringers (23) have been defined by bringing together the walls partially covered with composite material. Further, a first spar (20) has been defined by the composite material provided on one of the walls completely covered with composite material. In a similar manner, two mandrel modules which are each split in two respective mandrel module members (16,17;16′,17′) coupled with each other have been coupled to respective spacer modules (12B,12B′) tailored for achieving the web height determined (z1), according to the embodiments shown inFIG.5. Later on, the mandrel module members (16,17;16′,17′) and the spacer modules (12B,12B′) coupled thereto have been provided with composite material distributed according to a C-shape pattern. Then, the mandrel module members (16,17;16′,17′) coupled to respective spacer modules (12B,12B′) have been arranged and coordinated among themselves by means of a longitudinal rod with rectangular shape (25), such that two stringers (23) have been defined by bringing together the walls partially covered with composite material. Further, a second spar (22) has been defined by the composite material provided on one of the walls completely covered with composite material. Then, the four mandrel modules and respective spacer modules have been further assembled and coordinated among themselves in order to define an intermediate spar (21) by bringing together the other walls completely covered with composite material of each arrangement corresponding to the embodiments ofFIGS.3and5. Then, composite material has been provided on both the upper and lower base of the assembled modular tooling (10) in order to define the upper skin (26) and lower skin (27) of a multi-spar torsion box (100). FIG.9shows an aircraft (1000) comprising a multi-spar torsion box (100) manufactured that embodies the invention. While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority. | 19,201 |
11858230 | Throughout the drawings, identical reference characters and descriptions indicate similar, but not necessarily identical, elements. While the embodiments described herein are susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, the embodiments described herein are not intended to be limited to the particular forms disclosed. Rather, the instant disclosure covers all modifications, equivalents, and alternatives falling within the scope of the appended claims. DETAILED DESCRIPTION The instant disclosure relates generally to high pressure presses and methods of making high pressure presses. In one embodiment, a high pressure press may include a spacer and plurality of tie bars positioned between each pair of adjacent press bases of the high pressure press. In one embodiment, the plurality of tie bars may surround the periphery of the spacer. Furthermore, each tie bar may be in tension while the spacer may be in compression. Such a configuration provides a high pressure press having improved alignment of the bases, while also making the high pressure press easier to manufacture, assemble and repair. For purposes of explaining the features of the high pressure presses disclosed herein, a cubic high pressure press will be described and illustrated. However, the high pressure presses disclosed herein are not limited to a cubic configuration. For example, the features of the high pressure presses disclosed herein may also be used in a tetrahedral press. As shown inFIG.3, a high pressure press100comprises six press bases110configured in a cubic orientation. By cubic orientation it is meant that each press base110is positioned so that its central axis points at, and is perpendicular to, a different face of a cubic reaction cell located about a central region102of high pressure press100during operation. High pressure press100also comprises six pistons120, which may each be housed in a piston cavity114of an associated press base110. While not labeled or viewable inFIG.3, piston cavity114is shown inFIGS.4,5and6. Pistons120may move in and out of press base110towards and away from central region102of high pressure press100. Outward movement of piston120towards the central region102may be accomplished by any suitable mechanism for moving a piston. In one example, the introduction of hydraulic fluid into the bottom (or some other portion) of piston cavity114in press base110forces piston120to move out of piston cavity114and towards central region102. Tooling may be included at the end of piston120closest to central region102. The tooling may include, for example, a flat, square surface that is perpendicular to the axis of motion of piston120and which will press against a side of the cubic reaction cell located at central region102during operation of high pressure press100. When pistons120begin to move in towards central region102and apply pressure against the cubic reaction cell, it is desirable that high pressure press100apply pressure to all sides in equal or substantially equal amounts in order to, among other things, avoid or limit the introduction of stress in various components of high pressure press100. Where pressure is not applied equally on all sides (or where pressure is equally applied, but asymmetric loading or stress is still experienced by the tie rods or bases), the negative effects of such an imbalance (which may include, for example, crack formation and propagation in components of the of press100) may be mitigated or eliminated by adding support structures between press bases110as described in greater detail hereinbelow. The endurance limit, or the ability to handle the application of cyclic stress states without mechanical or material failure, of various components of the high pressure press100(e.g., the press bases110) may be improved substantially by the implementation of the support structure described herein. In the embodiment described with respect toFIG.3, a support structure may include a spacer140extending between each pair of adjacent press bases110and a set of two or more tie bars150extending between each pair of adjacent press bases110. In one embodiment, the spacer may include a structure that exhibits a relatively large diameter or cross-sectional area as compared to the diameter or cross-sectional area of an individual tie bar. For example, in one embodiment, a spacer140may exhibit a diameter of approximately 9 inches and the tie bars may exhibit a diameter of approximately 1.75 inches, although other sizes and size ratios are also contemplated. As shown inFIG.3, tie bars150may be arranged about the periphery of spacer140(i.e., about the periphery of the spacer's cross-section as taken substantially perpendicular to a longitudinal axis of the spacer extending between associated, adjacent press bases110). Tie bars150may be arranged about the periphery of spacer140such that tie bars150are evenly spaced about the periphery of spacer140, although other uneven or geometrically asymmetrical spacing arrangements may also be used. In one embodiment tie bars150may be positioned such that they abut or are contiguous with the spacer140. In another embodiment, tie bars150may be set off from or spaced relative to the spacer140so that a gap exists between the sides of tie bars150and the side of spacer140. Also, as shown inFIG.3, tie bars150may be aligned to be substantially parallel with spacer140as they extend between adjacent press bases110. Spacers140and tie bars150may have any suitable shape for providing stability to high pressure press100. As shown inFIG.3, spacer140and tie bars150may exhibit substantially cylindrical shapes. In one embodiment, all of the tie bars150of a given high pressure press100may exhibit the same or similar geometry. Similarly, in one embodiment, all of the spacers140of a high pressure press100may exhibit the same or similar geometries, whether or not they be generally similar in shape or geometry to tie bars140. In another embodiment, different spacers140of the same high pressure press100may exhibit different shapes, just as different tie bars150of the same high pressure press100may have different shapes. Furthermore, as indicated above, spacers140and tie bars150of the same high pressure press150may have the same shape or different shapes. Referring now toFIGS.4,5and6, the manner of positioning tie bars150and spacer140between adjacent press bases110is described and illustrated. With respect to spacer140, the ends142of spacer140may be positioned to abut an outer side surface112of two adjacent press bases110. Spacers140may be placed under compression as will be described in further detail below. The use of a spacer140placed in compression and having a relatively large cross-sectional area may provide a more reliable joint between associated press bases110than previously used designs that rely heavily on tensioned elements. Positioning spacers140by abutting them against outer side surface112of press bases110provides an advantage over previously known configurations. Particularly, the press bases110may be easier and less costly to manufacture. Referring now toFIGS.5and7, press base110may include a recessed or shouldered surface, referred to herein generally as an indent116(or indentation), on outer side surface112for receiving and aligning spacer140. Indent116may have a shape approximate the cross-sectional shape of spacer110such that indent116receives and aligns spacer140when spacer140is positioned against press base100. In one embodiment, as shown inFIG.7, indent116may include rounded corners117to generally conform to the circular cross-section of spacer140. Of course, as noted previously, the spacer may exhibit other cross-sectional geometries and, therefore, the indent may be configured to accommodate such. As also shown inFIG.7, indent116may also include a straight wall portion118between rounded corners117. Straight wall portion118may be used in conjunction with a notch144located at ends142of spacer140, as shown inFIG.8, to prevent spacer140from rotating within indent116. For example, if indent116and spacer140are both circular (or if indent116is “oversized” compared to the cross-sectional geometry of the spacer140), spacer140may freely rotate within indent116. However, by implementing straight wall portion118and notch144with the spacer140being positioned such that the notch144engages the straight wall portion118, spacer140will not be able to freely rotate in indent116. The above features of the disclosed embodiment may assist in assuring that high pressure press100is properly aligned. Indent116may be formed on outer side surface112of press base110with a desired level of accuracy and precision, thereby ensuring proper alignment of spacers140. As mentioned briefly above, misalignment of press bases110of high pressure press100may be a factor in failure of components of high pressure presses and, therefore, the above features help to reduce the possibility of misalignment. FIGS.4,7and8also illustrate the securement of spacer140to side surface112of press base110.FIG.7shows that an aperture or a first spacer securing pocket119may be formed through a portion of indent116. First spacer securing pocket119may or may not pass all the way through press base110.FIG.8shows that spacer140may likewise include an aperture or a second spacer securing pocket146. First and second spacer securing pockets119,146may be used in conjunction to secure spacer140to press base110. For example, spacer140may be aligned in indent116such that first and second spacer securing pocket119,146are aligned with one another. Then, where first spacer securing pocket119extends through press base110, a bolt or some other alignment or securing mechanism may be inserted into first spacer securing pocket119from the opening opposite the opening in indent116. The bolt or other aligning or securing mechanism may then pass through the opening in indent116and into second spacer securing pocket146of spacer140. In one embodiment, second spacer securing pocket146may, e.g., include female threads to receive male threads of the bolt or other alignment or securing means to thereby allow spacer140to be coupled with press base110.FIG.4illustrates the result of securing spacers140to press base110in accordance with one embodiment. Unlike spacers140that may abut outer side surfaces112of press bases110, the plurality of tie bars150positioned between adjacent press bases110extend into and through a portion of the press bases110and are then put under tension. As shown inFIGS.5-7, tie bars150may extend through press bases110via holes or apertures in press bases110, referred to as tie bar pockets152herein. Tie bar pockets152may extend through press bases110from outer side surface112of press bases110to a tie bar cavity111in press base110as illustrated inFIG.6. Tie bar cavity111may be formed in a surface of press base110that is generally opposite the surface of press base110having piston cavity (not shown) formed therein. Tie bar cavity111in press base110may serve to provide a surface generally perpendicular to the axis of tie bars150as they pass through press bases110. In this manner, a securing means, such as a nut or other fastener, may be tightened against the surface of the tie bar cavity111so as to tension tie bars150after they are in place between adjacent press bases. As shown inFIG.6, tie bar cavity111may provide four such surfaces to accommodate tie bars150passing through press base110from four different directions (i.e., the surfaces lie in planes that are not parallel to one another). Tie bar cavity111of press base110may include more or fewer surfaces depending on the configuration of high pressure press100. The openings of tie bar pockets152at outer side surface112may be arranged about indent116such that when tie bars150and spacer140are positioned between adjacent press bases110, tie bars150are arranged about the periphery of spacer140as discussed above. In one embodiment, and as noted previously, tie bar pockets152may have a shape approximately equal to the cross sectional shape of tie bars150in order to provide a close fit for tie bars150. For example, where tie bars150are cylindrical, tie bar pockets152may have a circular shape with a diameter approximately equal to the outer diameter of tie bars150, but large enough to accommodate passage of the tie bars150therethrough. Tie bars and corresponding tie bar pockets152are relatively small in cross-sectional area as compared to associated spacers140, and their installation through press bases110do not require that large amounts of material be removed from press bases110. Accordingly, the overall strength of each press base110is generally maintained after tie bar pockets152are formed. A plurality of smaller tie bar pockets152is also easier and less expensive to manufacture in press base110than the large diameter spacer pockets used in previously known designs. Moreover, smaller tie bar pockets152may be formed with greater precision and accuracy (as compared to prior art designs), thereby improving the overall alignment of high pressure press100. Tie bars150may be any suitable structure for passing through adjacent press bases110and being placed under tension. In the embodiments illustrated, tie bars150may include bolts having a capped end, the cap being larger than openings of tie bar pockets152, and a threaded end. The threaded end of tie bar150may be first inserted into an opening of a tie bar pocket152in tie bar cavity111of press base110and passed through press base110until the threaded end emanates from outer side surface112of press base110. The threaded end may then be inserted into a corresponding opening of tie bar pocket152in outer side surface112of a press base110located adjacent the first press base110that tie bar150was passed through. The threaded end then emanates from tie bar pocket152in tie bar cavity111of the adjacent press base110. At this point, the capped end of tie bar150may be flush against or otherwise abut the opening of tie bar pocket152in tie bar cavity111of the first press base110(of course, it is noted that washers or other similar components might be installed between the cap and the press base). A nut, or other appropriate fastening device may then be coupled with the threaded end of tie bar150and tightened so as to place the tie bar150in tension (again, it is noted that washers or other components might be installed between the nut and press base). In another embodiment, both ends if the tie bar150may be threaded and nuts or other threaded members may be coupled to each end of the tie bar150. By using relatively small cross-sectional area (e.g., small diameter) tie bars150, the amount of tension experienced by each tie bar150may be closely and accurately controlled. For example, considering the above-described embodiment, the amount of torque applied to each nut of a given tie bar150is significantly more controllable than when larger nuts and tie bars are being used, and therefore the amount of tension applied to each tie bar150may be accurately controlled. However, the tie bars may also be placed in tension by other means. For example, in one embodiment, tie bars150may be hydraulically tensioned within +/−1% of a desired level of tension, as compared to previous designs which only allowed accuracy to within +/−10%. More accurate tensioning of tie bars150may lead to more overall stability of high pressure press100and less fatigue of such components. The plurality of tensioned tie bars150act in conjunction with one another to distribute stress substantially equally amongst the plurality of tie bars150about the periphery of the space140. In distributing stress in a generally uniform manner, any number of tie bars150greater than one may be used between each pair of adjacent press bases110. A greater number of tie bars150allows for a greater distribution of stress, and correspondingly, either less stress per tie bar150or use of tie bars with smaller cross-sectional areas. However, space constraints may limit the number of tie bars110that can be used between a pair of adjacent press bases110. In one example, eleven tie bars150may be positioned between each pair of adjacent press bases110. Tie bars150may be spaced evenly around the periphery of spacer140or may be spaced apart from each other at uneven distances. Referring back toFIG.3, spacer140is illustrated as having a larger cross-sectional area than the cross-sectional area of each tie bar150. A spacer140with a large cross-sectional area allows the cross-sectional area of tie bars150to be smaller without drastically influencing the reliability of the joint. Furthermore, tie bars150having a large length to diameter ratio are less sensitive to bending stresses in general, and therefore add to the overall stability of the joints. The ratio of the cross-sectional area of spacer140(AS) to the sum of the cross-sectional areas of tie bars150(AT), the ratio being hereinafter referred to as AS/AT, has been found to be a value that impacts the effect of a press cycle on the joint between adjacent spacers, and correspondingly, the fatigue life of the components of high pressure press100. In general terms, a higher AS/ATvalue results in less force being applied to tie bars150over the course of a press cycle, and therefore likely prolongs the life of components of high pressure press100due to the application of less stress per cycle.FIG.9illustrates this concept. Multiple high pressure presses according to the disclosed embodiment, having varying AS/ATratios, were subjected to the same press cycle. The graph illustrates the load (or force) experienced by tie bars150during a press cycle and as well as the load (or force) experienced by a spacer140during a press cycle. The “Force” axis is normalized such that represents a magnitude of force applied to the specified components. When the AS/ATratio (indicated inFIG.9as R) was 0.5, the force applied to tie bars150(being pre-loaded in a tensile state) jumped from 100% (i.e., preload condition) to about 150% of preload condition during the press cycle, while the force applied to spacer140(being pre-loaded in a compressive state) dropped from 100% of preload condition to about 75% of preload condition. When the AS/ATwas increased to10, the force applied to tie bars150changed only a relatively tiny amount during the press cycle, while the force applied to spacer140took a significant drop to less than 50% of preload condition. The only minor increase in force applied to tie bars150during the press cycle when the AS/ATratio was 10 will likely result in a longer overall life for the high pressure press, since tie bars150are not undergoing large amounts of stress every cycle that will tend to cause failure in high pressure press components. Accordingly, high pressure press100may preferably have a AS/ATgreater than 0.5, more preferably a AS/ATgreater than 5.0, and most preferably a AS/ATratio greater than 10. It is noted that the above-described embodiment may also be characterized as having a plurality of springs positioned between the press bases110and that the above ratio AS/ATis derived from a stiffness ratio of the tie bars and spacer. Thus, the stiffness ratio, while described as being altered through manipulation of cross-sectional areas in the example above, may be also be manipulated in other ways, such as by altering the materials from which the components are made. Thus, tie bars140may be considered as a plurality of springs in tension with each exhibiting a relatively low spring constant (k). The spacer140may be considered as a spring in compression with a relatively large spring constant. In one embodiment, when the press100is assembled, such as shown inFIG.1, tie bars150may be placed in tension up to, for example, 95% of their elastic limit. On the other hand, the spacer140may be placed in compression at a level of, for example, less than approximately 5% of its elastic limit. During operation of the press100(i.e., when pistons120are actuated and applying pressure to a cubic reaction cell) press bases110may become slightly displaced relative to one another. Under conventional operating conditions, tie bars150will experience additional tension (although not typically exceeding their yield strength) while spacer140may see a reduction in the magnitude of compression, although it may not necessarily experience a zero load (or complete lack of compression loading). Such a configuration enhances the fatigue life of the press100including components such as press bases110, spacers140and tie bars150. In addition to improved fatigue life, the above described embodiment provides a variety of other advantages. For example, repair work is easily facilitated with such a configuration. If a component were to fail, for example, due to overloading or fatigue, the above described embodiment is configured such that the most likely component to show failure would be the tie bars150. Tie bars150are easily replaced as is apparent from the discussions above. Additionally, tie bars150are one of the less expensive and less difficult components of the press100to manufacture. Moreover, the above-described embodiment retains a relatively “open” configuration to provide ready access to the cubic reaction cell during intended operation of the press100as well as to provide access to the pistons120and related components for both routine and unexpected maintenance or repair. In another embodiment of the instant disclosure, a method of manufacturing a high pressure press may include positioning a first end of one or more spacers at a first press base, positioning a second press base at a second end of at least one of the spacers, coupling two or more tie bars with each of the first press base and the second press base, and tensioning the two or more tie bars extending between the first press base and the second press base. Additionally, the method may include placing the spacer in a compressive stress state. FIG.10illustrates a first act of the method. Press base210ais illustrated as having first ends of one or more spacers240apositioned at desired locations relative to the press base. In the embodiment shown inFIG.10, four spacers210aare positioned on press base210a.However, the number of spacers240apositioned on or about the press base210ais not so limited.FIG.10also shows spacers240aequally spaced about press base210a,although spacers240aneed not be equally spaced. As described previously, spacers240may be positioned relative to press base210aby having a first end of spacer240aabut outside side surface212of press base210a.Alignment of spacer240aon press base210amay be guided by an indentation, recess or shouldered surface in outside side surface212of press base210aas described in greater detail previously. Furthermore, to hold spacer240ain position on outside side surface212of press base210a,spacer240aand press base210amay include spacer securing pockets. A spacer securing pocket in spacer240amay be aligned with a spacer securing pocket in press base210a,followed by inserting an alignment structure or a securing structure or mechanism into both spacer securing pockets as described in greater detail above. Following positioning of spacers240aon press base210a,additional press bases210bmay be positioned relative to a second end of at least one of spacers240a.As shown inFIG.11, additional press bases210bare positioned on two of spacers240a.As with press base210a,press bases210bmay be aligned with spacers240avia indentations, recesses or shouldered surfaces located on outside side surfaces of press bases210b.Additionally, press bases210bmay be secured to spacers240aby aligning spacer securing pockets in each component and extending a securing structure or mechanism, such as a bolt, into both press bases210band spacers240a. Press bases210bas shown inFIG.11only have spacers240apositioned relative thereto. However, as shown inFIG.12, press bases210cmay have spacers240cpositioned thereon prior to being positioned on spacers240a.For example, after positioning press bases210brelative to spacers240a,press bases210cas shown inFIG.12may then be positioned relative to press bases210band210a.The result is illustrated inFIG.13, wherein spacers240care positioned between press bases210band210cto form a ring-like structure. Positioning of spacers240cbetween press bases210band210cmay be accomplished as described above, such as by using indentations in press bases210band210cfor alignment and spacer securing pockets and securing means to secure spacers240cto press bases210band210c.It should also be noted that spacers240aand240cshown inFIG.13will be placed under compression as with other spacers described herein. In order to complete the basic frame of the high pressure press, a press base210d,which is identical to press base210aillustrated inFIG.10, may be positioned at the top of the high pressure press (referring to the orientation shown inFIGS.10-14) as shown inFIG.14. Press base210dincludes one or more spacers240dwhich have been positioned relative to press base210d,and possibly coupled thereto, prior to positioning press base210don the partially completed high pressure press frame. Spacers240dmay be positioned relative to press base210dby using indentations on press base210dand by using spacer securing pockets and securing mechanisms as described above. Upon completion of the basic frame of the high pressure press as shown inFIG.14, tie bars may be positioned between adjacent press bases as described in greater detail above. For example, press bases210a,210b,210c,and210dmay each include tie bar cavities and tie bar pockets to enable tie bars to be coupled with adjacent press bases and placed under tension. Tensioning of tie bars may be accomplished by any suitable means. In one example, the tie bars are bolts having a capped end and a threaded end, and are tensioned by twisting a nut on to the threaded end of the tie bars to a specified level of torque. In another embodiment, the tie bars may include bolts that are placed in tension with a hydraulic pulling assembly and subsequently released after installation of a nut or other fastening component. The method may include an additional act of tensioning the tie bars according to a predetermined order. For example, one tie bar (or another specified number of tie bars) between each adjacent pair of press bases may be tensioned before a additional tie bars between any adjacent pair of press bases may be tensioned. Alternatively, all of the tie bars between one adjacent pair of press bases may be tensioned before any other tie bars are tensioned. Additionally, the order of tensioning the tie bars about the periphery of a spacer may be prescribed. For example, the tie bars may be tensioned in a “star pattern” or some in some other predetermined pattern or order. Referring briefly toFIG.15, a press100′ is shown in accordance with another embodiment of the present invention. The press100′ is similar to that which has been describe above with respect, for example, toFIG.3and may include six press bases110configured in a cubic orientation with each press base110is positioned so that its central axis points at, and is perpendicular to, a different face of a cubic reaction cell located about a central region102of high pressure press100during operation. Press100also comprises six pistons120, which may each be housed in a piston cavity114of an associated press base110and configured such has been described hereinabove. In the embodiment described with respect toFIG.15, a support structure may include a spacer140′ extending between each pair of adjacent press bases110and a set of two or more tie bars150extending between each pair of adjacent press bases110. Spacer140′ may be configured as a generally tubular member, or as a body with a cavity extending therethrough. Tie bars150may be arranged about the internal periphery of spacer140(i.e., within the cavity) such that tie bars150are evenly spaced thereabout, although other uneven or geometrically asymmetrical spacing arrangements may also be used. In one embodiment tie bars150may be positioned such that they abut or are contiguous with the spacer140′. In another embodiment, tie bars150may be set off from or spaced relative to the spacer140′ so that a gap exists between the sides of tie bars150and the internal periphery of spacer140′. Also, tie bars150may be aligned to be substantially parallel with an internal surface of the spacer140as they extend between adjacent press bases110. It is noted that other components may be used in place of those shown and described regarding, for example, the spacers and tie bars. For example, tie bars may include any of a variety of tensile elements including, for example, cables or other structures relatively strong in tension. While certain embodiments and details have been included herein for purposes of illustrating aspects of the instant disclosure, it will be apparent to those skilled in the art that various changes in systems, apparatus, and methods disclosed herein may be made without departing from the scope of the instant disclosure, which is defined, in part, in the appended claims. The words “including” and “having,” as used herein including the claims, shall have the same meaning as the word “comprising.” | 29,561 |
11858231 | Further aspects of the invention will become apparent from the following description of the invention which is given by way of example only of particular embodiments. BEST MODES FOR CARRYING OUT THE INVENTION FIG.1shows a carton lidding and stacking apparatus1according to an embodiment of the present invention. The apparatus prepares stacks of cartons, or boxes, with are lidded ready for palletisation. The apparatus1provides a carton lidding and stacking station in a packhouse apparatus. In this embodiment the cartons have lid panels2that are configurable in an open configuration with lid panels extending from respective walls and a closed configuration in which the lids are held in a position covering an opening in the cartons. The lid panels are secured in the closed configuration by tabs3formed on the on the top edge of a side wall of the carton. When the lid panels are in the closed configuration the tabs are received in slots formed in the lid panels. By this action the lid panels engage the tabs to secure the lid panels in the closed configuration. In this embodiment the tabs extend through and beyond the lid panels. In this embodiment the carton has slots in its base that interlock with tabs on another carton when the cartons are stacked vertically to secure the cartons in alignment. In this embodiment the slots are defined in the base of side walls of the carton. The apparatus is able to receive cartons singularly into the lidding station4. The lidding device is able to hold the carton so that the slots on the lid flaps align with the tabs on the carton top edge. In this embodiment the lidding device has slotted rollers able to roll across the lid flaps to press the slots formed in the lid flap onto the tabs on the carton top edge to engage the tabs. The lidding and stacking station inFIG.1has a carton lifter, or pusher,5which is able to lift the lidded carton7vertically above the lidding station past carton holding ledges6mounted on a chassis of the stacking device. In this embodiment the carton holding ledges6move out of the way as the carton moves upwards allowing the carton to pass by. The ledges then move back into the holding position so that the carton7is supported in a position8above the lidding station as the carton lifter5moves downwards. In this embodiment a subsequent carton9is lidded in the lidding station4and then moved vertically by the carton lifter5. As the subsequent carton9is lifted, the tabs on the top of the carton align with slots in the base of the waiting carton7. The cartons are locked together and as carton9is lifted and pushes on the underside of carton7moving both cartons upwards until the base of carton9is past the carton holding ledges6. At the end of this step there are two cartons stacked together in the stacking apparatus with carton9now being in position8above the lidding station. In this embodiment a printer10is mounted on the end of the apparatus. The printer is able to print and apply a printed label to an end of each carton as the carton is moved into position8. This label may be in the form of a barcode and may have unique information used in the subsequent supply chain of the packaged carton. A conveyor11is shown inFIG.1. The conveyor11is able to receive stacks of cartons from the lidding and stacking apparatus. The stacking apparatus is able to release stacks of cartons to the conveyor. In this embodiment the number of cartons in each stack is determined by stored data or determined by control operations of a machine operator. When the appropriate number of cartons have been stacked and have had the printed label applied the carton lifter5is able to hold the stack of cartons while the carton holding ledges6are moved out of the way. The carton lifter is then able to move downwards with the carton stack depositing the stack onto the conveyor11. The stack of cartons can then be moved out of the apparatus and onto the conveyor11. FIG.2shows a process according to another, preferred embodiment of the present invention for providing a stack of closed cartons. At step S1-1an open carton which contains items which have been packed is supplied to a lidding device. At step S1-2the carton is held firmly by fixtures of the lidding device while the lid panels are closed. The lid panels are closed by being folded inwards and pressed down until slots defined in the lid panels receive and engage with tabs defined on the top of walls of the carton. At step S1-3the carton is lifted into a holding position above the lidding station. Movable ledges are translated inwards to hold the carton above the lidding station. At step S1-4a printer prints and applies a label to the carton. Step S1-4may be omitted in some embodiments. The steps S1-1to1-4are repeated for subsequent cartons. As each carton is lifted into the holding position, tabs on the top of the carton are pushed into slots in the base of the carton above. Each carton pushes on the base of the carton above so that all cartons in the stack are pushed upwards with the bottom carton coming to rest in the holding position provided by holding ledges. At step S1-5the last carton in the stack completes steps S1-1to S1-4. When step S1-4is complete the movable ledges retract, and the stack of cartons is released onto a conveyor. At step S1-6the stack of cartons is conveyed away from the lidding station. FIGS.3to6show another embodiment of the lidding and stacking apparatus. FIG.3shows a box lidding device101which forms part of a lidding and stacking apparatus similar to that ofFIG.1. Shown inFIG.3is a carton102to be lidded or closed. The carton has a carton opening103into which contents have been received at another packhouse station. The carton opening103is defined by side walls104and end walls105aand105b. Extending from the end walls105aand105bare lid panels106aand106b. In this embodiment the lid panels106are connected to respective walls by foldable joins (not shown) which allow the lid panels106to be folded to cover the carton opening103and provide a closure for the carton102. The carton102has closure tabs107aand107bwhich extend upwards, as shown, from the side walls104. As shown, the tabs extend by a distance from the remaining edge of the wall104that is greater than the thickness of the lid panels106. The lid panels105of this embodiment have closure slots (not shown) which receive and engage the closure tabs107to hold the lid panels in a closed position, or folded configuration, over the box opening103. The lidding device101has closure elements108aand108bwhich are operable to move over the box opening. This movement is transverse to the end walls105. In this embodiment the closure elements move above the walls104and105with a clearance that is approximately the thickness of the lid panels106. The thickness of the lid panels in this embodiment is less than the height of the closure tabs and the clearance between the closure element108aand the wall104is less than the distance of the top of the tabs107, as shown, and the top of the wall104. In this embodiment the closure elements108are rollers109mounted on axles110which are mounted on movable arms111. In this embodiment the box has two lid panels and the device101has a corresponding two closure elements108aand108b. In this embodiment the rollers109have tab-clearance slots (not shown) which admit the tabs107to allow the rollers to pass over the tabs. The same action assists in pushing the closure slots (not shown) formed in the lid panels into firm engagement with the closure tabs107.FIG.3shows the lid panels105in an unfolded or open configuration. FIG.4shows the lidding device folding the lid panels106into a folded configuration.FIG.4shows the closure tabs107extending partially through the closure slots (not shown) formed in the lid panels105. The closure arms111have moved transversely to the walls105and inwards towards each other to positions partially towards meeting each other over the box opening. The closure elements110have folded the lid panels in a configuration partially over the box opening103. The lid panels105can be secured in the folded configuration to cover the box opening by engagement of the closure slots (not shown) and closure tabs107. FIG.4shows the rollers109of the closure elements108just clearing or rolling over the walls105. FIG.5shows the closure arms111having moved further towards each other over the box opening. The closure rollers109have been moved past the closure tabs107to force the tabs107through the closure slots (not shown) in the lid panels. As shown inFIG.5the closure tabs107extend through and beyond the lid panels105. FIGS.3,4and5show the box held by fixtures112. In this embodiment the fixtures have a cross-section which forms corner matching outside, lower edges of a carton102. FIG.6shows a stacking device121of a preferred embodiment of the present invention. As shown a carton102is held in place by fixtures112. In this embodiment the fixtures112are the fixtures of the lidding device101ofFIGS.3,4and5. In this embodiment the lidding device101and stacking device121are at a common lidding and stacking station of a packhouse apparatus. FIG.6also shows a second carton122supported by supports123above the first carton102. The supports123are movable at a pivot connection (not shown) to a chassis (not shown). The supports are also or able to be withdrawn to release a stack of cartons downwards. In this embodiment the carton122is formed using the same blank pattern as carton102. In this embodiment the cartons102and122have slots defined in the walls at the base of each carton to receive closure tabs107of a carton below. FIG.6shows a third carton124staked on the second carton122in a similar manner to how the second carton will be stacked on top of the first carton102. FIG.6shows two lifting elements, or pushing elements,125aand125b. InFIG.6the lifting elements125are shown in a retracted configuration below the carton102. Also shown inFIG.6is an aperture defined by the fixture112to allow the pushing elements to extend past the fixtures112to push the carton102upwards as shown inFIG.6. FIG.7shows the pushing elements125extending past the fixtures112and to a partially extended configuration in which the first carton102has been moved into contact with the second carton122. The closure tabs107of the first carton102have engaged slots (not shown) in the base of the second carton122to secure the second carton122against movement lateral and relative to the first carton102. As shown inFIG.7the supports123are in a pivoted position which allows the first carton102to be pushed past the supports123. The supports123are able to pivot upwards but not downwards when in a non-return configuration to allow cartons to move upwards past the supports but not return downwards. The supports are able to remain in an upward pivoted position when in a release configuration to allow cartons to move downward past the supports to release the cartons. FIG.8shows the pushing elements125in a partially retracted configuration after a fully extended configuration which has pushed the carton102entirely past the supports123. As shown inFIG.7the supports123are in their original configuration which provides levers to support carton102with carton122stacked upon carton102. Further and additional embodiments of the invention are illustrated below. In various embodiments a lid panel is formed as a flap of a carton. In one example the lid panel is formed as a flap of wall on a blank for the carton. In alternative embodiments the fixtures are arranged to define a space with is not necessarily an aperture. In one example, the fixtures are provided on posts arranged about a space for a lifting or pushing element. In further embodiments a rolling element or a folding element are moved over the carton but between the tabs. This may allow the folding element to fold the lid to a level which is below an extremity of the respective tab to force the slot of a lid over a tab such that the tab is received in the slot of a respective lid. In further embodiments the folding element may include a rod adapted to slide over the lid. In various embodiments the folding element is a closing element. In various embodiments one or more lid panels are configurable into a closed configuration in which they provide a closure for the carton. In various embodiments the lid panels are folded into a position in which they provide a closure for the carton. In various embodiments a movable support is formed of a lever which is able to pivot upwards to allow a carton to pass when pushed upwards past the lever and pivot downwards to support the carton as it returns downwards from a position past the lever. The lever may lock against a downward force provided by the carton and the reader may recognised the lever as a locking lever. The movable support may provide a non-return function to prevent cartons pushed upwards from returning downwards. In the embodiment ofFIG.1the printer10prints a label for each carton and the label is applied to the carton end. The printer is connected to a central processor which provides information to be printed onto the label and records details about what has been printed. In further embodiments the printer prints directly onto the carton end. In alternative embodiments the lidding device and stacking device do not share fixtures. In alternative embodiments the stacking device may have fewer than two pushing elements. In other embodiments the stacking device may have more than two pushing elements. The reader may recognise a pushing element as a lifting element in various applications. In alternative embodiments the clearance tolerance may be less than the thickness of the lid panels, so the panels are compressed while the closure elements move over them. In some embodiments a tab is formed as a flange on a wall of a carton. In alternative embodiments a single lid panel is folded over an open end of the carton to provide a closure for the panel. In alternative embodiments a lid panel has a single slot formed therein to engage with a single tab. In alternative embodiments a carton has a single slot formed in it's base to receive a single tab of another carton. Alternative embodiments may have any number of lifting or pushing elements known to the reader, and may specifically have one integrated pushing element. In further embodiments the printer is replaced with a RFID encoder device which writes data to an RFID tag that is applied to the carton. In further embodiments the printer is replaced with a reader device linked to a central processor. The reader device may be an optical reader, barcode reader, RFID reader or other similar device. The reader is used to scan the information that has been applied to the carton prior to its delivery to the lidding station. In further embodiments the printer or reader may not be required. In further embodiments the packhouse apparatus has fixtures, folding elements and pushing elements to handle two or more boxes substantially simultaneously. In alternative embodiments holding ledges, movable supports or locking levers are mounted on a wall of the apparatus. In various embodiments supports are configurable between a non-return configuration in which they allow a carton to move past the supports in one direction but not to return in the opposite direction and a release configuration in which the cartons are able to return in said opposite direction to release the cartons, typically, downward. Various embodiments are implemented using a controller operable to control the apparatus to perform the steps and operations of the embodiments described and illustrated above. Various embodiments have a controller known by the reader to be suitable for given applications and may include programmable logic arrays, microcontrollers, microprocessors, computers, computer services or software services. Various embodiments of the invention are implemented using software stored on a computer readable medium to define the processes or operations of various embodiments described and illustrated above. Various embodiments of the invention are implemented using a computer running executable code defining the processes or operations of various embodiments described and illustrated above. As used herein the term “a” is used in an inclusive sense to specify the presence of the stated feature or features and is not intended to exclude “another” of the features or features. As used herein the term “closure” may be a noun for a panel, flap or other element used to close a carton, such as by covering an opening or a portion of an opening for example. In the preceding description and the following claims, the word “comprise” or equivalent variations thereof is used in an inclusive sense to specify the presence of the stated feature or features. This term does not preclude the presence or addition of further features in various embodiments. As used herein the term ‘operable’ is used broadly to refer to being able to perform a given function, movement, operation, motion or role. Herein individual examples of similar components may be referenced using a and b, but for succinctness a reference to a plurality of the components may omit the a or b and reference the components by the number only. It is to be understood that the present invention is not limited to the embodiments described herein and further and additional embodiments within the spirit and scope of the invention will be apparent to the skilled reader from the examples illustrated with reference to the drawings. In particular, the invention may reside in any combination of features described herein, or may reside in alternative embodiments or combinations of these features with known equivalents to given features. Modifications and variations of the example embodiments of the invention discussed above will be apparent to those skilled in the art and may be made without departure of the scope of the invention as defined in the appended claims. | 18,133 |
11858232 | DETAILED DESCRIPTION In the present description, certain specific details are set forth in order to provide a thorough understanding of various embodiments of the disclosure. However, upon reviewing this disclosure one skilled in the art will understand that the various embodiments disclosed herein may be practiced without many of these details. In other instances, some well-known structures and materials of construction have not been described in detail to avoid unnecessarily obscuring the descriptions of the embodiments of the disclosure. In the present disclosure, to the extent the terms “about” and “approximately,” are used, they mean±20% of the indicated range, value, or structure, unless otherwise indicated. In the present description, the terms “a” and “an” as used herein refer to “one or more” of the enumerated components. The use of the alternative (e.g., “or”) should be understood to mean either one, both, or any combination thereof of the alternatives. As used herein, the terms “include” and “comprise” are used synonymously, and these terms and their variants are intended to be construed as non-limiting. The definitions in this paragraph are intended to apply throughout this disclosure unless otherwise expressly stated. In some embodiments of the present disclosure, a dunnage machine is provided that includes modules that can easily be assembled together, as well as disassembled, even by a single individual. Each of the module can be individually fabricated, repaired, tested, assembled, and “connected” to other modules of the dunnage machine. FIG.1illustrates a perspective view of internal assembly10of a dunnage machine that includes modules that can be easily assembled together. For illustrative purposes, the internal assembly10is shown without external housing (seeFIGS.10A &10B, which illustrates the corresponding dunnage machine with external housing). The internal assembly10includes an internal mounting frame module20, a power supply electronic box (“E-box”) module30, a gear and motor module40, a cutter module50, and an expander module60. In various embodiments, each of these modules may be easily connected together when the internal assembly10is being assembled, either initially, or for parts replacement. When the internal assembly10needs to be repaired or parts need to be replaced, the internal assembly10may be disassembled by, for example, disconnecting (e.g., unscrewing various screws) and pulling apart the various modules as needed. The internal assembly10includes a rear section12, which is the rear of the internal assembly10facing a direction from which sheet material may be fed into the internal assembly10via the expander forming module60. Opposite from the rear section12is a forward (or front) section14facing a direction in which cushioning material may be outputted from the internal assembly10through cutter module50. Note that the internal mounting frame module, E-box module, expander module, gear and motor module, and cutter module, each may be described as having a rear section12and a forward (or front) section14. Note that for ease of illustration and explanation, various relative spatial terms such as “longitudinal,” “lateral,” “vertical,” “top,” and “bottom” may be used in the following description. Unless the context expressly indicates otherwise, the term “longitudinal” as used herein refers to an axis running generally parallel to the line that forms arrow “Z” inFIG.1. Thus, a sheet material may be initially fed and processed through the internal assembly10along a longitudinal path (e.g., having a component of travel in a direction parallel with arrow “Z”). Unless the context expressly indicates otherwise, the term “lateral” as used herein refers to an axis that is parallel to the line that forms arrow “X” and that runs generally horizontal and perpendicular to the longitudinal axis ofFIG.1. In contrast, unless the context expressly indicates otherwise, “vertical” as used herein can refer to an axis that is parallel to the line that forms arrow “Y” and that runs generally vertically perpendicular to both the longitudinal axis and the lateral axis, relative to the internally assembly10as illustrated inFIG.1. The internal assembly10illustrated inFIG.1is depicted in an upright orientation (e.g., the orientation of the internal assembly10when the internal assembly10is operational). Thus, the terms “top” and “bottom” to be used herein will be respect to the specific orientations of the various components of the internal assembly10as illustrated inFIG.1. FIG.2Ashows the internal mounting frame module20in stand-alone state, and also illustrates generally a sliding direction for the E-box module30ofFIG.1to be connected to the internal mounting frame module20ofFIG.1. In particular, for example, when the internal assembly10ofFIG.1is being assembled, the E-box module30may be slid into the internal mounting frame module30as illustrated inFIG.2A, between the internal mounting frame module's upper longitudinal parallel frame members22a&22b, and lower longitudinal parallel frame members24a&24b, and between its front vertical parallel frame members26a&26band rear vertical parallel frame members28a&28b. In various embodiments, the internal mounting frame module20may be the supporting structure for the other modules described herein. Once the E-box module30has been slidably inserted within (e.g., mounted to) the internal mounting frame module20, the E-box module30may be securely connected to the internal mounting frame module20by fastening members (e.g., screws)202.FIG.2Billustrates the E-box module30and the internal mounting frame module20when the E-box module30has been successfully mounted to the internal mounting frame module20, with fastening members202having been inserted through aperture tabs202aon the E-Box, and into fastening receivers20aon the internal mounting frame20. The E-box module30may include various electronics for controlling and/or for providing power to various motors (e.g., electric motors for the cutter module50and the gear and motor module40) that may be included in the internal assembly10. The electronic components of the E-box module30may be covered and protected by an external housing of the E-box module30. FIG.3Asubstantially mirrorsFIG.2Band shows portions of a substantially similar E-Box module30and internal mounting frame module20, such as depicted inFIGS.2A and2B. Moreover, referring toFIG.3B, when the E-box module30is fully inserted into the internal mounting frame module20, after having been slid into the internal mounting frame module20from its right side to its left side, a left side portion30aof the E-box module30can abut against attachment tabs302, located on a left side of the internal mount frame module20. The attachment tabs302can each include an aperture308that aligns with a corresponding aperture306on the E-box module, and thereafter, fastening members (e.g., pins or screws)304can be inserted through the respective apertures,306,308, to further securely connect the E-box module to the internal mounting frame module30, as will be appreciated by those skilled in the art after reviewing the present disclosure. Referring toFIG.4A, the gear and motor module40may be connected to the internal mounting frame module20according to various embodiments. In some embodiments, the gear and motor module40may be connected to the internal mounting frame module20by mounting (e.g., lifting and setting down) the gear and motor module40onto the front section14of the internal mounting frame module20(see alsoFIG.5B). In particular, the gear and motor module40may be placed onto and between two mounting fins410of the internal mounting frame module20. The two mounting fins410may be formed or disposed on a top portion of the internal mounting frame module20and on the front section14of the internal mounting frame module20. The two mounting fins410each have a top end and a bottom end that is opposite of the top end, the bottom ends of the two mounting fins410being attached to, or formed on, respective upper parallel longitudinal frame members22a,22bof the internal mounting frame module20, projecting upwards therefrom. In some embodiments, one or more cables404may hang from the bottom of the gear and motor module40for controlling and/or providing electric power to the gear and motor module40. Once the gear and motor module40is mounted to the internal mounting frame module20, as illustrated inFIG.4B, the gear and motor module40may be secured to the internal mounting frame module20with fastening members (e.g., screws)402, that may be threaded (or otherwise connected) through respective aligned apertures506,508(seeFIG.5B) disposed in mounting fins410of the internal mounting frame module20and the gear and motor module40. As illustrated inFIG.4B, a cable404may be plugged into, or connected to, the E-box module30 In various embodiments, the gear and motor module40may be configured to pull sheet material that is fed into and passes through the expander module60. In various embodiments, the gear and motor module40may further be designed to compress, or stitch, at least a portion (e.g., a longitudinal portion or strip) of sheet material outputted by the expander forming module60, as will be appreciated by those skilled in the art after reviewing this disclosure. FIG.5Asubstantially mirrorsFIG.4B, including illustrating a boundary of the enlarged region depicted inFIG.5B. Referring toFIG.5B, the gear and motor module40can include a pair of opposite mounting sidewalls510, defining outer left and outer right perimeter portions of the gear and motor module40, except for holding studs502which extend laterally further than the opposite mounting sidewalls510, with each mounting sidewall510having a laterally outwardly protruding holding stud502. Also, a corresponding holding notch504may be provided at a top portion of each mounting fin410of the internal mounting frame module20. The opposite mounting sidewalls510can be configured such that the gear and motor module40can be partially inserted between the mounting fins410with at least a portion of the mounting sidewalls510being aligned laterally inward of the mounting fins410. In some embodiments, opposite inward faces of the mounting fins410may be spaced apart by approximately 6 inches to 20 inches, which may also approximate a lateral width of the internal frame module in some embodiments of the present disclosure. In some embodiments, a clearance between outer faces of the opposite mounting sidewalls and each corresponding mounting fin410may be about 0.01 cm to 1 cm. Moreover, the holding studs502can be formed, or attached, near a top portion of the mounting sidewalls510. As such, in some embodiments, a user can lift the gear and motor module40onto the mounting fins410and deposit the holding studs502of the gear and motor module40into the corresponding holding notches504of the internal mounting frame module20to mount the entire gear and motor module40in position aligned with the mounting fins410of the internal mounting frame module20. In some embodiments, once the holding studs502are deposited into holding notches504, the gear and motor module40can hang on the holding notches504, and a rear portion40aof the gear and motor module40, below the holding studs502, can abut against an upper front lateral frame member27aof the internal mounting frame module40. See, e.g.,FIG.4A. In some embodiments, this can “stop” the gear and motor module40from pivoting rearward about the holding studs502past the lateral frame member27aas it “hangs” in the holding notches504, since the holding studs502may be positioned rearward of a center-of-mass of the gear and motor module40. Similarly, in some embodiments, disposed just below each holding stud502of each mounting sidewall510is a corresponding fastening member aperture508that aligns with a corresponding aperture506of the mounting fins410when the holding stud502is deposited/sits in the holding notch504, and a rear portion40aof the gear and motor module40abuts against the internal mounting frame40(e.g., a lateral frame member27athereof). When corresponding apertures508,506are aligned a fastening member402(e.g., screw) may be threaded, or otherwise coupled, through the apertures to securely connect the gear and motor module40to the internal mounting frame module30. The holding notch504and the holding stud502described above may prove to be particularly useful when, for example, only a single individual is securing the gear and motor module40onto the internal mounting frame module20, or removing the gear and motor module40therefrom. That is, the gear and motor module40, which may include a motor for driving the various mechanical components (e.g., gears and forming members) of the gear and motor module40, may be relatively heavy. However, by simply depositing the holding studs502of the gear and motor module40into the holding notches504of the internal mounting frame module20, a single individual user may hang the gear and motor module40before adjusting (inserting) the fastening members402to connect the gear and motor module40to the internal mounting frame module20, and conversely, when the user is removing the gear and motor module40, the fastening members402may be removed completely before handling the heavy module (e.g., lifting it from its hanging position on the holding notches504), as will be appreciated by those skilled in the art after reviewing the present disclosure. Referring toFIG.6A, a cutter module50may be connected to other portions of the internal assembly10, such as, for example, by attaching it to the gear and motor module40, according to various embodiments. As will be appreciated by those skilled in the art after reviewing the present disclosure, the cutter module50may be provided to automatically cut cushioning material (e.g. crumpled sheet material, or dunnage) outputted by the gear and motor module40to form discrete strips of dunnage. In some embodiments, the cutter module50may include one or more cutting components such as one or more blades (not explicitly shown), a motor602, and one or more cables604for providing control and/or power to the motor602. When the cutter module50is successfully mounted to a front section14of the gear and motor module40, two or more fastening members (e.g., screws)606may be used to securely connect the cutter module50to the gear and motor module40. When the cutter module50is connected to the gear and motor module40, the one or more cables604may be plugged or connected to the E-box30as illustrated inFIG.6B. FIG.7Asubstantially mirrorsFIG.6Band includes an indication of a boundary region circle showing the location of the enlarged views inFIG.7B. Referring toFIGS.6A and7B, when a rear face50aof the cutter module50is mated with a front section14of the gear and motor module40, it can be mated above left and right side stopping studs704on the gear and motor module40, and then slid downward until it abuts against the stopping studs704, each stopping stud704protruding rearwardly from the front section14of the gear and motor module40. In particular, at the bottom portion of the front section14of the gear and motor module40are at least two protruding stopping studs704(one of which is shown inFIG.7B). Conversely, at a bottom portion of the rear face50a(seeFIGS.6A and7B) of the cutter module50are left and right holding notches702, configured to rest on the stopping studs704when the cutter module50is aligned with the gear and motor module40for connection. Once the left and right holding notches702are resting on the left and right stopping studs704, the mounted cutter module50may be securely connected to the gear and motor module40using fastening members (e.g., screws)606, as will be appreciated by those skilled in the art after reviewing this disclosure. In various embodiments, the holding notches702of the cutter module50and the stopping studs704of the gear and motor module40may be particularly useful for mounting and securing the cutter module50to the gear and motor module40. In particular, the holding notches702and the stopping studs704may be used to properly align the cutter module50with the gear and motor module40so that the fastening members606used to secure the cutter module50to the gear and motor module40may be aligned with corresponding holes (606′,606″) disposed on the cutter module50and the gear and motor module40. Moreover, in some embodiments, after a user aligns the cutter module50with the gear and motor module40, and rests the holding notches702on the stopping studs704, the cutter module50can rest in alignment (be mounted) without a user holding the cutter module50against the gear and motor module40, and the user's hands may be free to apply the fastening members606to secure the cutter module50. Alternatively, the user can use a single hand to press the cutter module50against the gear and motor module40with the modules aligned, and then apply the fastening members606. Referring toFIGS.8A and8B, in some embodiments, the expander module60may be mounted onto the internal mounting frame module20before being securely connected thereto. Once the expander module is mounted, it can be securely connected to the internal mounting frame module20with fastening members (e.g., screws)802.FIG.8Billustrates the internal assembly10for some embodiments after the expander module60has been mounted onto to the internal mounting frame module20and secured thereto. In some embodiments, the internal mounting frame module20may include a roller804with left side and right side end portions rotatably coupled to respective opposite sides of a roller mount806. The roller804and the roller mount806can be located at the rear section12of the internal mounting frame module20, such that sheet stock material is guided by the roller804into the expander module60, as will be appreciated by those skilled in the art after reviewing this disclosure. In various embodiments, the expander module60has a rear section12and front section14and an opening provided therethrough for receiving sheet stock material for expanding the sheet stock material in the expander module60before the sheet stock material is pulled through the gears in the gear and motor module40, as will be appreciated by those skilled in the art after reviewing this disclosure. In some embodiments, the expander module includes a rear section base plate808, forming a bottom wall leading to a feed entrance of the expander module60. FIG.9AmirrorsFIG.8Bexcept further including a boundary region marked by a circle indicating a region shown in enlarged view inFIG.9B. As previously indicated the internal mounting frame module20includes a roller804that is coupled to a roller mount806. Disposed on the roller mount806are one or more holding tabs810extending forward from the roller mount806. In some embodiments, in order to mount and secure the expander module60to the internal mounting frame module20, a portion of the bottom base plate808of the internal mounting frame module20may be slid in the direction of arrow “9” to a location under the one or more holding tabs810as illustrated in the right-side drawing inFIG.9B. In some embodiments, a mounting configuration between the holding tabs810and base plate808when the expander module60is placed atop the internal mounting frame20(as shown inFIG.9A) is such that, the expander module60can be slid forward so that the base plate808fits snugly beneath the holding tabs810, with at least some pressured exerted between contact faces between the base plate808and holding tabs810. Thereafter, fastening members802can be applied to secure the expander module60to the internal mounting frame20, as will be appreciated by those skilled in the art after reviewing the present disclosure. FIG.10Aillustrates examples of how a front housing1002and a top cover housing1004may be placed onto the internal assembly10ofFIGS.1and8B. The front housing1002and the top cover housing1004may be secured to the internal assembly10with fastening members (e.g., screws)1006.FIG.10Billustrates an assembled dunnage machine1010according to some embodiments. FIGS.1,2A,2B,3A,3B,4A,4B,5A,5B,6A,6B,7A,7B,8A,8B,9A,9B,10A, and10B, and the above discussion related to the figures are directed to the assembly of a dunnage machine1010illustrated inFIG.10B. However, one of ordinary skill in the relevant art will recognize after reviewing the present disclosure that the assembly process described above may be used as a basis for disassembling the dunnage system1010ofFIG.10Bby, for example, reversing the operations described above. As noted previously, an example advantage to providing the mounting structures such as, for example, the holding notches, holding studs, stopping studs, holding tabs, in addition to fastening members (e.g., screws), is that during assembly, a module when applicable can be mounted and stabilized so that a user conducting the assembly or disassembly alone, may have both hands free even before fastening members are secured, or after fastening members are removed, without the modules misaligning or otherwise, falling away. This can be particularly useful when the modules (e.g., gear and motor module40) are relatively heavy. Turning now toFIG.11, a process1100is illustrated for assembling an internal assembly10of a dunnage machine with modular components according to some embodiments. In some cases, the process1100may be implemented using the modules described herein and may begin at1102when an E-box module30is mounted (inserted/slid) into an interior space of the internal mounting frame module30. At1104a gear and motor module40is mounted to the internal mounting frame module20. In some embodiments, this may be accomplished by hanging the gear and motor module40onto the mounting fins410of the internal mounting frame module20. At1106, a cutter module50is attached to the front section of the gear and motor module40. At1108, an extender module60is mounted onto the internal mounting frame module20. Also, after each mounting step, fasteners may be immediately applied to secure the module mounted to the module to which it has been mounted. Note that although process1100appears to show various operations being performed in a specific sequence, those having ordinary skill in the art after reviewing the present disclosure will recognize that in various embodiments, one or more of the illustrated operations may be performed in any sequence with respect to the other illustrated operations, or may be performed concurrently. For example,FIG.11appears to show that operation1102is being performed first before the other operations (e.g., operations1104,1106, and/or1108) are to be performed. However, operation1102could be performed concurrently or subsequently to the performance of one or more of the other illustrated operations (e.g., operations1104,1106, and/or1108) in various alternative implementations. In some embodiments, the dunnage machine1010, includes all components necessary to expand sheet stock material and process the sheet stock material to form cushioning material or dunnage. That is, aside from a sheet stock supply system to deliver the sheet stock material to the dunnage machine1010, and a power source supply to the E-box of the dunnage machine, the internal mounting frame module20, E-box30, gear and motor module40, cutter module50, and expander module60, can provide essentially of all modules necessary to process sheet stock material within the dunnage machine1010to form dunnage (e.g., cushioning material). Thus, in some embodiments, the entire dunnage machine1010exhibits traits of portability with easy assembly and disassembly for any component of the dunnage machine1010that may need repair and/or replacement. That is, for some disclosed embodiments, there are only five (5) modules, and those modules encompass all parts of the dunnage machine (except the sheet stock supply system if any). Thus, a repair or replacement of any component of the dunnage machine1010may comprise simply removing the module20,30,40,50,60within which a component is contained, and repairing the component or shipping the particular module away for repair, while replacing the module with a replacement module20,30,40,50or60, in operative condition. Although the examples illustrate five modules, various embodiments can include a dunnage machine consisting essentially of two or three modules, or up to eight or more modules, which modules still encompass all required mechanical and electrical parts for processing dunnage in a dunnage machine, excluding the sheet stock supply system (e.g., the supply systems can be considered separate from the dunnage machine and part of the dunnage system). In such alternative embodiments, one or more of the modules expressly described above and illustrated in theFIGS.1-10B, may be divided into separate modules or combined into one module. The various embodiments described herein, are presented as non-limiting example embodiments of the present disclosure, unless otherwise expressly indicated. After reviewing the present disclosure, an individual of ordinary skill in the art will immediately appreciate that some details and features can be added, removed and/or changed without deviating from the spirit of the disclosure. Reference throughout this specification to “various embodiments,” “one embodiment,” “an embodiment,” “additional embodiment(s)”, “alternative embodiments,” or “some embodiments,” means that a particular feature, structure or characteristic described in connection with the embodiment(s) is included in at least one or some embodiment(s), but not necessarily all embodiments, such that the references do not necessarily refer to the same embodiment (s). Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure. | 26,435 |
11858233 | DETAILED DESCRIPTION FIG.1shows a diagram of a portion of a corrugated board production line, in which the double facer, indicated as a whole by reference numeral1, is arranged. The structure of the double facer is known per se and therefore the main components thereof useful for understanding the invention will be referred to in the present description. The double facer section has an inlet3and an outlet5. Reference F indicates the direction of advancement of the continuous strip of corrugated board C through the double facer1. The double facer comprises a heating section7and a cold traction section9. The heating section7comprises a plurality of hot plates11arranged in sequence along the advancement path of the corrugated board C. Each hot plate11is heated to a suitable temperature, for example by means of a heat transfer fluid. In some cases, the heat transfer fluid is steam. The traction section9comprises a lower flexible member13, for example consisting of a suitably motorized continuous belt. Reference f13indicates the direction of advancement of the lower flexible member13. In some embodiments, the lower flexible member13is guided around rollers15,17,19. One of these rollers is motorized. In the example shown, the motorized roller is roller15. Reference16schematically indicates a first electric motor for driving the roller15and therefore the lower flexible member13. The upper branch of the lower flexible member13advances in contact with a support plate21, which extends between the guide roller17and the motorized roller15. Along the active branch of the lower flexible member13, its inner surface is in sliding contact with the support plate21, while the outer surface of the lower flexible member13is in contact with the corrugated board C. By inner surface of a continuous flexible member it is meant the one facing the inside of the closed path along which the flexible member moves, while by outer surface it is meant the one facing the outside of the closed path. As will be clarified below, the lower flexible member helps to pull the corrugated board C through the heating section7and the cold traction section9. The friction between corrugated board C and lower flexible member13transmits a dragging force from the lower flexible member13to the corrugated board C. As can be seen inFIG.1, the lower flexible member13extends downstream of the heating section7, and therefore downstream of the hot plates11, to the outlet5of the double facer1. An upper flexible member25extends along all the double facer, preferably from the inlet3to the outlet5, and therefore both through the heating section7and through the cold traction section9. Reference f25indicates the direction of advancement of the upper flexible member25which, similarly to the lower flexible member13, may consist of a continuous belt. The upper flexible member25is guided around a plurality of rollers, at least one of which is motorized. In the illustrated example, the upper flexible member25is guided around a motorized roller27, located at the outlet5. Reference28schematically indicates a second electric motor which drives the motorized roller27and advances the upper flexible member25. Reference29indicates a guide roller of the upper flexible member25located at the inlet3of the double facer1. An active branch of the upper flexible member25extends between the rollers29and27, parallel to the hot plates11and parallel to the support plate21. The return branch of the upper flexible member25is guided around a series of guide rollers31,32,33,34,35,36. Along the active branch of the upper flexible member25, the outer surface thereof is in contact with the upper surface of the corrugated board C, to transmit (by friction) a traction force. Along the same active branch, the inner surface of the upper flexible member25advances in contact with pressure members41carried by a stationary bearing structure43, placed above the hot plates11. The pressure members41are adapted to press the active branch of the upper flexible member25against the corrugated board C, so as to guarantee a sufficient friction force between the corrugated board C and the upper flexible member25. Furthermore, the pressure of the pressure elements41ensures the contact of the board C on the upper surface of the hot plates11, so as to achieve correct heating of the corrugated board C. The pressure and the heating cause the smooth and corrugated sheets of paper, which form the corrugated board C, to glue together by virtue of adhesive applied on the crests of the corrugated sheets before entering the double facer1, in a per se known manner. The large mutual contact surface between corrugated board C, hot plates11and upper flexible member25ensures that the pressure is relatively low and in any case such as not to cause crushing of the corrugated board. The length of the hot plates11and the advancement speed are selected in such a way as to ensure a contact time between corrugated board C and hot plates11sufficient to obtain gluing. In the cold traction section9the lower branch of the upper flexible member25is pressed against the corrugated board C and against the upper branch of the lower continuous flexible member13, which slides on the stationary contrast surface. In this way, the corrugated board C is retained between the two active branches of the upper flexible member25and of the lower flexible member13, and is effectively dragged forward according to the arrow F to the outlet5of the double facer. The pressure of the upper flexible member25against the lower flexible member13, against the corrugated board C and against the support plate21is ensured, for example, by pressure members51mounted on a bearing structure53in the cold traction section. The upper flexible member25is much longer than the lower flexible member13and provides most of the traction force to the corrugated board C, required to overcome the friction thereof on the surfaces of the hot plates11. The power supplied by the second electric motor28is approximately three to four times greater than the power supplied by the first electric motor16. The greater length and the greater stresses, also thermal, to which the upper flexible member25is subjected, cause wear of the latter which is faster than the wear of the lower flexible member13. Wear leads to thinning of the flexible parts. The guide rollers, and in particular the drive rollers15,27, also undergo different wear. In particular, the upper drive roller27wears faster than the lower drive roller15. Wear affects the coating, typically in silicone rubber, of the drive rollers and therefore causes a reduction in their diameter. Consequently, if the rotation speed of the electric motors16and28remains constant, wear causes a reduction in the linear speed of the upper and lower flexible members25and13. Since the wear of the two flexible members and the respective rollers are different, this entails a different variation in the linear speed of the flexible members. Typically, when the double facer is started with new flexible members, a small difference is set between the advancement speeds (i.e. the linear speeds) of the two flexible members25,13, for example a difference typically less than 1% between the linear advancement speed V13of the lower flexible member13and the linear advancement speed V25of the upper flexible member25, with the lower flexible member13faster than the upper flexible member25. Due to the aforementioned effects of differential wear of the flexible members and of the respective motorized rollers, the difference between the linear speeds tends to vary over time and tends to increase.FIGS.2and3illustrate this situation.FIG.2illustrates a diagram showing the time on the abscissa and the linear speed of the continuous flexible members13and25on the ordinate, in the absence of corrections. Reference V25indicates the linear speed of the upper flexible member25; V13indicates the linear speed of the lower flexible member13, with the rotation speed of the respective electric motors28and16constant.FIG.3shows the difference ΔV=(V13−V25) between the two speeds as a function of time t. As can be seen from these two graphs, the above mentioned phenomena of differential wear between the two upper and lower flexible members cause an increase in the difference in speed. Different situations from that illustrated inFIGS.2and3of gradual increase of the speed difference may also arise, with faster slowing down of the upper flexible member25. For example, an abrupt change in the speed of one of the two flexible members13,25may occur. This can happen when one of the two flexible members is replaced. For example, if the worn upper flexible member25is replaced with a new one, there is a sharp increase in its linear speed, a circumstance which the control system must take into account in order to make the traction system of the corrugated board C work correctly again. The variation in the difference between the two linear speeds of the two upper25and lower13flexible members causes inadmissible tensions on the corrugated board. This is clarified by the diagrams inFIGS.4,5A and5B, which show in a simplified manner a portion of corrugated board C with single flute, comprising a lower liner C1, an upper liner C2and an intermediate corrugated sheet C3. In both figures, F25indicates the traction force applied by the upper flexible member25and F13indicates the traction force applied by the lower flexible member13.FIG.4shows the correct operating condition. Both the upper flexible member25and lower flexible member13exert a traction in the advancement direction F of the board. With increased speed difference between the upper flexible member25and the lower flexible member13, situations of the type illustrated inFIG.5A or5Bmay occur. InFIG.5Athe speed of the upper flexible member25is too low and generates a force F25lower than necessary on the corrugated board. This is the situation that typically occurs due to the faster wear of the upper flexible member25. InFIG.5B, the speed of the upper flexible member25is excessive compared to that of the lower flexible member13. This can occur, for example, following the replacement of the upper flexible member25. The anomalous situations ofFIGS.5A and5Bgenerate tensions in the corrugated board, causing defects or even breaks in the corrugated board C. In order to alleviate or avoid this problem, one or more electric parameters of at least one of the electric motors16,28are controlled, for example via a control unit55, and these electric parameters are used to implement a control method which maintains the linear speed difference between the lower flexible member13and the upper flexible member25within an acceptable tolerance range. In practical embodiments, the second electric motor28, which has a power typically multiple than that of the first electric motor16, is used as a master, i.e. its rotation speed is kept at a value that corresponds to the line speed. This speed may vary according to the conditions of the production line. The first electric motor16is controlled as a slave, i.e. the rotation speed thereof is modulated so as to maintain the desired small difference in linear speed between the two upper (slower) flexible member25and lower13(faster) flexible members. The mechanical power that the electric motor must develop to advance the corrugated board depends on the resisting force that must be overcome to drag the corrugated board C. Therefore, when a situation of the type represented inFIG.5occurs, the resisting force F25increases the electric power absorbed by the first electric motor16to develop the mechanical power necessary to drag the corrugated board. This increase in absorbed electric power is detectable as an increase in the current absorbed by the motor. Therefore, by controlling the current I absorbed by the first electric motor16as an electric parameter and by acting with a control loop on the rotation speed of the first electric motor16to maintain the current absorbed around a desired value, it is possible to offset the effect of the difference of wear described above and prevent the linear speed of the lower flexible member13from becoming too high with respect to the linear speed of the upper flexible member25. The method can be further improved by controlling a further electric parameter to prevent the first electric motor16from rotating at such a speed as to advance the lower flexible member13at a linear speed V13too low with respect to the linear speed V25of the upper flexible member25. If the linear speed of the upper flexible member25exceeds that of the lower flexible member13, the first electric motor16would tend to be driven in rotation by the second electric motor25. The onset of this circumstance can be detected electrically. For example, it is possible to use the DC voltage on the power bus (DC Bus voltage of the drive) of the first electric motor16as the second electric control parameter. The increase in this voltage indicates that the first electric motor16is operating in generator mode, that is, it is being dragged instead of contributing to the traction of the corrugated board C. The diagram inFIG.6illustrates the method for controlling the rotation speed of the first electric motor16so as to maintain the linear speed of the lower flexible member15to the correct value (slightly higher) with respect to the linear speed of the upper flexible member25, corresponding to the speed of the production line. With reference toFIG.6, the method comprises the following steps which are repeated in an iterative manner. In block101it is checked whether the value of the DC bus voltage of the drive of the first electric motor16(VDCBus) is higher than a maximum voltage VMax. Exceeding this maximum voltage value indicates an abnormal operation of the first electric motor16in generator mode and therefore that the speed of the lower flexible member13is too low. If this occurs, by executing block102, the speed V13of the lower flexible member13is increased, with an increase c which can be fixed or variable according to the difference between VDCBus and VMax. If the check in block101gives a positive result (VDCBus≤Vmax), the check on the current I absorbed by the first electric motor16is performed in block103. The current value is compared with a maximum threshold IMax. If the current absorbed by the first electric motor16is greater than the maximum allowed threshold, block104is executed, and the speed of the lower flexible member13is reduced, for example always by a value a, fixed or variable, or any other suitable value. If the absorbed current is equal to or less than the threshold (I≤IMax), a minimum current check is performed (block105). Here, the current I absorbed by the first electric motor16is compared with a minimum threshold value IDes. If I≤IDes, the speed of the lower flexible member is increased in block106. If the absorbed current is greater than IDes, no correction is performed and control returns to block107. FIG.7shows the functional block diagram of the control described above. It is clear that what described above constitutes a possible embodiment. Those skilled in the art will appreciate that many modifications, changes and omissions are possible without departing from the spirit and scope of the claims. | 15,402 |
11858234 | DETAILED DESCRIPTION OF THE INVENTION Asphaltic Membrane In the present description, it will be understood that the polyethylene material may be a low density polyethylene (PEBD, Spanish acronym), a high density polyethylene (PEAD, Spanish acronym) or mixtures of same. The asphaltic membrane of the present invention is made up by 3 layers: a first lower non-stick layer, an second intermediate layer that grants waterproof features and a third upper layer that grants protection to the intermediate layer and, in our case, provides the desired design pattern. The lower layer is a non-stick sheet. Its function is to protect the lower part of the intermediate layer during the stowage until its application. A high density polyethylene sheet is preferred. The polyethylene sheet has a thickness that ranges between 7μ and 30μ, preferably 15μ. This lower layer may also be made with non-stick asphalt to allow its cold application. The second layer, the intermediate one, and also known as support, provides at least three components: a polyethylene layer, preferably of high density. The polyethylene sheet has a thickness ranging between 7μ to 120μ. The bitumen is modified with inert mineral loads, such as ashes, calcareous fillers and in percentages of up to 70% of the total asphaltic product. In certain embodiments, the intermediate layer may also include an additional polyethylene layer and an asphaltic layer of modified bitumen. The third layer, the upper one, is made of 3 sheets. Its display, from the outside to the inside, is: a polyethylene sheet, preferably of high density, a polyester sheet and a support. The polyester sheet has a thickness ranging between 7μ to 20μ, preferably 12μ. The support may be a metallic sheet, preferably aluminium, a non woven geotextile fabric or aluminized polyethylene. The metallic sheet preferably has a thickness that ranges between 7μ and 30μ. The geotextile fabric may have a weight that ranges between 50 and 180 g/cm2. The polyethylene sheet has a thickness that ranges between 7μ and 150μ, preferably 60μ, and is added with components for the protection against UV rays. Before its lamination with the other two sheets to form the upper layer of the asphaltic membrane, a printing is applied to the polyester sheet on its lower side. Said printing shall be in contact with the support and be protected from the outside by the polyethylene sheet itself. The decorative asphaltic membrane of the present invention may provide designs which are away from the common grey, so that its application on walls or vertical surfaces is attractive. The printing is made through a flexographic process or by means of a hollow engraving process. The digital photopolymer is prepared with the desired design. Inks shall be compatible with the lamination process. Inks are preferably based on solvents, water or UV inks. They are not viscous to attain a quick drying. They must be translucent since colors are added and not hidden. Manufacturing Process: As in any process known in the art related to the manufacturing of asphaltic membranes, same are laminated through a rolling mill with the required speeds and temperatures to obtain the final product. In the present invention, an additional printing process is added onto one of the layers, before using the rolling mill. The printing process may be temporally or physically independent of the lamination process of the asphaltic membrane. The printing of the lower side of a polyester sheet is made with techniques known in the prior art. The ink is dried and this printed polyester sheet shall enter a first rolling mill to form the upper layer; a support, preferably aluminium, the printed polyester sheet and the polyethylene sheet. Then, a second rolling mill will laminate the three layers: the upper one (already printed), the intermediate one (already made up by a polyethylene between two layers of asphalt) and the lower one to form the decorative asphaltic membrane. | 3,991 |
11858235 | The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein. DETAILED DESCRIPTION The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a trim breaker for an appliance cabinet having a metallic plate inserted therein. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements. For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented inFIG.1. Unless stated otherwise, the term “front” shall refer to the surface of the element closer to an intended viewer, and the term “rear” shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. The terms “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. With respect toFIGS.1-4, reference numeral10generally refers to a trim breaker that is incorporated within a structural cabinet16for an appliance40. The trim breaker10extends between opposing metallic plates24, typically in the form of an outer wrapper12and an inner liner14, that cooperate to form the structural cabinet16having an insulating cavity18defined therein. According to various aspects of the device, the structural cabinet16can be in the form of a vacuum insulated structure that includes a trim breaker10having a wrapper channel20and a liner channel22that extend perimetrically about the trim breaker10. The inner liner14is attached to the liner channel22of the trim breaker10and the outer wrapper12is attached to the trim breaker10at the wrapper channel20. Through this configuration, the inner liner14, the outer wrapper12and the trim breaker10cooperate to form the vacuum insulated structure. A metallic plate24is disposed within the trim breaker10and extends from a first area26proximate the liner channel22to a second area28proximate the wrapper channel20. The metallic plate24, through this configuration, defines an internal barrier30to gas permeation through the trim breaker10. Within structural cabinet16, the inner liner14and the outer wrapper12can be made of a metallic material that is generally resistant to gas permeation therethrough. The trim breaker10that extends between the inner liner14and the outer wrapper12can be made of a plastic material32. Plastic is generally a material that, by itself, allows gas to permeate therethrough. In the condition of a vacuum insulated structure, this gas permeation can, over time, allow gas to infiltrate into the insulating cavity18and degrade the at least partial vacuum70that is defined within the insulating cavity18of the structural cabinet16. The inclusion of the metallic plate24within the trim breaker10reinforces the trim breaker10and also provides an additional internal barrier30to gas permeation that can limit the amount of gas that can permeate through the trim breaker10over time. The metallic plate24can also slow the rate of gas permeation by a significant amount. This configuration can extend the life of the at least partial vacuum70within the insulating cavity18. In turn, this configuration can extend the life of an appliance40and the effectiveness and efficiency of the appliance40over its lifespan. Referring again toFIGS.1-4, it is contemplated that the trim breaker10includes a plastic material32that can be injection molded around the metallic plate24. In this manner, the metallic plate24can be entirely encased within the plastic material32of the trim breaker10as a single unitary piece. In such an embodiment, no portion of the metallic plate24is visible from the outside surface50of the trim breaker10. Using this configuration, the inner liner14and the outer wrapper12are prevented from having any direct physical connection with the metallic plate24. By separating the metallic plate24from the inner liner14and the outer wrapper12, thermal conductivity through the metal components of the structural cabinet16is prevented. At the same time, the metallic plate24and the metallic material of the inner liner14and the outer wrapper12provide a substantially continuous barrier to gas permeation around the insulating cavity18. The only gaps are defined by the spaces52between the metallic plate24and the inner liner14and the outer wrapper12, respectively. As exemplified inFIGS.5-7, which illustrate a process for forming the trim breaker10, a portion of the trim breaker10may be at least partially exposed within an outside surface50of the trim breaker10. In such a configuration, an edge60of the metallic plate24may be co-planar with a plate-supporting portion62of the trim breaker10. This plate-supporting portion62of the trim breaker10may be used to support the metallic plate24within a mold64so that injectable material66that is injected into the mold64and molded around the metallic plate24can be accurately positioned so that the injectable material66surrounds the remaining portions of the metallic plate24other than the edge60of the metallic plate24. In order to prevent the edge60of the metallic plate24from providing a path for thermal conduction or a significant path for gas permeation, the edge60of the metallic plate24and the plate-supporting portion62of the trim breaker10can be positioned within a surface of the trim breaker10that faces into the insulating cavity18of the structural cabinet16. Through this configuration, the edge60of the metallic plate24is positioned adjacent to an insulating material68and exposed to the at least partial vacuum70maintained within the insulating cavity18. As exemplified inFIG.8, it is also contemplated that the entire metallic plate24can be embedded within the material of the trim breaker10so that the metallic plate24is completely surrounded by the injectable material66and is not exposed to areas outside of the trim breaker10. To achieve the positioning of the metallic plate24within the trim breaker10, the metallic plate24can be insert injection molded within a mold64. Through this process, the metallic plate24can be positioned within the mold64and can be positioned by one or more pins80, that position the metallic plate24within the mold64so that the metallic plate24is supported in a consistent position as the injectable material66flows around the metallic plate24to form the structure of the trim breaker10. After the trim breaker10is removed from the mold64, the voids left behind by the use of the pins80may be backfilled so that the entire metallic plate24is surrounded by the plastic material32of the trim breaker10. As discussed above, the location of the pins80may also be oriented so that the voids within the plastic material32of the trim breaker10left behind by the use of the pins80are located within, or exposed to, the insulating cavity18for the structural cabinet16. In either instance, it should be understood that the injectable material66of the trim breaker10is intended to surround, or substantially surround, the metallic plate24. By using the phrase “substantially surround,” it should be understood that certain portions of the trim breaker10may be exposed, such as the edge60of the metallic plate24or the location of the supporting pins80from the mold64, which may provide for a minimal exposure of the metallic plate24to areas outside of the trim breaker10. Referring again toFIGS.1-8, in addition to the metallic plate24providing a barrier to gas permeation, the injectable material66that surrounds the metallic plate24can also include materials that resist, or partially resist, gas permeation. In this manner, various aspects of the device can include gas-blocking flakes90that are incorporated within the injectable material66of the trim breaker10. These gas-blocking flakes90can include mica, glass particles, or other similar naturally-occurring or manufactured particles that can be included within the injectable material66to assist in preventing gas permeation through the trim breaker10. Where the gas-blocking flakes90are incorporated, the injectable material66, typically a plastic material32, is a substantially homogenous mixture of the plastic material32and the gas-blocking flakes90. The substantial homogeneity of the injectable material66is achieved through the size of the gas-blocking flakes90being substantially microscopic, such that each particle of the gas-blocking flakes90has a dimension in the order of microns. The small size of these gas-blocking flakes90make them substantially imperceptible with a naked eye when mixed with an injectable material66. Accordingly, the substantial homogeneity of the injectable material66can be achieved when the gas-blocking flakes90are incorporated within the plastic material32of the injectable material66. Referring again toFIGS.3-8, the trim breaker10that can be used within vacuum insulated structures, such as the structural cabinet16described herein, can include a plastic body100that defines the wrapper channel20and the liner channel22. A plurality of gas-blocking flakes90are disposed throughout the material of the plastic body100. The metallic plate24is disposed entirely within the trim breaker10and extends from the first area26proximate the liner channel22to the second area28proximate the wrapper channel20. The first and second areas26,28between which the metallic plate24extends are areas within an interior of the trim breaker10. As exemplified inFIGS.4,7and8, the first area26proximate the liner channel22is within a portion of the trim breaker10that defines the liner channel22. This first area26, as with the metallic plate24, is positioned entirely within the material of the trim breaker10. Accordingly, the first edge102of the metallic plate24is located at this first area26proximate the liner channel22and is typically entirely encased within the trim breaker10. As discussed above, in certain aspects of the device, the first edge102, or a portion of the first edge102of the metallic plate24, can be co-planar with the plate-supporting portion62of the trim breaker10, such that the first edge102of the metallic plate24, or a portion thereof, is exposed to the exterior of the trim breaker10, but is located within the insulating cavity18for the structural cabinet16. The second edge104of the trim breaker10is positioned within the second area28that is positioned proximate the wrapper channel20. This second area28is configured to be located within an interior portion of the trim breaker10and within the injectable material66. Through this configuration, the second edge104of the metallic plate24that is located at this second area28is also entirely encased within the material of the trim breaker10. In various aspects of the device, it is contemplated that the first edge102and/or the second edge104of the trim breaker10can wrap at least partially around the wrapper channel20and the liner channel22, respectively. As exemplified inFIG.7, the second edge104of the metallic plate24wraps partially around the wrapper channel20. The location of the metallic plate24relative to the wrapper channel20and the liner channel22are configured to provide a substantially continuous barrier to gas permeation. Through this configuration, the metallic plate24is configured to cooperate with the metallic material of the inner liner14and the outer wrapper12to provide the substantially continuous barrier to gas permeation. As exemplified inFIGS.3-8, the wrapper channel20is configured to receive and secure the metallic outer wrapper12, typically via an adhesive110. The metallic plate24is separated from the metallic outer wrapper12at least by a portion of the plastic body100for the trim breaker10. Similarly, the liner channel22receives and secures the metallic inner liner14, typically via the adhesive110. The metallic plate24is separated from the metallic inner liner14at least by a portion of the plastic body100. As discussed above, the plastic body100includes the plastic material32and, in certain configurations, the gas-blocking flakes90, that form the homogenous material, or substantially homogenous material, that is injection molded around the metallic plate24as a homogenous injectable material66. Referring again toFIGS.1-8, the vacuum insulated structure can include the trim breaker10having the wrapper channel20and the liner channel22. The inner liner14is attached to the trim breaker10at the liner channel22and the outer wrapper12is attached to the trim breaker10at the wrapper channel20. The metallic plate24is insert injection-molded within the trim breaker10and extends from a first area26proximate the liner channel22to a second area28proximate the wrapper channel20. As discussed above, the metallic plate24defines an internal barrier30to gas permeation through the trim breaker10. Typically, the metallic plate24is made of steel, a steel alloy, or other similar metallic material that is resistive to gas permeation. According to various aspects of the device, the plastic material32of the trim breaker10can include various plastic-type materials that can include any one of various plastic-type materials such as polymers, composite materials, and combinations thereof. Such exemplary plastic materials32can include, but are not limited to, polyvinyl chloride (PVC), polyethylene terephthalate (PET) that is at least partially glass-filled, various polyester materials, various co-polyester materials, and other similar polymers. Additionally, the outside surface50of the trim breaker10that is exposed to the insulating cavity18can be coated with various coating materials116that can include, but are not limited to, aluminum silicate (AL SiO2,) titanium coatings, and other similar coating materials116. As discussed above, the gas-blocking flakes90can include mica, glass and other similar materials. These gas-blocking flakes90can be incorporated within the trim breaker10at various amounts. By way of example, and not limitation, the injectable material66for the trim breaker10can include a range of from approximately 5% to approximately 25% of the gas-blocking flakes90, by volume. Other percentages of the gas-blocking flakes90can be incorporated depending upon the size of the particles of gas-blocking flakes90, the weight of the gas-blocking flakes90and the individual characteristics that form the material of the gas-blocking flakes90. Referring now toFIGS.1-9, having described various aspects of the trim breaker10that includes the metallic plate24, a method400is disclosed for forming a trim breaker10having an aspect of the metallic plate24. According to the method400, a metallic plate24is disposed within the mold64(step402). As discussed previously, the metallic plate24can be held in place through various pins80that are incorporated within the mold64or through the plate-supporting portion62for the trim breaker10. According to the method400, the injectable material66is formed (step404). As discussed above, the injectable material66can include plastic and a plurality of gas-blocking flakes90. After forming the injectable material66, the injectable material66is injected into the mold64and around the metallic plate24(step406). This injectable material66is then cooled and solidified around the metallic plate24to form a unitary assembly with the metallic plate24embedded therein. The trim breaker10can then be removed from the mold64(step408). As discussed herein, the metallic plate24is encased, or substantially encased, within the trim breaker10. As exemplified inFIGS.5-7, an aspect of the method400for forming the trim breaker10can include attaching the metallic plate24to a support section120that supports the metallic plate24relative to the mold64. After the injectable material66is injected into the mold64and is solidified, the trim breaker10can be removed from the mold64. Any excess portion of the metallic plate24that may extend from the trim breaker10can be removed through cutting, grinding, or other similar process for eliminating excess portions of the metallic plate24that may extend from the plate-supporting portion62of the trim breaker10. As discussed above, any portion of the metallic plate24that is exposed to the outside of the trim breaker10can be positioned within the insulating cavity18. Additionally, these exposed portions can be covered with at least a portion of the plastic material32, coatings, and other gas-permeation resistive materials described herein. According to various aspects of the device, the metallic plate24set within the trim breaker10is used to prevent gas permeation through the trim breaker10that might cause a degradation of an at least partial vacuum70within an insulating cavity18. This barrier to gas permeation can also be used to maintain insulating gasses within the insulating cavity18and prevent leakage of these insulating gasses outside of the insulating cavity18of the structural cabinet16. These insulating gasses can include, but are not limited to, carbon dioxide, various inert gasses, and other similar gasses that are typically used within insulating structures. The trim breaker10having the metallic plate24incorporated therein can be used within various appliances40. Such appliances40can include, but are not limited to, refrigerators, freezers, coolers, laundry appliances, ovens, water heaters, small appliances, and other similar appliances and fixtures that may require a pressure differential between the atmosphere and an interior insulating cavity18. According to another aspect of the present disclosure, a vacuum insulated structure includes a trim breaker having a wrapper channel and a liner channel that extend perimetrically about the trim breaker. An inner liner is attached to the trim breaker at the liner channel. An outer wrapper is attached to the trim breaker at the wrapper channel. A metallic plate is disposed within the trim breaker and extends from a first area proximate the liner channel to a second area proximate the wrapper channel. The metallic plate defines an internal barrier to gas permeation through the trim breaker. According to another aspect, the trim breaker includes gas-blocking flakes that are incorporated throughout the trim breaker. According to yet another aspect, the trim breaker includes a plastic material and the gas-blocking flakes as a homogenous material. According to another aspect, the trim breaker is an injection molded piece, wherein the homogenous material is injection molded around the metallic plate. According to yet another aspect, the metallic plate is entirely encased within the homogenous material of the trim breaker. According to another aspect of the present disclosure, the metallic plate is separated from the inner liner and the outer wrapper at least by a plastic material of the trim breaker, wherein the plastic material substantially surrounds the metallic plate. According to another aspect, an edge of the metallic plate is co-planar with a plate-supporting portion of the trim breaker, wherein the plate-supporting portion of the trim breaker is positioned within an insulating cavity defined between the inner liner, the outer wrapper and the trim breaker. According to yet another aspect, the gas-blocking flakes are at least one of mica and glass. According to another aspect of the present disclosure, the metallic plate is insert injection molded within the trim breaker. According to another aspect, a trim breaker for a vacuum insulated structure includes a plastic body that defines a wrapper channel and a liner channel. A plurality of gas-blocking flakes are disposed throughout the plastic body. A metallic plate is disposed entirely within the trim breaker and extends from a first area proximate the liner channel to a second area proximate the wrapper channel. According to yet another aspect, the wrapper channel receives a metallic wrapper that is secured within the wrapper channel, and wherein the metallic plate is separated from the metallic wrapper at least by a portion of the plastic body. According to another aspect of the present disclosure, the liner channel receives a metallic liner that is secured within the liner channel, and wherein the metallic plate is separated from the metallic liner at least by a portion of the plastic body. According to another aspect, the material of the plastic body and the gas-blocking flakes are injection molded around the metallic plate as a homogenous injectable material. According to yet another aspect, the gas-blocking flakes are at least one of mica and glass. According to another aspect of the present disclosure, a vacuum insulated structure includes a trim breaker having a wrapper channel and a liner channel. An inner liner is attached to the trim breaker at the liner channel. An outer wrapper is attached to the trim breaker at the wrapper channel. A metallic plate is insert injection molded within the trim breaker and extends from a first area proximate the liner channel to a second area proximate the wrapper channel. The metallic plate defines an internal barrier to gas permeation through the trim breaker. According to another aspect, the trim breaker includes gas-blocking flakes that are incorporated within an injectable material of the trim breaker, wherein the injectable material is a substantially homogenous material. According to yet another aspect, the metallic plate is entirely encased within the substantially homogenous material of the trim breaker. According to another aspect of the present disclosure, an edge of the metallic plate is co-planar with a plate-supporting portion of the trim breaker. The plate-supporting portion of the trim breaker is positioned within an insulating cavity defined between the inner liner, the outer wrapper and the trim breaker. According to another aspect, the gas-blocking flakes are at least one of mica and glass. According to another aspect of the present disclosure, the metallic plate is steel. It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated. It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations. It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting. | 26,425 |
11858236 | DETAILED DESCRIPTION The foregoing and other objectives, features, and advantages of the disclosure will become more apparent from the following detailed description taken in conjunction with the accompanying drawings. Mirrors in aerospace applications present a number of critical issues that are not issues in other non-aerospace applications, including safety, high usage, and weight. Accordingly, the disclosed mirror configured and implemented for aerospace applications addresses safety, high usage, and weight. Additionally, weight is a critical issue for mirrors in aerospace applications. Because of the nature of flight, it is critical to reduce weight of every component in aerospace applications, including mirrors, to improve efficiency and aircraft operation. Hereinafter, a foam core mirror and a method of producing the foam core mirror according to the disclosure will be described in detail with reference to the accompanying drawings. The described aspects are provided so that those skilled in the art can easily understand the technical spirit of the disclosure, and thus the disclosure is not limited thereto. In addition, the accompanying drawings are schematic drawings for easily understanding the aspects of the disclosure and thus the matters represented in the accompanying drawings may be different from those actually implemented. Meanwhile, each component shown below is only an example for implementing the disclosure. Therefore, other components may be used in other implementations of the disclosure without departing from the spirit and scope of the disclosure. Additionally, it should be understood that the expression “including” certain elements is an “open type” expression indicating certain components and does not exclude additional components. FIG.1is a perspective exploded view of a foam core mirror for interior aerospace applications according to an aspect of the disclosure. FIG.2is a cross sectional exploded view of a foam core mirror for interior aerospace applications according toFIG.1. FIG.3is a cross sectional view of a foam core mirror for interior aerospace applications according toFIG.1. In particular,FIG.1illustrates a foam core mirror100for aerospace applications such as an aircraft application. The foam core mirror100may be configured and arranged for use in an aircraft cabin and/or aircraft cockpit. For example, the foam core mirror100may be configured and arranged for use in an aircraft lavatory, decorative bars, branding panels, galleys, and/or the like areas of an aircraft cabin and/or aircraft cockpit. Additionally, the foam core mirror100of the disclosure may be configured to implement sheet configurations, may be modified for specific aerospace or aircraft configurations formed from the sheet configurations, and/or may be modified for specific decorative shapes for aerospace or aircraft configurations formed from the sheet configurations. Alternatively, the foam core mirror100may be implemented as a standalone configuration. The foam core mirror100may include at least three different layers of materials. In particular, the foam core mirror100may include at least three different layers of materials configured as a laminate structure. The foam core mirror100may include a transparent mirror layer102that may be configured to have reflective mirror properties. The transparent mirror layer102may include a transparent material. The transparent mirror layer102may possess high tensile strength configured to be operated in extreme conditions. Likewise, the transparent mirror layer102may be configured to include high elasticity to reduce a likelihood that the transparent mirror layer102does not break in extreme conditions. Moreover, the transparent mirror layer102may be configured as a rigid surface. Non-limiting examples of the material of the transparent mirror layer102may include polycarbonate materials, glass derivative materials, and/or the like. Additionally, it is important that an outer surface of the foam core mirror100is highly wear resistant. For example, the outer surface of the foam core mirror100does not substantially wear when utilized in high usage applications associated with commercial aircraft and/or business aircraft. In this regard, should the outer surface of the foam core mirror100be easily worn, a transparency of the foam core mirror100may degrade, resulting in reduced reflection and less than satisfactory operation of the foam core mirror100. As such, the transparent mirror layer102of the foam core mirror100is configured to have high wear resistance, high scratch resistance, and the like. Accordingly, an outer face122of the transparent mirror layer102may be hard-coated to increase scratch resistance and/or wear resistance. The outer face122of the transparent mirror layer102may be the outward surface when implemented within a commercial aircraft and/or business aircraft. The hard coating may be arranged on the outer face122of the transparent mirror layer102. The hard coating may be applied by wet processes. Non-limiting examples of the wet process may include a flow coating process, a spray coating process, a chemical deposition coating process, a physical deposition coating process, a flat-line reciprocator coating process, and other like processes. A non-limiting example of the coating material on the outer face122of the transparent mirror layer102may include siloxane. In one aspect, the hard coating may be applied by a flow coating process utilizing siloxane, a spray coating process utilizing siloxane, a chemical deposition coating process utilizing siloxane, a physical deposition coating process utilizing siloxane, a flat-line reciprocator coating process utilizing siloxane, and other like processes utilizing siloxane. The hard coating may be applied by other processes and the hard coating may utilize other materials. Additionally, it is also important that the foam core mirror100possess good reflectivity properties. Thus, an inner surface132of the transparent mirror layer102may be metalized. The inner surface132of the transparent mirror layer102may be coated by vacuum deposition of one or more metals to provide reflective properties to the foam core mirror100. Alternatively, the inner surface132of the transparent mirror layer102may be coated by sputter deposition of one or more metals to provide reflective properties to the foam core mirror100. Moreover, other coating technologies may be utilized to provide reflective properties to the foam core mirror100. Additionally, other reflective materials may be used in coating, deposition, or the like for the inner surface132of the transparent mirror layer102to provide reflective properties to the foam core mirror100and are accordingly within the scope of the disclosure. Next, a core layer106may be configured and arranged adjacent to the inner surface132of the transparent mirror layer102. In other words, the first surface126of the core layer106may be arranged adjacent to the inner surface132of the transparent mirror layer102. The shape of the core layer106may be configured to match the shape of the transparent mirror layer102. The core layer106and the transparent mirror layer102may be attached together by the inner surface132of the transparent mirror layer102and the first surface126of the core layer106. In particular, the core layer106and the transparent mirror layer102may be attached together by the inner surface132of the transparent mirror layer102and the first surface126of the core layer106by an adhesive. The adhesive may be an epoxy adhesive, an epoxy based adhesive, or the like. However, other attachment technology is contemplated and may be utilized as well. The core layer106may include a light weight foam material. The core layer106may be configured to absorb substantial force applied to the foam core mirror100. The core layer106may also be configured to reduce weight of the foam core mirror100. Non-limiting examples of the materials used for the core layer106may be polyetherimide, polyphenylsulfone, and/or polycarbonate. In particular, the materials used for the core layer106may be a polyetherimide foam material, a polyphenylsulfone foam material, and/or a polycarbonate foam material. Other types of foam materials are contemplated as well. Additionally, other thick and robust materials may be utilized such as honeycomb constructions. A backing layer110may be configured to be arranged adjacent to the core layer106. A first face140of the backing layer110may be arranged adjacent to the second face136of the core layer106. The shape of the backing layer110may be configured to match the shape of the core layer106. The core layer106and the backing layer110may be attached together by the first face140of the backing layer110and the second face136of the core layer106. The core layer106and the backing layer110may be attached together by the first face140of the backing layer110and the second face136of the core layer106by an adhesive. The adhesive may be an epoxy adhesive, an epoxy based adhesive, or the like. However, other attachment technology is contemplated and may be utilized as well. A second face150of the backing layer110may be configured to be attached to a wall or other surface of lavatories, decorative bars, branding panels, galleys, and/or the like areas of an aircraft cabin and/or aircraft cockpit. Alternatively, the second face150of the backing layer110may be configured such that the foam core mirror100is implemented as a standalone configuration. Moreover, the backing layer110may be configured as a rigid surface. The backing layer110may be configured to absorb substantial force applied from the second face150of the backing layer110. As such, the backing layer110may be configured to possess high tensile strength to be operated in extreme conditions. Likewise, the backing layer110may be configured to possess high elasticity so that it does not break in extreme conditions. Non-limiting examples of the material of the backing layer may include polyetherimide, polyphenylsulfone, glass epoxy, glass derivatives, combinations thereof, and/or the like. Accordingly, the foam core mirror100that may include at least three different layers of materials as described herein and the foam core mirror100forms a rigid and highly resistant to deformation laminate structure. In particular, the foam core mirror100that may include at least the transparent mirror layer102, the core layer106, and the backing layer110as described herein forms a structure where at least the transparent mirror layer102forms a rigid surface and the backing layer110forms a rigid surface. Moreover, the foam core mirror100having the transparent mirror layer102that forms a rigid surface, the backing layer110that forms a rigid surface, and the core layer106that separates the transparent mirror layer102from the backing layer110may be configured such that the foam core mirror100implements a laminate structure and/or system having a high moment of inertia. In particular, the transparent mirror layer102and the backing layer110may resist a bending moment about the X axis and the backing layer110may resist substantial shear force. FIG.4is a perspective exploded view of a foam core mirror for interior aerospace applications according to an aspect of the disclosure. FIG.5is a cross sectional exploded view of a foam core mirror for interior aerospace applications according toFIG.4. FIG.6is a cross sectional view of a foam core mirror for interior aerospace applications according toFIG.4. In another aspect of this disclosure, the foam core mirror100may include at least five different layers of materials. The foam core mirror100may include the transparent mirror layer102, the core layer106, and the backing layer110as described herein. Additionally, the foam core mirror100may include a first adhesive layer304. The first adhesive layer304may be configured and arranged adjacent to the inner surface132of the transparent mirror layer102. In other words, an outer surface324of the first adhesive layer304may be arranged to be adjacent to the inner surface132of the transparent mirror layer102. The shape of the first adhesive layer304may be configured to match the shape of the transparent mirror layer102, and the first adhesive layer304and the transparent mirror layer102may share a same mating surface. The outer surface324of the first adhesive layer304may be configured to be attached to the inner surface132of the transparent mirror layer102. The first adhesive layer304may be configured to be a film type adhesive. Alternatively, the first adhesive layer304may be configured to be a spray type adhesive. In some aspects, the first adhesive layer304may not match the shape of the transparent mirror layer102. However, the first adhesive layer304may be configured to cover the majority of the inner surface132of the transparent mirror layer102. The first adhesive layer304may include an epoxy adhesive, an epoxy based adhesive, or the like. The core layer106may be arranged so that the first surface126of the core layer106may be adjacent to an inner surface334of the first adhesive layer304. As shown, the shape of the core layer106may be configured to match the shape of the first adhesive layer304. In some aspects, the first adhesive layer304may not match the shape of the core layer106. However, the first adhesive layer304may be configured to cover the majority of the first surface126of the core layer106. The core layer106may include a light weight foam material as described herein. A second adhesive layer308may be configured and arranged adjacent to the second face136of the core layer106. In other words, an outer surface328of the second adhesive layer308may be arranged to be adjacent to the second face136of the core layer106. The shape of the second adhesive layer308may be configured to match the shape of the core layer106, and the second adhesive layer308and the core layer106may share a same mating surface. The second adhesive layer308may be configured to be attached to the second face136of the core layer106. The second adhesive layer308may be configured to be a film type adhesive. Alternatively, the second adhesive layer308may be configured to be a spray type adhesive. In some aspects, the second adhesive layer308may not match the shape of the core layer106. However, the second adhesive layer308may be configured to cover the majority of the second face of the core layer106. The second adhesive layer308may include an epoxy adhesive, an epoxy based adhesive, or the like. The backing layer110may be arranged so that the first face140of the backing layer110may be adjacent to an inner surface338of the second adhesive layer308. As shown, the shape of the backing layer110may be configured to match the shape of the second adhesive layer308. In some aspects, the second adhesive layer308may not match the shape of the backing layer110. However, the second adhesive layer308may be configured to cover the majority of the first face of the backing layer110. Accordingly, the foam core mirror100that may include at least five different layers of materials as described herein and the foam core mirror100forms a rigid and highly resistant to deformation laminate structure. In particular, the foam core mirror100that may include at least the transparent mirror layer102, the core layer106, and the backing layer110as described herein forms a structure where at least the transparent mirror layer102forms a rigid surface and the backing layer110forms a rigid surface. Moreover, the foam core mirror100having the transparent mirror layer102that forms a rigid surface, the backing layer110that forms a rigid surface, and the core layer106that separates the transparent mirror layer102from the backing layer110may be configured such that the foam core mirror100implements a laminate structure and/or system having a high moment of inertia. In particular, the transparent mirror layer102and the backing layer110may resist a bending moment about the X axis and the backing layer110may resist substantial shear force. The layers illustrated and described with respect toFIGS.1-6have been illustrated to include rectangular shapes. However, the foam core mirror100is not limited to a rectangular shape. The foam core mirror100may be implemented to have a decorative shape. The foam core mirror100may be implemented as any shape, such as a circle, an ellipse, an oval, a triangle, a pentagon, a hexagon, and/or the like. The foam core mirror100may be implemented as an irregular shape. Moreover, in some aspects, the inner surface132may be masked to limit metalizing on the inner surface132and subsequent layers may be machined away to allow light to come through specific areas of the foam core mirror100. In these areas, there is not reflective property for the foam core mirror100. In another aspect of this disclosure, the foam core mirror100may include at least four different layers of materials, some of which have been previously described herein. Additionally, the foam core mirror100may include a metallized layer. The metallized layer may be implemented as described herein with respect to the inner surface132. In the various aspects described herein, a thickness190of the foam core mirror100may be configured to be less than 9.0 mm (millimeters), where the thickness190is a distance defined between the outer face122of the transparent mirror layer102and the second face150of the backing layer110and/or the thickness190is a distance defined by the arrows illustrated inFIG.3andFIG.6. In particular, the thickness190of the foam core mirror100may be configured, but not limited, to be 3 mm-4 mm, 4 mm-5 mm, 5 mm-6 mm, 6 mm-7 mm, 7 mm-8 mm, or 8 mm-9 mm. Configurations of various layers described herein of the foam core mirror100may be configured to reduce a total weight of the foam core mirror100, for example, but not limited to, by at least 10%-30%, 10%-20%, 15%-25%, or 20%-30% in comparison to the prior art mirror configurations. In one aspect, the various layers described herein of the foam core mirror100may be configured to reduce a total weight of the foam core mirror100by 10%-30%, 10%-20%, 15%-25%, or 20%-30% in view a single layer 3.0 mm polycarbonate mirror with equal or greater flexural modulus. Materials of the foam core mirror100are configured to be in compliance with 14 C.F.R. § 25.853 (or FAR 25.853). Additionally, the materials of the foam core mirror100are configured to be in compliance with appendix F of 14 C.F.R. § 25.853. Both documents are incorporated entirely herein. Appendix F of 14 C.F.R. § 25.853 provides several material test criteria, and the materials used in the foam core mirror100of the disclosure, including the transparent mirror layer102, the first adhesive layer304, the core layer106, the second adhesive layer308, the metallized layer, and/or the backing layer110are configured and manufactured in compliance with the test criteria. Among others, materials used in foam core mirror100are configured to pass a 12 second vertical burn per FAR/JAR 25.853, Appendix F, part I. Materials used in the foam core mirror100, individually and collectively, are configured to pass a 12 second vertical burn per FAR/JAR 25.853, Appendix F, part I. Additionally, the specific optical smoke density (Ds), which is obtained by averaging the readings of three specimens of the foam core mirror100obtained after 4 minutes of the ASTM F814-83 test are configured to not exceed 200. FIG.7illustrates a process of implementing a foam core mirror for interior aerospace applications according to an aspect of the disclosure. In particular,FIG.7illustrates a process of producing an aerospace foam core mirror900. It should be noted that the process of producing an aerospace foam core mirror900is merely exemplary and may be modified consistent with the various aspects disclosed herein. In this regard, each of the processes described may be implemented in a different order. First, a transparent mirror layer may be provided901. The transparent mirror layer may include a first transparent mirror layer face and a second transparent mirror layer face as described herein. Next, the first transparent mirror layer face may be hard coated902as described herein. Then, the second transparent mirror layer face may be metalized903as described herein. Next, a core layer may be provided904. The core layer may include a first core layer face and a second core layer face as described herein. A first adhesive layer may be provided905. The first adhesive layer may be arranged between the second transparent mirror layer face and the first core layer face. As described above, the first adhesive layer may be a film adhesive layer, a spray applied adhesive layer, and/or the like. Next, a backing layer is provided906. The backing layer may include a high tensile strength material as described herein. The backing layer may include a first backing layer face and a second backing layer face as described herein. Finally, a second adhesive layer is provided907. The second adhesive layer may be arranged between the second core layer face and the first backing layer face as described herein. Accordingly, the disclosure has set forth a mirror configured for aerospace applications that provides optimal reflective mirror properties, light-weight, resistance to deformation, and an ability to operate in extreme conditions. The many features and advantages of the disclosure are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the disclosure which fall within the true spirit and scope of the disclosure. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the disclosure. | 22,090 |
11858237 | For the sake of simplicity the glazings have been shown flat but are in fact generally curved. The figures are not to scale and are schematic. All of the figures describe a collimation optic and a redirection optic obeying at the laws of geometric optics. A holographic redirection optic may be substituted, the angle of deviation will depend on the pitch and on the wavelength of the light. FIG.1is a front-on view of a back window1000with two series of LEDs providing redirected, collimated light according to the invention each on a diode carrier. The inorganic light-emitting diodes4are surface mount devices (SMDs) mounted on a diode carrier, said diodes for example emitting MV red for rear lights or MV yellow for indicator lights, and therefore in the direction of the exterior face F111of the back window1. The following are shown:a first series of 6 LEDs4providing MV red light that is collimated and redirected by optics (collimation and redirection4toward the ground) along the upper edge and centered in a rectangular strip in order to form a third stoplight101(zone L3)a second series of 6 LEDs4providing MV yellow light that is collimated and redirected by optics (collimation and redirection4toward the ground) along the lower edge in a rectangular strip in order to form an indicator side-repeater light103(zone L4) The diode carrier is a printed circuit board (PCB board) of thickness of at most 0.2 mm and preferably of 0.1 mm to 0.2 mm. The diode carrier extends beyond the edge face of the back window, which is a laminated or single glazing. It for example includes a diode-bearing portion, and an electrical-connection portion35extending beyond the glazing and (partially) between one or more internal and/or external peripheral masking layers that are in particular made of black enamel (not shown). The face called the front face of the diode carrier bears conductive tracks facing the face F2 and the back face is for example against face F3 if the back window is laminated. Each diode has an emitting face emitting in the direction of the exterior glazing1, and each diode has an edge face. The diodes4(with a single semiconductor chip here) are of square shape of width of about 5 mm or less. FIG.1ais a front-on detail view of the diode carrier3with on the front face the diodes4(with the chips41and the outline40) each diode being equipped with its individual collimation optic made up of an array of prisms extending along the horizontal H and its redirection optic5made up of an array of asymmetric prisms extending along the horizontal H on the side of the exit surface30′. Thin and transparent optical films that are for example each of square shape and in particular a stack of two or three or more films is preferred. FIG.1bis an alternative front-on detailed view with (collimation and redirection) optics5that are common to the diodes4. Thus, the collimation optic and the redirection optic5extend far enough to cover all or some of the diodes (at least coverage per group of diodes). Between the diodes4the optics (non-functional portions55′) may be of small width or even of zero width and/or without texture (texture only facing the diodes4). For each optic, one or more thin and transparent optical films, for example of rectangular shape (constant or small width between the diodes as mentioned above), and in particular a stack of two or three or more films, is preferred. FIG.1iis an overview of a collimation optic according to the invention. The collimation optic5ais here a prismatic optical film that will for example be fastened on its periphery by a double-sided adhesive or a glue to the exit surface (generating an air-filled cavity entry-side) of the diode or even on a diode carrier (in particular prismatic film common to a plurality of diodes). It is for example a question of a plastic, in particular PET, film of less than 0.3 mm thickness that is partially textured in its thickness. It includes in its front face an array of preferably contiguous and even symmetric prisms50with apexes S and with a pitch T between the apexes that is from 10 μm to 500 μm, extending longitudinally along an axis making an angle of at most 10° to the reference direction, here the horizontal for the back window (or as a variant a windshield), and even parallel to the reference direction. Each prism is defined by two longitudinal faces. Each prism has an angle at the apex ranging from 60 to 110°, better still of 90° and each longitudinal face makes with the plane of the optical film5aan angle ranging from 30 to 55° and better still of 45°. For example, the pitch is 160 μm and the height 80 μm and the remaining thickness is 175 μm with angle at the apex and valley side of 90° (+−20 arc). Air is between the exit surface and the entrance face of this single optical film5aforming the collimation optic. Air is between the prisms of the front face of this collimation optical film5a; the apexes of the features of each front face make physical contact for example with a redirection optical film. The adhesive bonding of this optical film5ato the exit surface of the diode (or diodes or of the diode carrier) may be frame-like and form a seal. Here the apexes and valleys are pointed (the features are contiguous). As a variant, the apexes are rounded and the lateral faces curved; angles representative of the prisms (angle at the apex, angle to the plane of the film) are defined on the basis of two straight lines b1, b2 that are secant in A, passing through the inflection points I1, I2. The radius of curvature is also limited. FIG.1jis an overview of a collimation optic. This figure differs fromFIG.1iin that to form the collimation optic an identical second prismatic film5bthat is crossed at 90° and for example adhesively bonded (welded, etc.) on its periphery to the first prismatic film5ahas been added. FIG.1kis an overview of a collimation optic. FIG.1kdiffers fromFIG.1iin that the collimation optic5a(again a plastic film that is partially textured in its thickness, for example a film made of PET of less than 0.6 mm thickness) bears two-dimensional features. Each two-dimensional feature being defined by a flank and in a plane P normal to the film5aeach two-dimensional feature has an angle at the apex ranging from 60 to 110°, each intersection of the flank with the plane P making with the plane of the film an angle ranging from 30 to 55°. Preferably, an angle at the apex (in the plane P) of 90° is chosen and the2other angles are chosen to be 45°. The two-dimensional features are here raised, the apexes of the features of each front face are free or make physical contact with a transparent element (face F2 of the exterior glazing for example), and air is between the two-dimensional features. FIG.1lis an overview of a collimation optic according to the invention. This figure differs from the preceding figure in that here the two-dimensional features of the film5aare recessed, the array of two-dimensional features is an array of cavities, the apexes S are oriented (toward the interior of the passenger compartment (toward face F3 of a laminated glazing)) and the top surface of each cavity is free or makes physical contact with a transparent (redirection optical) element and air is in the cavities. FIGS.1mto10are overviews of a collimation optic. This figure differs fromFIG.1lin that what is shown is not a film but a part with a textured 2D plate and a peripheral extension55a. The part5, which forms a collimation optic of a diode4, includes a smooth entrance face5(spaced apart from the exit surface40) and a textured exit face, in particular a textured functional central zone, here an array of recessed pyramids. The part5includes a peripheral extension, preferably taking the form of a hollow body or surround for attaching to the diode carrier3, for example with a glue, and/or to the diode, and/or forming a barrier to the PVB (by way of precaution) if the glazing is laminated. The part5for example has a square outline and in particular an outline similar to that of the diode. The part5is for example made of PMMA and obtained by molding. In the case of a laminated glazing, the walls53preferably make contact with the PVB. The part5is thus here housed entirely in the through-aperture of a potential PVB. The part5preferably includes a portion housing the diode4. The walls53of the surround include two or better still four internal stubs55afor holding the diode via its edge face. This part5may receive a redirection film. FIGS.1pto1rshow an overview of a collimation optic. The part5forming the collimation optic of the diode4includes a textured face, here a Fresnel lens with a central zone, and a peripheral extension55, preferably taking the form of a hollow body or surround for attaching to the diode carrier3, for example with a glue, and/or to the diode, and/or forming a barrier to the PVB (by way of precaution) if the glazing is laminated. The part5for example has a square outline. It is for example made of PMMA and obtained by molding. The walls55preferably make contact with the potential PVB (cavity forming the through-aperture). The part5is here housed entirely in the through-aperture20a. The part5here comprises a portion55bhousing (retaining) the diode4. The walls55of the surround include two or better still four internal stubs55afor holding the diode via its edge face. The collimation optic (the textured plate) is spaced apart from the exit surface40′. The functional zone, and therefore a central zone, of the textured exit face is located facing the exit surface. The peripheral zone may or may not be textured or even serve to create an air-filled cavity. The Fresnel lens is able to cover the diode4like a hat. This part bearing the collimation optic has fastening stubs55afor holding the diode40,41. Once the light has been collimated (with one or more films, a plate or molded part) it is necessary to redirect it toward the ground for the back window or as a variant for the windshield (or for a rear window, etc.). FIG.1sis a front-on view of a redirection optic that will be on the front face of the collimation optic (fastened to its periphery, for example by adhesive bonding or welding or spaced apart therefrom by most 1 mm). It is a redirection optical film including an array of asymmetric prisms with apexes and with a pitch T′ between apexes that is from 10 μm to 500 μm, with preferably at least 4 or even 10 features facing the exit (or light-emitting) surface, The redirection optic thus includes a first optical film5that is asymmetric prismatic with, on a main face opposite to the exit surface, called the final front face, said array of asymmetric prisms extending longitudinally along a third axis making an angle of at most 10°, at most 5° or at most 2° to said first axis and even parallel and/or to the reference direction of the glazing (the horizontal for the back window) and even is parallel, in particular with a submillimeter-sized thickness. Each asymmetric prism is defined by first and second longitudinal faces the prism preferably having a length L and a width W with L>2 W and better still L>5 W or L>10 W. Each asymmetric prism has an angle at the apex a′0 ranging from 50 to 60° better still of 55°±5° or 55°±2° and the first longitudinal face51(called the long side) makes with the plane of the film a first angle, ranging from 31 to 41° better still of 35°±5° or 35°±2° (naturally the second longitudinal face (called the short side))52makes with the plane of the film a second angle, ranging from 79 to 99° better still from 85 to 90° or 88 to 90°, and preferably of at most 90°. Preferably, the difference a4-a3 is larger than 40° and even than 50°. The film is preferably a plastic film that is partially textured in its thickness, for example a film made of PET and of less than 0.6 mm or 0.3 mm thickness. As a variant, an assembly consisting of two parallel optical films that are asymmetric prismatic is chosen. FIG.2ais a cross-sectional view of a rear window200(back window) according to a second embodiment. This back window200comprises a transparent first glazing1made of organic or mineral glass, with main faces11,12called faces F1 and F2, and an edge face10, and a so-called reference direction that is the horizontal in the plane of the (optionally curved) glazing Each diode (on a diode carrier3) emits in the MV red toward the face F2 with a half emission angle at the apex of 50° to 70° and a main emission direction normal to the plane of the diode. As a variant it has a primary optical. To the exit surface is fastened by a peripheral adhesive bonding61a first optical film5awith said array of prisms extending longitudinally along a first axis. To the front face of this first film5ais fastened by a peripheral adhesive bonding62(glue, double-sided adhesive, etc.) a second optical film5bwith the second array of prisms extending longitudinally along a second axis making an angle to said first axis of 90°; the first or second axis makes with the reference direction a zero angle. To the front face of this second film5bis fastened by peripheral adhesive bonding63(glue, double-sided adhesive, etc.), a first redirection optical film5with array of asymmetric prisms with a long side51and a short sides52extending longitudinally in the reference direction. The normal N to the long side is directed toward the face F2 and oriented toward the top of the rear window or of the windshield (for a redirection toward the ground). The front face of this redirection film5is fastened by peripheral adhesive bonding64(glue, double-sided adhesive, etc.) to face F2; this is optional because here a protective rear film7(here a bilayer70,71covers and extends beyond the assembly consisting of the carrier3, the LED4and the optical films5a,5b,5) is fastened with adhesive65to face F2 of the single glazing (or F4 of a laminated glazing) and bears the diode carrier3. For example, this film7,70is tinted (in its bulk) or bears an electrically conductive functional layer71(solar control, etc.) on one of its main faces. The back window200is for example oriented between 12° and 80° from the ground and for example from 50 to 70°. The redirection film5for example redirects the light by an angle of at least 15° toward the ground. FIG.2bis a cross-sectional view of a rear window (back window)200aaccording to an alternative of the second embodiment. It differs from the preceding figure,FIG.2a, in that the collimation optic5bis a molded part with an array of prisms5b(with an array of crossed prisms thereabove) or an array of two-dimensional features. This part is fastened to the diode carrier3by adhesive bonding60(glue, double-sided adhesive). It may be a question of the part described inFIGS.1mto1r. FIG.2cis a cross-sectional view of a rear window200baccording to another alternative of the second embodiment. It differs fromFIG.2aabove all in that the diode4is reverse mounted and the collimation optical film5bincludes two-dimensional features (or two crossed prismatic films are employed). The diode carrier3may be apertured.FIG.2dshows this type of diode. The collimation optical film5bis adhesively bonded on its periphery by any means61to the diode carrier3 FIG.2eis a cross-sectional view of a rear window (back window)200daccording to another alternative of the second embodiment. It differs fromFIG.2ain that the collimation optic5bis a molded part that is common to a plurality of diodes4, with two-dimensional features, the redirection film5, which is adhesively bonded on its periphery to the part5bby any means62, also being common to these diodes. The diode carrier may be adhesively bonded by any means65′ (glue, double-sided adhesive, etc.) to the face F2 of the single glazing1(or as a variant F4 of a laminate). FIG.2fis a cross-sectional view of a rear window200eaccording to another alternative of the second embodiment. It differs fromFIG.2din that the collimation optic5bis a prismatic film or a film comprising two-dimensional features that is common to a plurality of (conventionally mounted) diodes just like the redirection film5that surmounts it. FIG.3ais a front-on view of a deflector (fixed side window)300with LEDs4providing collimated and redirected light according to one embodiment of the invention.FIG.3bis a cross-sectional view of the deflector300of the latter embodiment. This deflector300comprises a transparent first glazing1made of organic or mineral glass, with main faces11,12called faces F1 and F2, and an edge face10, and a so-called reference direction that is the normal to the horizontal in the plane of the (optionally curved) glazing. It is for example of quadrilateral shape with an upper edge of smaller width. It includes a masking layer15(black enamel, etc.) for example on face F2 and equipped with an aperture15a. The series of diodes3is located facing the aperture15aand interior-side and emits MV yellow toward the (interior) face F2. For example, it is a question of a luminous strip that is rectangular (or any other shape) on the lower border. To the exit surface is fastened by a peripheral adhesive bonding60a first optical film5awith said array of prisms extending longitudinally along a first axis (seeFIG.3b). To the front face of this first film is fastened by a peripheral adhesive bonding61a second optical film5bwith the second array of prisms extending longitudinally along a second axis making an angle to said first axis of 90°; the first or second axis makes with the reference direction a zero angle. To the front face of this second film is fastened by peripheral adhesive bonding62, a first redirection optical film5with array of asymmetric prisms with a long side51and a short sides52extending longitudinally in the reference direction. The normal N to the long side is directed toward the face F2 and oriented toward the front of the deflector (for a redirection toward the rear). The front face of this redirection film is fastened by peripheral adhesive bonding64to face F2; this is optional because here a protective rear film7with adhesive65is present (here a bilayer70,71covers and extends beyond the assembly consisting of the carrier, the LED and the optical films5a,5b,5). For example, it is tinted or bears an electrically conductive functional (solar-control, etc.) layer71. The back window is for example oriented between 12° and 80° from the ground and for example from 50 to 70°. The film for example redirects the light by an angle of at least 15° toward the ground. As a variant, it is a question of a laminated glazing with adhesive bonding to face F4. The enamel may be on face F2 or F3 or F4 (each with an aperture). In relation to the embodiment ofFIG.3a,FIG.3cis a front-on detail view of the diodes4(with the chips41and their outline40) each diode being equipped with its individual collimation optic made up of an array of prisms extending along the normal to the horizontal H and its redirection optic5made up of an array of asymmetric prisms extending along the normal to the horizontal H on the side of the exit surface30′. Thin and transparent optical films that are for example each of square shape and in particular a stack of two or three or more films is preferred. In relation to the embodiment ofFIG.3a,FIG.3dis an alternative front-on detailed view with (collimation and redirection) optics that are common to the diodes. Thus, the collimation optic and the redirection optic5extend far enough to cover all or some of the diodes (at least coverage per group of diodes). Between the diodes4the optics (non-functional portions55′) may be of small width or even of zero width and/or without texture (texture only facing the diodes4). For each optic, one or more thin and transparent optical films, for example of rectangular shape (constant or small width between the diodes as mentioned above), and in particular a stack of two or three or more films, is preferred. FIG.4is a cross-sectional view of a glazing400providing collimated and redirected light according to the invention. This laminated vehicle and in particular motor-vehicle back window400comprises:a transparent first glazing1, made of mineral or even organic glass, forming the exterior glazing, with main faces11,12called faces F1 and F2, an edge face10, and a so-called reference direction that is the horizontal between the lateral edges of the back windowa second glazing1′, forming the interior glazing, for example made of TSA (or clear or extra-clear) glass and in particular of 2.1 mm thickness or even 1.6 mm thickness or even of less than 1.1 mm thickness (in particular chemically toughened glass), with third and fourth main faces13,14called face F3 and face F4, respectively;between face F2 and face F3, which form the internal faces12,13of the laminated glazing, a lamination interlayer2,21,22made of polymeric material, here made of PVB, of thickness that is at most 2 mm or submillimeter-sized and preferably about 1 mm or less, for example of about 0.76 mm for a conventional PVB (RC41 from Solutia or Eastman) or, as a variant, if necessary, a (three-layer or four-layer) acoustic PVB for example of about 0.81 mm thickness, including a layer of PVB21with a face FB making adhesive contact with the (bare or coated) face F2 and an aperture2ethat emerges onto the face F2; the edge face20of this PVB being set back, for example by 2 mm, from the edge face of the glazings,an optional for example low-emissivity (ITO, etc.) functional layer on face F4 and/or alternatively face F3, which is optionally coated with a (heating, low-emissivity, etc.) functional layerpreferably internal and external peripheral masking layers on face F1 or 11 or on F3 or 13 or preferably on face F2 and even on F4 or 14, for example made of black enamel. In the emergent aperture of the PVB2is housed a light-emitting element that is an LED4on a carrier3, and which is able to emit MV red light in order to form a stoplight or another signaling light (or MV yellow for an indicator side-repeater light inter alia) or to serve for an external symbolism (pictogram, etc.) emitted toward face F212, said LED having an exit surface30toward face F2 and an opposite entrance surface30at the bottom of the aperture. The carrier3includes a connector35that extends beyond the edge face of the first glazing, which is here fastened entrance-surface side on its periphery. Facing the LED4is placed in this order:a collimation optic5a, having a rear face40on the side of the exit surface of the diode and a front face40′ opposite to the rear facea redirection optic5, having a rear face on the side of the exit surface of the diode and a front face opposite to the rear face As a variant, facing the LED is placed a holographic redirection optic having a rear face exit-surface side and a front face opposite to the rear face. The emergent aperture2encircles the LED4and the optics5a,5and even makes contact with its edge face or as a variant is spaced apart by at most 0.5 mm and even at most 0.1 mm from this edge face. The following are for example chosen during manufacture: a first and only sheet21, made of PVB, with one through—(or as a variant blind) aperture and, as a variant, also a rear second sheet of PVB on the rear-face side. By reflow, the two sheets are optionally joined with an interface possibly being visible. The collimation optic5ais here a prismatic optical film or preferably a film comprising two-dimensional features that is fastened on its periphery by a double-sided adhesive or a glue61to the exit surface of the diode (generating an air-filled cavity entry-side). It is for example a question of a plastic film of less than 0.3 mm thickness and made of PET that is partially textured in its thickness. For example, the pitch is 160 μm and the height 80 μm and the remaining thickness is 175 μm with angle at the apex and valley side of 90° (+−20 arc). Air is between the exit surface and the entrance face of this single first optical film of the collimation optic. Air is between the features of the front face of the collimation optic; the apexes of the features make physical contact with the redirection optic5. The redirection optic5is here an asymmetric prismatic optical film against or preferably as here fastened on its periphery by a double-sided adhesive or a glue60to the front face of the optic4(generating an air-filled cavity entry-side) and preferably against or as here fastened on its periphery by a double-sided adhesive or a glue60to the face F (generating an air-filled cavity entry-side). Air is between the prisms of the front face of the redirection optic; the apexes of the features make physical contact with face F2. The stack of these two films5a,5may be very thin. FIG.5is a cross-sectional view of a glazing500with LEDs providing collimated and redirected light according to the invention. This figure differs fromFIG.4in that there has been added, in the through-aperture of the PVB2, with respect to the redirection optic, which would include just the first prismatic film5a, a second prismatic optical film5bthat is crossed with the first film and with peripheral adhesive bonding62; and indeed a rear PVB22. The following are for example chosen during manufacture: a first sheet21, made of PVB, with one through—(or as a variant blind) aperture with a face FB making adhesive contact with the face F212(outside of the diode zone) and a second rear PVB sheet on the side of the rear face22with a face FA making adhesive contact with the face F313. By reflow, the two sheets are optionally joined with an interface (here shown by the dotted line) possibly being visible. If necessary, the carrier3is fastened beforehand to the rear sheet22by adhesive bonding or by creating point adhesive contact by applying spot heating (and pressure). Point adhesive contact may be created between the two sheets21,22outside of the LED zone or carrier zone3before or after installation between the two glazings1,1′. The stack of these three films5a,5b,5may be very thin. FIG.6is a cross-sectional view of a glazing600(back window or deflector) with LEDs providing collimated and redirected light according to the invention. This figure differs fromFIG.4in that a second redirection optical film5′ has been added (in the through-aperture of the PVB2) to the first redirection film5and adhesively bonded on its periphery63. FIG.7is a cross-sectional view of a glazing700(back window or deflector) with LEDs providing collimated and redirected light according to the invention. This figure differs fromFIG.4in that a rear PVB22is optionally added and the collimation optic (in the aperture of the PVB) is a molded part (with prismatic features5a) for example made of PMMA with an extension55adhesively bonded to the diode carrier3. A crossed prismatic film5bthat is on the molded part and under the redirection film5is used. As a variant, facing the LED is placed a molded part with a holographic redirection optic having a rear face exit-surface side and a front face opposite to the rear face. FIG.8is a cross-sectional view of a glazing800(back window or deflector) with LEDs providing collimated and redirected light according to the invention. This figure differs fromFIG.7in that the aperture in the PVB is internal (blind). For example, during manufacture a front PVB sheet23is put in place and the rear PVB sheet has even been removed (diode carrier adhesively bonded to face F3). To prevent reflow during the lamination from suppressing the optical function of the redirection optic5, a local plastic protective film7, for example of less than 0.3 mm thickness and made of PET, is adhesively bonded on its periphery to the front face of the redirection prismatic optical film5. This film7may be a color filter. The redirection optic5is here an asymmetric prismatic optical film against or as here fastened on its periphery by a double-sided adhesive or a glue60to the plastic protective film7. As a variant, facing the LED is placed a molded part with a holographic redirection optic having a rear face exit-surface side and a front face opposite to the rear face, and the protective film is preserved. FIG.8′ is an alternative of a cross-sectional view of a glazing800′ (back window or deflector) with LEDs providing collimated and redirected light according to the invention. This figure differs from the preceding figure in that the rear PVB sheet22is preserved and the plastic protective film7is a covering film for example of less than 0.3 mm thickness and made of PET that is adhesively bonded on its periphery to the front face of the redirection prismatic optical film5and/or that simply covers (closes) the emergent aperture. It makes adhesive contact with the front PVB sheet23and is for example preassembled therewith (functional PET/front PVB together before lamination). This film7,71may be tinted and/or have an electrically conductive functional coating72face-F2 or face-F3 side: solar control coating, low-E coating, etc. FIG.9is a cross-sectional view of a glazing100′ (back window or deflector) with LEDs providing collimated and redirected light according to the invention. This figure differs fromFIG.4in that the redirection optic5is larger than the emergent aperture (the collimation optical film59remains housed therein). The redirection optic5is against or as here fastened on its periphery by a double-sided adhesive or a glue63to face F2. A rear PVB sheet22has also been added. FIG.10is a cross-sectional view of a glazing110(back window or deflector) with LEDs providing collimated and redirected light according to the invention. This figure differs from the preceding figure in that the diode4is reverse mounted, and the diode carrier3is closer to face F2 and is apertured and receives the optics5a,5. As a variant, facing the LED is placed a holographic redirection optic having a rear face exit-surface side and a front face opposite to the rear face, and the diode carrier3is closer to face F2 and is apertured and receives this optic. FIG.11is a cross-sectional view of a glazing120(back window or deflector) with LEDs providing collimated and redirected light according to the invention. This figure differs from the preceding figure in that the diode carrier3is unapertured and forms the redirection optic5and the collimation optic is adhesively bonded beforehand to the exit surface face-F2 side. | 30,486 |
11858238 | DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS I. Definitions Before describing the present invention in detail, it is to be understood that this invention is not limited to particularly exemplified systems or process parameters that may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments of the invention only, and is not intended to limit the scope of the invention in any manner. All publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference. The term “comprising” which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. The term “consisting essentially of” limits the scope of a claim to the specified materials or steps “and those that do not materially affect the basic and novel characteristic(s)” of the claimed invention. The term “consisting of” as used herein, excludes any element, step, or ingredient not specified in the claim. It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a “surfactant” includes one, two or more surfactants. Unless otherwise stated, all percentages, ratios, parts, and amounts used and described herein are by weight. Numbers, percentages, ratios, or other values stated herein may include that value, and also other values that are about or approximately the stated value, as would be appreciated by one of ordinary skill in the art. As such, all values herein are understood to be modified by the term “about”. Such values thus include an amount or state close to the stated amount or state that still performs a desired function or achieves a desired result. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result, and/or values that round to the stated value. The stated values include at least the variation to be expected in a typical manufacturing or other process, and may include values that are within 10%, within 5%, within 1%, etc. of a stated value. Some ranges may be disclosed herein. Additional ranges may be defined between any values disclosed herein as being exemplary of a particular parameter. All such ranges are contemplated and within the scope of the present disclosure. In the application, effective amounts are generally those amounts listed as the ranges or levels of ingredients in the descriptions, which follow hereto. Unless otherwise stated, amounts listed in percentage (“%'s”) are in weight percent (based on 100% active) of any composition. The phrase ‘free of’ or similar phrases if used herein means that the composition or article comprises 0% of the stated component, that is, the component has not been intentionally added. However, it will be appreciated that such components may incidentally form thereafter, under some circumstances, or such component may be incidentally present, e.g., as an incidental contaminant. The phrase ‘substantially free of’ or similar phrases as used herein means that the composition or article preferably comprises 0% of the stated component, although it will be appreciated that very small concentrations may possibly be present, e.g., through incidental formation, contamination, or even by intentional addition. Such components may be present, if at all, in amounts of less than 1%, less than 0.5%, less than 0.25%, less than 0.1%, less than 0.05%, less than 0.01%, less than 0.005%, less than 0.001%, or less than 0.0001%. In some embodiments, the compositions or articles described herein may be free or substantially free from any specific components not mentioned within this specification. As used herein, “disposable” is used in its ordinary sense to mean an article that is disposed or discarded after a limited number of usage events, preferably less than 25, more preferably less than about 10, and most preferably after a single usage event. The wipes disclosed herein are typically disposable. As used herein, the term “substrate” is intended to include any material that is used to clean an article or a surface. Examples of cleaning substrates include, but are not limited to, wipes, mitts, pads, or a single sheet of material which is used to clean a surface by hand or a sheet of material which can be attached to a cleaning implement, such as a floor mop, handle, or a hand held cleaning tool, such as a toilet cleaning device. The term “substrate” is also intended to include any material that is used for personal cleansing applications. These substrates can be used for hard surface, soft surface, and personal care applications. Such substrates may typically be in the form of a wipe. The substrates contemplated herein are made up of at least 3 individual, distinct layers, which are bonded together in the described calendaring process. Each layer of the substrate may be formed from individual fibers which are interlaid, typically in a manner that is not identifiable, similar to a nonwoven. Woven layers are also possible. Films, which may not necessarily be fibrous (e.g., for the middle thermoplastic layer) may also be possible (e.g., a cast or blown film that does not necessarily include fibers) The top and bottom surface layers included in the present substrates may be formed by any suitable process, typically through wetlaying, although airlaying may also be possible. Where the exterior surface layers are formed of pulp fibers, wetlaid and airlaid exterior surface layers may be typical. Where synthetic fiber materials could be used for the exterior surface layers, other processes may be used to form such layers that are the starting materials for the present processes. For example, the layer(s) could be meltblown, spunbond, spunlaid, SMS (spunbond-meltblown-spunbond), coformed, carded webs, thermal bonded, thermoformed, spunlace, hydroentangled, needled, or chemically bonded. Various processes for forming such nonwovens will be apparent to those of skill in the art, many of which are described in U.S. Pat. No. 7,696,109, incorporated herein by reference in its entirety. Pulp fibers may generally be ribbon-shaped, rather than the generally circular cross section seen with synthetic fibers. Examples of synthetic fibers often used in forming nonwoven layers and that could be used in multi-layer wipes (e.g., as exterior surface layers) include, but are not limited to, polypropylene, PLA, PET, PVC, polyacrylics, polyvinyl acetates, polyvinyl alcohols, polyamides, polystyrenes, or the like. Polyethylene or other thermoplastic polymers having the desired tan delta characteristics may be useful as the interior thermoplastic material layer. PLA (e.g., a spunbond PLA nonwoven layer, a PLA film, etc.) is an example of another material that may also be suitable for use in one or more of the layers, including as a thermoplastic layer having the desired tan delta properties. It may also be possible to include polyethylene in the exterior surface layers, in some embodiments. The thermoplastic interior layer may be provided as a synthetic nonwoven, formed according to any desired process. The thermoplastic layer may also be a “cast” film, e.g., rather than being comprised of fibers. Such layer could alternatively comprise loose fibers of a material having the desired tan delta characteristics, where a layer of such loose fibers are placed on one of the exterior layers, covered with the other exterior layer, and then processed as described herein. Structured nonwoven fixed fiber forms that do not involve use of loose fibers may be preferred. Avoiding the use of loose pulp fibers in the exterior surface layers (using structured fixed fiber forms) is particularly beneficial. The basis weight of any of the layers of the substrate (and the multi-layer substrate as a whole) may be expressed in grams per square meter (gsm). Basis weight may sometimes also be expressed in “pounds” (e.g., referring to lbs/3000 ft2of the sheet material). The substrates as a whole may have basis weight values from 30-80 gsm. The terms “wipe”, “substrate” and the like may thus overlap in meaning, and while “wipe” may typically be used herein for convenience, it will be appreciated that this term may often be interchangeable with “substrate”. As used herein, “wiping” refers to any shearing action that the wipe undergoes while in contact with a target surface. This includes hand or body motion, substrate-implement motion over a surface, or any perturbation of the substrate via energy sources such as ultrasound, mechanical vibration, electromagnetism, and so forth. The cleaning compositions dosed onto the substrate as described herein may provide sanitization, disinfection, or sterilization, other cleaning, or other treatment. As used herein, the term “sanitize” shall mean the reduction of “target” contaminants in the inanimate environment to levels considered safe according to public health ordinance, or that reduces a “target” bacterial population by significant numbers where public health requirements have not been established. By way of example, an at least 99% reduction in bacterial population within a 24 hour time period is deemed “significant.” Greater levels of reduction (e.g., 99.9%, 99.99%, etc.) are possible, as are faster treatment times (e.g., within 10 minutes, within 5 minutes, within 4 minutes, within 3 minutes, within 2 minutes, or within 1 minute), when sanitizing or disinfecting. As used herein, the term “disinfect” shall mean the elimination of many or all “target” pathogenic microorganisms on surfaces with the exception of bacterial endospores. As used herein, the term “sterilize” shall mean the complete elimination or destruction of all forms of “target” microbial life and which is authorized under the applicable regulatory laws to make legal claims as a “sterilant” or to have sterilizing properties or qualities. Some embodiments may provide for at least a 2 or more log reduction (e.g., 3-log reduction, or 6-log reduction) in a bacterial population within a designated time period (e.g., 10 minutes, 5 minutes, 4 minutes, 3 minutes, 1 minute, 30 seconds, 10 seconds or the like). A 2-log reduction is equivalent to a 99% reduction, a 3-log reduction is equivalent to at least a 99.9% reduction, a 4-log reduction is equivalent to at least a 99.99% reduction, a 5-log reduction is equivalent to at least a 99.999% reduction, etc. An example of a target microbe may beStaphylococcus aureus. It will be appreciated that microefficacy can also be achieved against other target microbes, numerous examples of which will be apparent to those of skill in the art. It will also be appreciated that the present cleaning compositions need not include an antimicrobial agent, where sanitization or disinfection is not necessarily desired. The term “texture” as used herein refers to the character or appearance of a substrate as determined by the arrangement and thickness of its constituent fibers, in at least some instances, texture can be quantified using imaging techniques and/or caliper measurements at the local and macro scales, as described in Applicant's application Ser. No. 16/042,690, filed Jul. 23, 2018, herein incorporated by reference in its entirety. By way of explanation, “patterns” are typically visual, with areas of discernable contrast. “Texture” is typically tactile, and relates to variations relative to the normal plane of the substrate (i.e., 3-dimensional texture in the substrate). Visual pattern and tactile texture interact in a complex manner with a user's visual/tactile sense of sight and touch to produce a given aesthetic perception for a given substrate, in addition to other quantifiable technical characteristics associated with such. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although a number of methods and materials similar or equivalent to those described herein can be used in the practice of the present invention, the preferred materials and methods are described herein. II. Introduction In an aspect, the present invention is directed to methods for manufacturing multi-layer substrates including at least 3 layers. In an embodiment, the exterior faces of the wipe are provided by structured plant based fibers (fixed fibers, rather than loose fibers), such as structured, fixed wood pulp fibers (e.g., tissue paper). Where used, the term “tissue” is used for convenience, and it will be appreciated that it is intended to be broadly construed, including tissue paper materials, as well as other similar materials formed from pulp. Synthetic exterior layers such as meltblown, spunbond, spunlaid, SMS (spunbond-meltblown-spunbond), coform, carded webs, thermal bonded, thermoformed, spunlace, hydroentangled, needled, or chemically bonded fibers may also be suitable for processing according to the present methods, e.g., as described in Applicant's Application bearing Clorox. Configurations based on tissue exterior layers re described in Applicant's Application bearing Clorox, each of which is herein incorporated by reference in its entirety. An interior “sandwich” layer comprising a thermoplastic material (e.g., different from the exterior layers) is provided, between the tissue or other pulp layers (or other top and bottom exterior layers), which adheres the entire multi-layer substrate together in a single mass, with low risk of delamination, while providing desired characteristics relative to hand-feel, stiffness, and absorbency (ability to load the substrate to a desired loading ratio with a cleaning composition), while also providing a fluid pathway through the thermoplastic layer through which the cleaning composition can migrate from the top surface layer, to the bottom surface layer, or vice versa. Because the thermoplastic layer melts in contact with fibers of the adjacent exterior surface layers, and particularly given the tan delta characteristics of the thermoplastic material, the melt softened thermoplastic material encapsulates, envelops, wraps, or otherwise coats individual adjacent fibers of the exterior surface layer, providing a strong bond between the two adjacent layers, such that delamination does not readily occur. Even if a synthetic fiber were used in the exterior layers, the fibers of the exterior surface layers may provide differing characteristics, such that they do not melt soften in the same way the interior sandwich layer does, at the given processing conditions. In addition, the thermoplastic sandwich “cheese” layer typically does not penetrate through the exterior “bread” surface layers, so that none of the melt softened thermoplastic material with specific tan delta characteristics is on the exposed exterior faces of the wipe. This results in the advantage that relatively softer (e.g., pulp) fibers are used for wiping and cleaning versus contact with harder more abrasive synthetic melt softened fibers. The wipe may thus be less harsh on the surfaces being treated so as to reduce risk of undesirable mechanical scratching, abrasion, or erosion. Such multi-layer substrates may be formed through a thermal and pressure calendaring process in which the top and bottom layers are provided preformed (e.g., the tissue or other layers are provided preformed, with the fibers already in a structure, fixed form, as a structured sheet, such as a nonwoven), and a thermoplastic material comprising polyethylene or another polymer having suitable tan delta values is also provided. The thermoplastic material may also be in the form of a structured sheet (e.g., also a nonwoven, as a cast film, etc.), or may even be provided as loose fibers that are positioned onto a face of the bottom exterior layer, covered by the top exterior layer, and then calendared. Many commercially available multi-layer hard surface cleaning substrates have external layers made of synthetic thermoplastic materials such as polyethylene, polypropylene, PET, and other commonly used synthetic materials, which can be abrasive and harsh. Typically, a layer of pulp fibers is provided in the middle of the synthetic material layers so that the pulp fibers are not lost through abrasion during the cleaning process. In contrast, embodiment of the present invention including pulp fibers have the opposite configuration where the layers of pulp materials are in a top surface layer and a bottom surface layer and the thermoplastic material is between the pulp material layers. In any case, the described process and 3-layer configuration allows bonding of the 3 layers into an integral, single substrate structure, without the need for any chemical adhesives. The layers may be assembled, e.g., with the tissue or other exterior layers as “bread” sandwiching the thermoplastic film layer (as “cheese”) therebetween, followed by subjecting the assembly to heat (and typically pressure) at a temperature and time period that melt softens the thermoplastic material. This heating may open up pores through the thermoplastic material, even if it was provided as a liquid impervious film layer prior to the treatment. Heat softening of the thermoplastic material also causes it to wrap around or otherwise coat and envelop the adjacent fibers of the top and bottom surface layers, effectively tying the adjacent layers to one another, without any chemical adhesive to prevent the layers from delaminating or pulling apart from one another. As mentioned, at the same time that this layer bonding occurs, any liquid impervious film characteristics that may have previously existed with respect to the interior thermoplastic layer are broken, so that a fluid pathway is created through the thermoplastic layer, through which a cleaning composition or other liquids applied to either the top or bottom layer can penetrate from one surface layer to the other surface layer, through the thermoplastic film layer. Once the dry substrate has been formed, a desired cleaning composition may be loaded onto the multi-layer substrate. Because of the presence of the fluid pathway, even if the cleaning composition is loaded as a liquid into only one of the top or bottom layers, it will flow through the substrate to the other exterior layer through the broken thermoplastic layer. III. Exemplary Multi-Layer Substrates FIGS.1A-1Dillustrate exemplary wipes100a-100d, each with a different applied surface texture and bonding pattern, but where each is configured as a multi-layer substrate including a melted thermoplastic layer sandwiched between top and bottom pulp fiber or other exterior surface layers. While shown with various textures, it will be appreciated that numerous other textures could be provided, or perhaps no texture at all. Additional exemplary textures are shown inFIGS.7A-7F.FIG.1Eshows photographs of 4 exemplary multi-layer wipes100a-100dthat were actually manufactured for evaluation. FIG.2shows a close up of one of the raised ridges102of an exemplary wipe, showing how the raised circular ridge102(a “dot”) is unbonded to the thermoplastic film layer disposed therebelow, such that there is actually a gap there-between, at the ridge102. The region104surrounding the raised ridge102is bonded (and is so labeled) to the underlying thermoplastic film layer disposed therebelow. Depending on the particular applied textured pattern, the bonded region104may be contiguous, as shown (i.e., there is a single contiguous bonded region, rather than multiple bonded regions that are fully separated from one another). In other words, by “contiguous”, one can reach any particular location in the bonded region from any other particular location in the bonded region, by traversing only other bonded regions, without any need to traverse an unbonded region. The bonded region104may thus be contiguous, even though it does not cover the entire top exterior face (or bottom exterior face) of the wipe, because there are spaced apart unbonded regions102. Stated another way, by analogy, the unbonded regions may be configured as “islands” in a “sea” of the bonded region. It will be appreciated that other configurations are of course possible. The texture may be an embossed texture that is applied during the thermal calendaring or other manufacturing operation that laminates the 3 layers of the “sandwich” structure together. Alternatively, the texture could have been introduced into the substrate structure as a result of the geometry used in the forming screen used during the tissue making process, when depositing the pulp fibers that make up the tissue or other exterior surface layer(s). FromFIG.2, it is apparent that the pulp fibers of the top surface layer (as well as the bottom surface layer) are ribbon shaped, rather than being generally circular in cross-section, as is the case with typical synthetic fibers of non-woven substrates. Such ribbon-shaped fibers rather have a generally rectangular cross-section, as opposed to being circular in cross-section.FIG.3is an SEM image of an end or cross-section through an exemplary multi-layer substrate, such as that ofFIG.2, showing the thermoplastic film layer106(labeled “Bico”) sandwiched between a through-air-dried (“TAD”) pulp fiber top surface layer108a, and a TAD pulp fiber bottom surface layer108b. Also labeled inFIG.3is a bonded region104, as well as an unbonded region, adjacent a raised ridge “dot” of the bottom pulp fiber layer108b. In this labeled unbonded region, there is a gap between the thermoplastic layer106and the bottom pulp fiber layer108b. While in this region the bottom pulp fiber layer108bis unbonded, in this same region, the thermoplastic layer106may (or may not be) bonded to the top pulp fiber layer108a. In other words, the unbonded characteristic may apply to one or both faces of the thermoplastic layer. a. Pulp Characteristics The fibrous portion of the top and bottom surface layers of the multi-layer substrates may be formed predominantly, and in an embodiment entirely, from pulp fibers, e.g., wood pulp or other plant fibers. Even where the thermoplastic layer is clearly not comprised of such pulp fibers (as it is instead a synthetic thermoplastic polymeric material, (e.g., having particular tan delta value characteristics), the substrate as a whole is one in which a majority of the fiber weight of the substrate may be pulp. For example, greater than 70% (by weight) of the fibers of the substrate may be pulp fibers. In an embodiment 75% to 90%, 75% to 85%, or 75% to 80% of the fibers in the substrate may be pulp fibers, by weight. In other words, synthetic fibers may account for less than 30%, such as 10% to 25%, 15% to 25%, or 20% to 25% by weight of the fibers. Such is the case where the thermoplastic interior layer is a fibrous film (e.g., a thin spunbond film). It will be appreciated that in another embodiment, the thermoplastic film may not necessarily be fibrous, e.g., such as in the case of a cast or “bubble” blown film that is not made up of numerous fibers, but is simply a continuous thin (e.g., cast) sheet. In such an embodiment, the thermoplastic material may still account for less than 30%, 10% to 25%, 15% to 25%, or 20% to 25% of the dry substrate, but may simply be in non-fibrous form (e.g., a cast or blown sheet). In such a case, technically, 100% of the fibers of the substrate may be pulp fibers. In an embodiment, all fibers of the top surface layer and bottom surface layer may consist of or consist essentially of pulp fibers. For example, these layers may not include any synthetic fibers, or any synthetic structural components (e.g., no synthetic fillers). By forming the multi-layer substrates from a high fraction of pulp, the substrates may be more sustainably sourced, e.g., where a higher fraction of the components used are derived from sustainable sources as compared to, e.g., existing wipes formed from a blend of pulp and synthetic fibers. In addition, the location of pulp versus synthetic materials in the wipe may differ in that all pulp may be in the exterior surface layers, rather than having pulp fibers intermixed (e.g., homogenously) through a given (e.g., interior) layer. The pulp fibers may typically be obtained from wood, although other possible sources of pulp are also possible, e.g., from cotton, Esparto grass, bagasse, hemp, flax, jute or the like. Combinations of more than one material may be used. Various exemplary pulp fibers may include, but are not limited to, thermomechanical pulp fibers, chemimechanical pulp fibers, chemithermomechanical pulp fibers, refiner mechanical pulp fibers, stone ground wood pulp fibers, peroxide mechanical pulp fibers, and the like. The fibers of the pulp substrate may generally comprise cellulosic fibers, which are typically hydrophilic. Such hydrophilicity differs from many synthetic fibers, which are typically hydrophobic, absent special treatment. Additional details relative to exemplary pulp fibers are found in Applicant's application Ser. No. 16/042,690, filed Jul. 23, 2018, already herein incorporated by reference herein. Such characteristics can be specifically selected to ensure sufficient quat release, as well as other characteristics. b. Other Top and Bottom Exterior Surface Layers The top and bottom surface layers may alternatively be formed from a material that comprises synthetic fibers, or a blend of pulp and synthetic fibers. Any of various nonwoven materials may be used, which are widely available from various commercial sources. Such layers and fibers may be meltblown, spunbond, spunlaid, SMS (spunbond-meltblown-spunbond), coform, carded webs, thermal bonded, thermoformed, spunlace, hydroentangled, needled, or chemically bonded. In an embodiment, such surface layers may also incorporate a fraction of pulp fibers therein (e.g., as a homogenous blend of randomly distributed synthetic and pulp fibers, or where the pulp fibers are positioned non-randomly, e.g., at an exterior, or at an interior surface). In any case, the fraction of synthetic fibers within the top and bottom exterior surface layers may be at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%, by weight, of the fibers present in a given layer. In an embodiment, 100% of the fibers in a given exterior surface layer may be synthetic fibers. A wide variety of synthetic materials that can be formed into fibers, and laid into a nonwoven substrate layer are appropriate for use in the contemplated multi-layer substrates. Examples of such polymeric synthetic materials include, but are not limited to polyethylene, polypropylene, PET, PVC, polyacrylics, polyvinyl acetates, polyvinyl alcohols, polyamides, polystyrenes, or the like. In an embodiment, the external surface layers may comprise a material other than polyethylene, and/or a material that does not have the tan delta characteristics possessed by the internal thermoplastic layer, which is configured to be melt-softened, bonding the 3 layers together. No matter the choice of materials in the top and bottom surface layers (e.g., pulp or synthetic), the top and bottom layers of the multi-layer substrate may have a basis weight of no more than 50 lbs, no more than 40 lbs, no more than 30 lbs, or no more than 20 lbs, at least 3 lbs, at least 5 lbs, or at least 10 lbs, such as from 7 lbs to 20 lbs, or 8 lbs to 15 lbs. Such “lbs” values refer to the weight per/3000 ft2, as will be appreciated by those of skill in the art. The multilayer substrate as a whole may have a basis weight of 30-80 gsm. In an embodiment, the top and bottom layers comprise pulp fibers, and do not include any added synthetic fibers, e.g., such as various polyolefins or other fibers formed from synthetic polymers, e.g., polyethylene, polypropylene, PET, PVC, polyacrylics, polyvinyl acetates, polyvinyl alcohols, polyamides, polystyrenes, or the like. While such synthetic fibers are widely used in the manufacture of nonwoven substrates, such embodiments may seek to reduce the use of such non-sustainable materials. Furthermore, by limiting or eliminating their use in the top and bottom exterior surface layers, additional benefits can be provided. For example, the present wipes can provide functional parity, and sometimes advantages, over conventional nonwoven wipes in durability, safety for use on all surfaces, ease and convenience, ability to clean and absorb light liquid spills, ability to clean large areas effectively, and microefficacy in the case of sanitization or disinfection. Furthermore, the use of significant quantities of synthetic resins in existing pre-moistened nonwoven wipes represents a significant expense, such that cost savings, renewability and sustainability benefits, and biodegradability benefits can be achieved using pulp substrates, as described herein. The individual layers of the top and bottom (e.g., pulp fiber) layers that are used in manufacturing the multi-layer substrate can be formed by any of a number of different techniques, e.g., such as any of those suitable for use in forming tissue layers. Examples include, but are not limited to wet-laying and air-laying, as well as conventional press-drying, and through-air drying techniques. Methods of making such substrate layers will be apparent to those of skill in the art. Wet-laying processes are described in U.S. Pat. Nos. 5,246,772 and 5,238,534 to Manning. Air-laying processes are described in U.S. Patent Publication No. 2003/0036741 to Abba et al. and U.S. Patent Publication No. 2003/0118825 to Melius et al. Conventional processes by which a manufactured substrate in a wet condition is pressed to remove process water, as well as through-air-drying processes will be familiar to those of skill in the art. In an embodiment, the top and bottom tissue layers are formed by through-air-drying. Such processes are typically carried out prior to the positioning and calendaring processes described herein, e.g., where the inputs to the presently described process are nonwovens or similar structured sheet or web materials, already processed into such structured sheets, so that the present processes do not require use of loose fibers (particularly loose pulp fibers), do not require use of process water to maneuver fibers along the plane or through a thickness of the given sheet or web (as the sheet or web is already formed in the material used as an input to the present process), do not require drying or another mechanism for removing process water, and do not require use of chemical binders to adhere the various layers to one another (as this is achieved through melt softening the interior thermoplastic layer). Where tissue layers are used as the exterior surface layers, one or both of the tissue layers may comprise more than a single ply, or each may comprise only a single ply. Where multiple plies are provided, they may be adhered together, so as to have adequate peel strength, e.g., as described in Applicant's application Ser. No. 16/042,690, filed Jul. 23, 2018, already incorporated by reference. Where only a single ply is present in each of the top and bottom tissue layers, no chemical adhesive may be present anywhere in the multi-layer substrates. Where two plies are used in either or both of the tissue layers, a chemical adhesive may be present in the tissue layers (i.e., between plies), but may not be present between the thermoplastic layer and the adjacent top and bottom tissue layers. c. Thermoplastic Layer The present multi-layer wipes include a sandwich structure in which a thermoplastic layer is provided, on the inside of the wipe, sandwiched between the top and bottom surface layers (e.g., pulp layers). While in an embodiment, the surface layers could also be thermoplastic, these exterior layers may include different tan delta characteristics than the sandwiched thermoplastic layer. Where no chemical adhesive is used to adhere the 3 layers into an integral, single structure that does not readily delaminate between layers, but in which the thermoplastic sandwich “cheese” layer itself is used for this purpose, the Applicant has found that not just any thermoplastic polymer will be suitable for such a purpose. For example, in testing various thermoplastic polymers, Applicant found that various materials, even upon heating, will not readily bond to the adjacent pulp fiber or other nonwoven top or bottom surface layers, but will form a very weak bond, if any at all. Such weak bonding is of course unacceptable in a multi-layer substrate to be used as a cleaning wipe, where delamination must be avoided. In the present invention, the multi-layer substrates have sufficient adhesion between the layers that they do not delaminate even when wet (e.g., allowed to soak for weeks, in storage) or when used for cleaning hard surfaces. The interior thermoplastic layer not only binds the multi-layer substrate together as it melts, but it also may impart additional strength to the exterior layers, where these layers may be relatively weak. It is surprising that this binding of the exterior layers occurs so well that there is not any significant shredding of the exterior surface layer, e.g., as the multi-layer substrate is pulled through a typical wipe dispensing orifice, even where such exterior layers consist essentially of pulp fibers (e.g., tissue). Values and testing protocols that may be applicable to the peel strength provided by the present bonding processes between the interior thermoplastic layer and the exterior surface layers are disclosed in Applicant's Application bearing Clorox, herein incorporated by reference in its entirety. Applicant found that while polypropylene may seem like a suitable thermoplastic material to achieve sufficient bonding between the top and bottom pulp fiber or other nonwoven surface layers separated by the interior thermoplastic material layer, polypropylene did not provide good bonding, but resulted in weak bonding and delamination between the 3 layers. Applicant found a key characteristic or indicator as to whether a given thermoplastic material would work, is tan delta value. Tan delta value is an engineering characteristic that can be evaluated for thermoplastic polymeric materials, and gives information relative to how much “liquid” viscous phase characteristics dominate versus “solid” elastic phase characteristics, in a given material, at a given temperature. Tan delta is simply calculated as the ratio of viscous modulus divided by elastic modulus for a given material, at a given temperature. FIG.4charts both tan delta and elastic modulus values for 3 tested thermoplastic materials—polyethylene, polypropylene, and a bicomponent material that comprises polyethylene. For example, the bicomponent material tested is believed to be comprised of bicomponent fibers, with a fiber core (that is not polyethylene), and an exterior coating or sheath on the core, that is polyethylene.FIG.4charts both elastic modulus and the tan delta value for these 3 materials over the temperature range of about 100° F. to 350° F.FIG.4shows how the elastic modulus (i.e., stiffness) of the polypropylene is the highest, followed by the “bico”, followed by the polyethylene, and that the stiffness of each decreases with increasing temperature. The tan delta value for the polypropylene is very low, less than 0.2, and remains less than 0.15 at temperatures from 100° F. to over 300° F. It isn't until nearly 350° F. that the tan delta value increases somewhat, but only slightly, up to a value of about 0.15, and certainly still less than 0.2. The polyethylene tan delta value is quite different, being about 0.2 at a temperature of 100° F., and increasing to about 0.25 to 0.3 at about 175° F.-190° F. After peaking at around this temperature, the tan delta value begins to decrease, to 0.2 at about 250° F., and dropping somewhat below 0.2 (e.g., about 0.18) at about 260°−270° F. Tan delta for the “bico” is between that of the polypropylene and the polyethylene for much of the temperature range, until about 250° F. where it is higher than the polyethylene. Both the polyethylene and the “bico” material (which comprises polyethylene) include points along the temperature range of 100° F. to 350° F. where tan delta is at least 0.2 (e.g., greater than 0.2 to 0.4, or greater than 0.2 to 0.3), meeting the stated requirement. The polypropylene tan delta never reaches 0.2 over this temperature range of 100° F. to 350° F. Thus, in an embodiment, the selected thermoplastic material for the interior “sandwich” layer has a tan delta value that is at least 0.2 (e.g., from 0.2 to 0.4, or from 0.2 to 0.3) somewhere within the temperature range of 100° F. to 350° F. In an embodiment, the selected thermoplastic material may have such a tan delta value at the particular temperature at which the thermal calendaring step is performed (e.g., 150° F., 175° F., 200° F., 225° F., 250° F., 275° F., 300° F., 325° F., etc.) or at any narrower range within the temperature range of 100° F. to 350° F. The selected thermoplastic material may advantageously have a melting temperature that is less than 400° F., less than 375° F., less than 350° F., less than 325° F., less than 300° F., at least 150° F., at least 175° F., at least 200° F., or at least 225° F. Having a relatively lower melting temperature of course reduces energy requirements needed in the calendaring process, but may also be important depending on what materials are used in the top and bottom surface layers, to ensure they do not decompose, ignite, or melt. Where any pulp fiber content is included in the exterior surface layers, it can be important to ensure the temperature is low enough that such pulp fibers do not ignite, or become embrittled or discolored due to “burning”, which may occur even below the paper ignition temperature of 451° F. As such, selection of lower melting temperature thermoplastic materials may be preferred, so long as they can provide a good bond to the exterior top and bottom layers. The interior thermoplastic layer may comprise, e.g., at least 25%, at least 30%, at least 35%, at least 40%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, from 25% to 100%, from 30% to 100%, or from 50% to 100% of a material having the desired tan delta characteristics. As illustrated by the bico fiber material, some portion or component of the thermoplastic material may not have the stated tan delta characteristics, so long as the thermoplastic material as a whole includes such characteristics. For example, the bico fiber is believed to include a polypropylene core, which does not have the stated tan delta characteristics, although the sheath portion of the fiber is believed to be polyethylene, which does have the stated tan delta characteristics. As shown byFIG.4, the bico fibers as a whole do meet the stated tan delta characteristics. Where the thermoplastic material is a bicomponent fiber or other bicomponent (or other multicomponent) structure, e.g., such as a layered film or the like, the polyethylene or other material having the stated tan delta characteristics may be positioned on the exterior of the thermoplastic material, so as to easily contact the adjacent exterior surface layers during the calendaring process. FIGS.5A-5Bshow how the present multi-layer substrates may be packaged within any of various exemplary flex packs (FIG.5A), cylinders (FIG.5B) or other containers for storage and dispensing. The wipes100may be pulled through an orifice such as typically provided with such containers, without fear of shredding or delamination of the various layers. In particular, Applicant tested prototype wipes such as shown inFIG.1Eby pulling them through orifices (e.g., as seen inFIGS.5A-5B), and there was no significant shredding of the exterior tissue layers, or delamination of the layers from one another. Rather, each wipe was able to be pulled through the orifice, remaining fully intact, time after time.FIG.6shows an SEM image at the interface between a spunbond fibrous thermoplastic layer106and an adjacent exterior tissue layer (e.g.,108a) showing how the pulp fibers at the interface are wrapped around, enveloped, or coated by the melt-softened thermoplastic material, that occurs during the thermal calendaring process. This strong connection between the pulp fiber layer and the thermoplastic layer provides a strong bond, so that shredding or delamination does not occur when pulling the wipe through a typical wipe pack orifice. These characteristics are believed to result because of the tan delta characteristics of the thermoplastic material described above in conjunction withFIG.4. FIG.5Bfurther shows how such wipes may be packaged as a “donut”, e.g., in a cylindrical container. The ability to package the wipes in such a donut configuration is somewhat surprising when the exterior surface layers are pulp, given the high pulp content (e.g., 75-80% pulp) of the substrate. For example, it is difficult to package pre-dosed 100% pulp substrates in such a configuration without the donut collapsing or creasing vertically, due to insufficient wet stiffness of the substrate. The thermoplastic film layer is not required to be particularly thick. For example, the thermoplastic film layer may have a thickness of 0.01 mm to 0.1 mm, or 0.01 mm to 0.05 mm. It may be so thin as to be transparent or translucent, prior to assembly into the sandwich structure. That said, it will be apparent that if desired, the thermoplastic middle sandwich layer may be thicker. For example, it may have a thickness that varies depending on the structural characteristics of such layer (e.g., whether it is deposited as loose fibers (e.g., loose bico fibers, or loose fibers otherwise comprising a material having the desired tan delta characteristics), an intact film, yarn (e.g., loose yarn), an intact nonwoven layer, a woven layer, or the like). It will be apparent that the thermoplastic middle sandwich layer may thus have a thickness ranging from 0.01 mm to 5 mm, from 0.01 mm to 3 mm, from 0.01 mm to 2 mm, from 0.01 mm to 1 mm, from 0.01 mm to 0.5 mm, or the like. Strength and/or stiffness characteristics of the wipe may be dictated at least in part by the characteristics of the middle thermoplastic layer of the present substrate. For example, strength and stiffness of the substrate as a whole may progressively increase as one uses, respectively, fibers, a film, a yarn, a nonwoven (e.g., a bico nonwoven), or a woven structured material for the middle sandwich layer. Such materials are listed generally in order of increasing resiliency, where strength and/or stiffness of the overall substrate increase with increasing resiliency of the middle layer. Of course, thickness of the middle layer will also affect the strength and/or stiffness of the finished substrate. By way of further explanation, at a given thickness, a woven structure for the thermoplastic middle sandwich layer may provide the greatest strength and/or stiffness to the substrate, while a nonwoven thermoplastic middle sandwich layer would typically provide somewhat lower strength and/or stiffness. Use of a yarn, e.g., where multiple fibers are twisted or otherwise arranged together, providing a yarn diameter significantly greater than that of the individual fibers making up the yarn may provide somewhat lower stiffness and strength, and a film or simple deposition of individual, loose fibers onto either of the exterior surface layers to form the thermoplastic middle sandwich layer may provide even lower stiffness and/or strength. It will be apparent that numerous possible configurations are possible as to the structure of the thermoplastic middle sandwich layer, and that numerous possible methods are possible for providing such (e.g., providing preformed layers, for example, as a film, nonwoven, or woven) that are simply placed between the exterior layers, or by providing one of the exterior surface layers, and then depositing individual loose fibers, yarn or the like onto the interior surface of such exterior layer, followed by positioning the other exterior surface layer there over, after which the 3-layer structure is then subjected to heat and/or pressure, to adhere the layers to one another, and cause the formation of cracks, fissures and the like through the thermoplastic middle sandwich layer, through which a cleaning lotion that eventually becomes loaded into the substrate can pass from one exterior surface layer, through the thermoplastic middle sandwich layer, to the other exterior surface layer. For example, one could provide a nonwoven exterior surface layer of any suitable material (e.g., pulp), which serves as a carrier to lay down loose fibers (or fibers formed into a yarn) of the thermoplastic material onto the pulp or other suitable exterior surface layer. Finally, the opposite exterior surface layer (e.g., another pulp nonwoven layer) may be positioned over the loose fibers or loose yarn, and the 3-layer structure may be processed with appropriate heat and/or pressure to melt soften the thermoplastic middle sandwich layer, as described herein. Another benefit associated with use of pulp exterior layers is that the resulting substrate exhibits lofted characteristics due to the “fuzzy”, loose bulk structure of the nonwoven randomly laid pulp fibers in the exterior layers. When using synthetic exterior layers, it may be desirable to provide the substrate with a lofted structure, so as to increase the bulk and thickness of the substrate, where such lofted characteristics may not otherwise be provided with synthetic exterior layers. Such lofting may be provided through overfeeding one or more of the layers (e.g., exterior layers) into the rollers which heat and press the layered substrate. For example, the feed rate of one or both exterior surface layers may be greater than a pick up rate on the other side of such rollers, which causes the material of the overfed layers to bunch up or create pleats as it enters the rollers (e.g., the heated nip and the opposite roller) where the melt softening of the middle layer occurs. This causes a bunched up, pleated, or similar lofted configuration including air gaps to be locked in to the exterior layer as the middle layer melt softens, and bonds to the exterior overfed layer. Such a lofted configuration gives more cloth-like hand feel characteristics, and may provide “reservoirs” within which the cleaning lotion may be stored. This lofted configuration is durable after dosing and during use, akin to what may be provided with a fuzzy, lofted pulp containing (non-synthetic) layer. Other techniques for providing a lofted layer (e.g., particularly on either or both exterior surface layers) may also be used. For example, a pin roller could be used to pull portions of the exterior surface layer laterally outward from the substrate plane, creating a fuzzy, lofted texture with decreased density and increased volume and thickness to such layer. Various other techniques will be apparent to those of skill in the art, in light of the present disclosure. Where desired, any synthetic substrate layers or materials could be selected to be biodegradable and/or compostable (e.g., meeting the standard of ASTM D6400 or other applicable standard). Of course, pulp layers easily meet such criteria. FIG.8schematically illustrates an exemplary calendaring process200that may be used to form the substrates including 3 or more distinctly identifiable layers.FIG.8shows use of a rolled web of the 3 starting sheet materials, although it will be appreciated that they could be provided as distinct, separate sheets of material, or that the middle thermoplastic layer could be laid down as loose fibers, before calendaring. Process200is shown as including a mechanism202for feeding thermoplastic material204, as well as mechanisms206a,206bfor providing top and bottom exterior surface layers208a,208b. As shown inFIG.8, the thermoplastic material204is sandwiched between exterior surface layers208a,208bas it is fed into calendaring portion of process100, e.g., along an optional conveyor belt210. A 4thoptional layer207is shown inFIG.8. For example, if desired, a layer having particular desired characteristics could also be fed into the sandwiching of such layers. Sandwiched structure212(thermoplastic material layer204between exterior surface layers208a,208b) may pass under a roller214and then to rollers216a,216b. Typically, one of rollers216a,216bis rubber, while the other is metal. The rollers may heat the sandwich structure212to the desired temperature, for a desired period of time, so as to melt soften the interior layer204, causing it to bond to the surface exterior layers208a,208b. The pressure applied may be e.g., at about 10 bars, at least about 15 bars, or at least about 25 bars. More generally, such pressure may be less than 300 bars, less than 200 bars, less than 100 bars or less than 50 bars, from 1 to 500 bars, from 5 to 500 bars, from 10 to 300 bars, or from 25 to 200 bars pressure. The thickness and weight of the constituent layers, may have an effect on the required pressure and temperature, and contact time in order to achieve good bonding, as described herein. After passing through calendaring rollers216a,216b, the sandwich structure212′ which is now bonded between the interior layer and the exterior layers passes to take up roller218. It will be appreciated that such a process is relatively simple, involving far less capital investment than associated with typical wipe manufacturing operations, which are based on production of such wipe substrates using loose fiber starting materials, and which require use of process water, drying operations to remove such process water, etc. For example, typical processes that incorporate pulp fibers into a wipe substrate are complex processes, involving high capital investment, use of process water to maneuver the fibers either along the plane of the substrate being formed, or through the thickness thereof, subsequent drying to remove such process water, etc. The presently described process is far simpler, in that it uses pulp layers that are already provided in structured form, where the fibers are already fixed relative to the pulp layer, and adhering two such pulp layers so as to form the exterior surface layers, sandwiching therebetween a thermoplastic layer having particular characteristics that permit bonding of the distinct 3 layers without use of any chemical adhesives that would require curing, etc. While principally described in the context of using rollers to perform the heating and pressing, it will be appreciated that heated plates could alternatively be used (e.g., introducing the sandwich structure between platen plates and pressing the sandwich), although the rollers configuration may be preferred as allowing for far higher production volumes. d. Cleaning Composition Many cleaning composition components as known within the art may be suitable for use in the present pre-dosed wipes. In an embodiment, the cleaning composition is an aqueous composition, including at least 70%, at least 80%, or at least 90% water by weight (e.g., 90% to 99% water). The composition may include 0.05% to 5% by weight of a quaternary ammonium compound, and/or 0.1% to 5% by weight of a glycol ether solvent. For example, the quaternary ammonium compound may be included from 0.05%, from 0.1%, up to 5%, up to 4%, up to 3%, up to 2%, or up to 1% by weight of the cleaning composition. The glycol ether solvent may be included from 0.1%, from 0.25%, up to 5%, up to 4%, up to 3%, up to 2%, or up to 1% by weight of the cleaning composition. Other solvents, surfactants, and various other adjuvants often included in cleaning compositions may optionally be present. While some embodiments may include lower alcohol solvents (e.g., C1-C4alcohols), the amount of such volatile solvents may be limited, e.g., to less than 10%, less than 5%, less than 3%, less than 2%, or less than 1% by weight. In some embodiments, the composition may be free of, or substantially free of, such lower alcohol or other highly volatile solvents. Quaternary ammonium compounds or other cationic biocides can have broad spectrum antimicrobial properties. A variety of different quaternary ammonium compounds can be used in the cleaning composition. Non-limiting examples of quaternary ammonium compounds are typically halides (e.g., a chloride) of alkyldimethylbenzylammonium, alkyldimethylethylbenzylammonium, alkyldimethylammonium, or the like. The alkyl groups of such quaternary ammonium compounds may typically range from C12to C18. Quaternary ammonium compounds are described in more detail in U.S. Pat. No. 6,825,158, incorporated by reference herein, and will already be familiar to those of skill in the art. Organic acids can also be used to provide antimicrobial properties. By way of example, such an organic acid may be included in an amount of at least 0.1%, or at least 0.5%, up to 5%, up to 4%, up to 3%, up to 2%, or up to 1% by weight of the cleaning composition. The cleaning composition may include a glycol ether solvent. Exemplary glycol ether solvents include, but are not limited to alkyl ethers of alkylene glycols and alkylene glycol ethers, such as ethylene glycol monopropyl ether, ethylene glycol monobutyl ether, propylene glycol n-propyl ether, propylene glycol monobutyl ether, propylene glycol t-butyl ether, diethylene glycol monoethyl or monopropyl or monobutyl ether, di- or tri-polypropylene glycol methyl or ethyl or propyl or butyl ether, acetate and/or propionate esters of glycol ethers. Those of skill in the art will appreciate that any among a wide variety of surfactants (e.g., anionic, cationic, non-ionic, zwitterionic, and/or amphoteric) may be included in the cleaning composition, as desired. Where included, a surfactant may be present from 0.05%, from 0.1%, up to 10%, up to 5%, up to 4%, up to 3%, up to 2%, or up to 1% by weight of the cleaning composition. Various surfactants and other optional adjuvants are disclosed in U.S. Pat. No. 3,929,678 to Laughlin and Heuring, U.S. Pat. No. 4,259,217 to Murphy, U.S. Pat. No. 5,776,872 to Giret et al.; U.S. Pat. No. 5,883,059 to Furman et al.; U.S. Pat. No. 5,883,062 to Addison et al.; U.S. Pat. No. 5,906,973 to Ouzounis et al.; U.S. Pat. No. 4,565,647 to Llenado, and U.S. Publication No. 2013/0028990. The above patents and applications are each herein incorporated by reference in their entirety. As used herein the term “liquid” and “cleaning composition” includes, but is not limited to, solutions, emulsions, suspensions and so forth. Thus, liquids may comprise and/or contain one or more of the following: disinfectants; antiseptics; diluents; surfactants, such as nonionic, anionic, cationic; waxes; antimicrobial agents; sterilants; sporicides; germicides; bactericides; fungicides; virucides; protozoacides; algicides; bacteriostats; fungistats; virustats; sanitizers; antibiotics; pesticides; and so forth. Examples of some such components and exemplary compositions are disclosed in U.S. Pat. Nos. 6,825,158; 8,648,027; 9,006,165; 9,234,165, 9,988,594 and U.S. Publication Nos. 2008/003906 and 2018/0216044, each of which is herein incorporated by reference in its entirety. In some embodiments, it may be possible to provide the substrates in dry form, where dosing with a selected cleaning composition may occur later (e.g., by the user). With regard to pre-moistened substrates, a selected amount of liquid may be added to the container or wipes during manufacture such that the cleaning substrates contain the desired amount of liquid. The substrates are not necessarily loaded to their saturation point, but are typically loaded with the cleaning composition to some ratio less than full saturation. For example, many substrates are capable of holding about 8 to 14 times their weight in liquid. For various reasons, the substrates may be loaded at a loading ratio less than saturation, e.g., less than 6:1, less than 5:1, less than 4:1, such as from 1:1 to 4:1, from 2:1 to 4:1, from 2.5:1 to 3.5:1, from 2.5:1 to 3:1 or from 2.5:1 to 3.75:1. Where the substrate may be configured so as to be all synthetic (e.g., without pulp in the exterior surface layers), this may offer additional flexibility in the chemistries that may be dosed (e.g., during manufacture) onto such substrate for use, while minimizing or eliminating risk of undesired incompatibility that may result between components of such compositions and substrates that may include pulp, other natural fibers, or other natural components. By way of non-limiting example, a wide variety of bleaching agents (e.g., chlorine-based and otherwise, including peroxides, hypochlorites, etc.) may be used with such synthetic substrates. Compositions which achieve disinfection based on acids (e.g., acetic acid) may also be used. Such acid disinfectants and bleaches are often incompatible with non-synthetic substrate materials. Non-limiting examples of such compositions are disclosed in U.S. Pat. No. 5,460,833 to Andrews et al.; U.S. Pat. No. 6,221,823 to Crisanti; U.S. Pat. No. 6,346,279 to Rochon et al.; U.S. Pat. No. 6,551,980 to Wisniewski et al.; U.S. Pat. No. 6,699,825 to Rees et al.; U.S. Pat. No. 6,803,057 to Ramirez et al.; U.S. Pat. No. 6,812,196 to Rees et al.; U.S. Pat. No. 6,936,597 to Urban; U.S. Pat. No. 7,008,600 to Katsigras et al.; U.S. Pat. No. 7,070,737 to Bains et al.; U.S. Pat. No. 7,354,604 to Ramirez et al.; U.S. Pat. No. 7,598,214 to Cusack et al.; U.S. Pat. No. 7,605,096 to Tamarchio et al.; U.S. Pat. No. 7,658,953 to Bobbert; U.S. Pat. No. 7,696,143 to McCue et al.; U.S. Pat. No. 7,915,207 to Chopskie et al.; U.S. Pat. No. 8,569,220 to Gaudrealt; U.S. Pat. No. 8,575,084 to Gaudrealt; U.S. Pat. No. 10,064,409 to Hazenkamp et al.; U.S. Pat. No. 10,076,115 to Salminen et al.; U.S. Publication No. 2007/0190172 to Bobbert; PCT Publication Nos. WO 99/18180 to Raso et al.; WO 99/53006 to Masotti et al.; WO 2004/067194 to Arrigoni et al.; WO 2004/104147 to Rosiello et al.; WO 2017/174959 to Convery; and EPO Publication EP 2843034 to Nedic et al. e. Other Characteristics The size and shape of the wipe can vary with respect to the intended application and/or end use of the same. The cleaning substrate can have a substantially rectangular shape of a size that allows it to readily engage standard cleaning equipment or tools such as, for example, mop heads, duster heads, brush heads, mitten shaped tools for wiping or cleaning, and so forth. In another embodiment, another shape, e.g., circular, oval, or the like) may be provided. The wipes or other cleaning substrates may be provided pre-moistened with a cleaning composition. The wet cleaning substrates can be maintained over time in a sealable container such as, for example, within a bucket or tub with an attachable lid, sealable plastic pouches or bags, canisters, jars, and so forth. Desirably the wet, stacked cleaning substrates are maintained in a re-sealable container. The use of a re-sealable container is particularly desirable when using aqueous volatile liquid compositions since substantial amounts of liquid can evaporate while using the first sheets thereby leaving the remaining sheets with little or no liquid. Exemplary re-sealable containers and dispensers include, but are not limited to, those described in U.S. Pat. No. 4,171,047 to Doyle et al., U.S. Pat. No. 4,353,480 to McFadyen, U.S. Pat. No. 4,778,048 to Kaspar et al., U.S. Pat. No. 4,741,944 to Jackson et al., U.S. Pat. No. 5,595,786 to McBride et al.; the entire contents of each of the aforesaid references are incorporated herein by reference. Typically, the cleaning substrates are stacked and placed in the container and the liquid subsequently added thereto, all during mass manufacturing. It is advantageous that the thermoplastic layer at the center of each wipe not be liquid impervious, to facilitate easier loading of the wipes. As described herein, even if the thermoplastic film as initially provided before lamination of the 3 layers together is liquid impervious, Applicant has found that cracks or other fluid pathways are opened up within the film during thermal calendaring, as contemplated herein. While this may not necessarily occur with any and all thermal calendaring operations, it does occur under the conditions contemplated herein. The presence of such cracks or other fluid pathways that are opened up during manufacture of the multi-layer substrate advantageously allow liquid cleaning composition dosed on either face of the substrate to migrate through the wipe, to the opposite exterior face, through the thermoplastic film layer. This similarly allows the dosed cleaning composition to migrate from one substrate to the next, e.g., where the substrates are stacked (e.g., by wicking the liquid from one to the next). For example, a given volume or weight of the cleaning composition may simply be dosed into the bottom of the container, allowing it to wick into the stack of wipes. In the case of a donut configuration, by placing the cleaning composition into the bottom of the cylindrical container, an end of each wipe actually make simultaneous contact with the cleaning composition in the bottom of the container, where it can be wicked up into the height of each wipe (and the height of the donut). This may actually occur with a donut configuration whether the thermoplastic film layer were “broken” to include the described fluid pathways or not (i.e., if it remained impervious), as both the top and bottom surface layers will contact the cleaning composition at the bottom of the container simultaneously. Where any initially liquid impervious characteristics of the film are “broken” by the thermal calendaring process, this may further aid the cleaning composition in wicking upwards throughout the full height of each wipe, and the donut as a whole. No matter the packaging and dosing process, once manufactured and packaged, the substrate can subsequently be used to wipe a surface. The moistened cleaning substrates can be used to treat various surfaces. As used herein “treating” surfaces is used in the broad sense and includes, but is not limited to, wiping, polishing, swabbing, cleaning, washing, disinfecting, scrubbing, scouring, sanitizing, and/or applying active agents thereto. The wipes or other cleaning substrates of the present invention can be provided in a kit form, wherein a plurality of cleaning substrates and a cleaning tool are provided in a single package. In addition to material composition and construction (e.g., tissue substrates on the exterior, thermoplastic layer having particular tan delta characteristics only on the inside, not on the exposed face, composition of the cleaning “lotion” and the like), wipe or other substrate dimensions can also be used to control dosing as well as provide ergonomic appeal. In one embodiment, substrate dimensions are from about 5½ inches to about 11 inches in length, and from about 5½ inches to about 11 inches in width to comfortably fit in a hand. The substrate can have dimensions such that the length and width differ by no more than about 2 inches. Larger substrates may be provided that can be used and then folded, either once or twice, so as to contain dirt within the inside of the fold and then the wipe can be re-used. Such larger substrates may have a length from about 5½ inches to about 13 inches and a width from about 10 inches to about 13 inches. Such substrates can be folded once or twice and still fit comfortably in the hand. While most synthetic or blended nonwoven substrates used in wipe manufacture exhibit significant differences in tensile strength in the machine direction (MD) versus the cross direction (CD), the present multi-layer substrates may exhibit values in each direction that result in a ratio of MD/CD that is relatively close to 1, e.g., such as 0.5 to 1.5, 0.75 to 1.25, or 0.8 to 1.2. In other words, the substrates may be substantially isotropic with respect to their tensile strength. Such substantially isotropic characteristics reduce the likelihood of there being problems when folding substrates into stacks for packaging, or forming donuts for packaging. Various other characteristics relating to stiffness, strength, density of pulp fibers, wet bulk factor, profile height, pore volume distribution characteristics, retention characteristics, lotion retention, MABDF, and others that may be provided by the present wipes are described in Applicant's application Ser. No. 16/042,690, filed Jul. 23, 2018, already incorporated herein by reference. f. Antimicrobial Efficacy & Other Characteristics Exemplary multi-layer substrates were tested for their ability to effectively deliver an antimicrobial quaternary ammonium compound to a surface during simulated cleaning. Applicant notes that the generally anionic characteristics of typical pulp substrates lead to a tendency of the substrate to bind or otherwise retain the cationic quaternary ammonium compound, even when squeezing an aqueous cleaning composition including such a quat from the substrate. In other words, typically, the concentration of quaternary ammonium compound in the “squeezate” (the cleaning composition as squeezed from the pre-loaded wipe) is less than the concentration of quaternary ammonium compound in the cleaning composition before it was loaded into the wipe. Since quaternary ammonium compounds are known to bind to pulp substrates, it was unexpected that the present wipes were able to release a significant enough portion of the quaternary ammonium compound to achieve disinfectancy and/or sanitization on a treated surface without the inclusion of any biocide release agent or latex binder in the substrate. Even more surprising was that even though the tested substrate was comprised of 78% pulp fibers by weight, when compared to a blended substrate including 60% pulp fiber by weight, the present substrates exhibited greater quat release in the “squeezate” as compared to the comparative wipe, which included lower pulp content. Because of these interesting and advantageous characteristics, there may not be a need to increase the quat concentration in the cleaning composition, in order to achieve a desired level of microefficacy, as compared to that used in the comparative wipe. For example, commercially available disinfecting wipes often contain about 0.1 to 5%, and preferably 0.1 to 3%, and more preferably 0.1 to 2% by weight of quat in the cleaning composition. Surprisingly, despite the fact that the multi-layer substrates of the present invention have higher levels of pulp they also have good microefficacy performance with 0.1 to 3%, and preferably 0.1 to 2% by weight of quat in the cleaning composition. By way of example, the multi-layer substrates of the present invention may be loaded with cleaning compositions including from 0.1% to 3%, such as 0.1% to 2% by weight of quat. In an embodiment, the wipes may release at least 40%, at least 50%, at least 55%, at least 60%, or at least 65% of the quaternary ammonium compound (i.e., quaternary ammonium compound in the squeezate as compared to the cleaning composition before loading). The wipes may exhibit at least a 3-log reduction in a target microbe, such asStaphylococcus aureus, within a given time frame (e.g., such as 5 minutes, 4 minutes, 3 minutes, 1 minute, 30 seconds, 10 seconds, etc.). Table 1 shows the results of testing in which a cleaning composition including a quaternary ammonium compound was loaded into a substrate according to the present invention, and as compared to a conventional blended substrate. The cleaning composition was squeezed from both substrates, and the squeezate was analyzed to determine the reduction in the concentration of the quaternary ammonium compound in the squeezate compared to the composition as loaded. TABLE 1Substrate% Quat Released60/40 blended substrate-51%comparative example78/22 exemplary multi-layer69%substrate The ability to achieve higher quat release while including higher pulp content is particularly surprising and unexpected. This characteristic advantageously allows for better relative microefficacy characteristics. This high quat release may be due to the presence of absorptive pockets or gaps, e.g., such as seen inFIG.3, adjacent the unbonded regions. Such gaps provide a significant absorptive region between the thermoplastic film layer and the unbonded raised region102, which can serve as a reservoir for the cleaning composition. Such regions allow significant quantities of the cleaning composition to be stored within the substrate, to be released upon squeezing, wiping, or other compression, where there is reduced contact between the quat in the composition and any anionic binding sites associated with the pulp fibers of the exterior surface layer. This combination of the reservoirs being partially bounded by the inert thermoplastic film material (which does not include significant concentration of anionic binding sites), in combination with the gaps associated with the reservoirs themselves is believed to at least partially account for the ability to release such high fractions of the quat upon squeezing the wipe. Other characteristics of the comparative and exemplary substrates are shown in Table 2 below. TABLE 260/40 blended78/22 exemplarysubstrate-multi-layerCharacteristiccomparative examplesubstrateBasis weight52 gsm55 gsm (26 lb tissuelayers + 12 gsmthermoplastic layerComposition (% pulp/60/4078/22% synthetic)Caliper (wet-mm)0.60.76Absorbency (g)1212Tensile Strength4.61/1.633.48/3.06(MD/CD − lbf)Dry Stiffness (mg · cm)285500Carrier release total-0.49/0.630.58/0.56S1/S2(g) By way of further explanation the dot patterns and textures shown inFIG.1Eincluded smallest dots (100b), small dots (100c), medium dots (100a), and large dots (100d). The wet thickness of the resulting substrates is affected by the dot pattern or texture. For example, a flat sample (not shown) had a wet thickness of 0.3 mm, the sample100a(smallest dots) had a wet thickness of 0.39 mm, the sample100b(small dots) had a wet thickness of 0.65 mm, the sample100c(medium dots) had a wet thickness of 0.66 mm, and sample100d(large dots) had a wet thickness of 0.83 mm. The forgoing values are for substrates with only one tissue layer textured. Two sided samples include somewhat higher wet thickness values. The dosed exemplary multi-layer substrate was tested for microefficacy againstStaphylococcus aureusat a loading ratio of 3.75:1, using an existing quat cleaning composition, at a contact time of 3 min 30 sec. The control population of 6.1 log was reduced to 0 in each of 60 replicates. Testing was performed under 5% soil load conditions. Such results indicated excellent efficacy againstStaphylococcus aureusat a 3:30 contact time. The dosed wipes were also tested for efficacy in various other household cleaning tasks, including cleaning kitchen grease (KG) and bathroom scum (BS). The results of such testing demonstrated parity or near parity with the comparative wipe, as shown below in Table 3. TABLE 3% soil% soilCycles toCycles toremoval at 30removal at 3075%75%Substratecycles-KGcycles-BSremoval-KGremoval-BS60/40 blended96.8796.6247substrate-comparativeexample78/22 exemplary97.9296.269multi-layersubstrate The small increase in cycles for 75% removal may be due to the absence of synthetic fibers on the exterior surface and reduced tendency of the present wipes to “dump” cleaning composition, as compared to the comparative example blended wipe. The reported values represent averages for two sides of the wipes. The conventional wipe “dumps” or releases more liquid from the first side, thereby requiring few cycles to clean, but also reducing mileage. This “dumping” characteristic is described in Applicant's application Ser. No. 16/042,690, filed Jul. 23, 2018, previously incorporated by reference. As mentioned, the present wipes do not include any synthetic fibers exposed at the exterior faces of the wipe, but any synthetic fibers are rather located only within the interior of the wipe (and potentially incidentally exposed at the edges). As a result, the exterior surface may be soft, rather than abrasive. While Applicant did prepare some prototype substrates that did include synthetic fibers on the exterior surfaces (i.e., using a blend of pulp and synthetic fibers to form the exterior “tissue layers”, the resulting wipes did not provide the same desired hand-feel characteristics as were provided where the exterior pulp fiber or tissue layers did not include exposed synthetic fibers. While 100% pulp fibers on the exterior faces may thus be preferred, it will be appreciated that some small fraction of synthetic fibers (e.g., less than 10%, less than 5%, less than 3%, or less than 1%) may be included in some embodiments. The exterior tissue layers may be of a through-air dried configuration. While conventional press-dried tissue was also tried in this exterior layer, this also resulted in less desirable hand-feel characteristics. Such conventional (not through-air-dried) tissue also undesirably presses out any initially included texture, while through-air-dried processing preserves such pre-existing texture. While these alternatives may not be preferred, they may still be suitable, for some uses. Various other possible tissue or nonwoven manufacturing techniques (e.g., dry crepe technique (DCT), structured tissue or new tissue technology (NTT), and others that will be apparent to those of skill in the art) may also be suitable in at least some embodiments. While use of polyethylene or another thermoplastic polymer having the described tan delta characteristics eliminates any need for a chemical adhesive to adhere the top and bottom surface layer to the thermoplastic layer, it will be appreciated that in other embodiments, e.g., even using polypropylene or another material having poor tan delta characteristics, it may be possible to achieve a multi-layer substrate that does not delaminate, e.g., by using a chemical adhesive to provide the needed bonding. The degree of lamination and strength of the bond between adjacent layers typically depends on the temperature, pressing or contact time, and applied pressure associated with the calendaring operation. Temperature may be a primary variable responsible for bond strength achieved, although pressure and time may also have an effect, and may also affect the resulting texture that is “embossed” into the pulp fiber surface layer, and the resulting bond pattern. Where the pulp fiber or other layers provided on both exterior faces are embossed with a texture, the resulting multi-layer substrate exhibits a more “cloth-like” feel that is drapable and less stiff, as compared to where only one of the two faces is embossed with a texture. In addition, it was observed that all else being equal, heavier exterior layers (i.e., greater lb or gsm weight) produces a stiffer substrate.FIGS.7A-7Fillustrate various possible embossing patterns that can be applied by the calendar rollers. It will be apparent that the possibilities are nearly limitless. Temperatures applied during calendaring may be at least 150° F., at least 175° F., at least 200° F., from 200° F. to 400° F., or from 200° F. to 350° F. Applied pressure may be at least 50 psi, at least 100 psi, at least 150 psi, at least 200 psi, from 100 psi to 1000 psi, or from 300 psi to 600 psi. Contact time (time at the given pressure and/or temperature) may be at least 100 ms, at least 200 ms, from 100 ms to 5 s, from 200 ms to 1 s, or from 200 ms to 500 ms. Such a manufacturing process may be attractive, e.g., as compared to traditional non-woven substrate manufacture, as it may not require any processing of individual fibers not already provided in a nonwoven layer, water usage, water filtration, drying steps, loss of fibers during processing, and the like. In addition, the present calendaring process may allow for greater production line speeds (e.g., up to 900 m/min, typically from 50 m/min to 600 m/min) as compared to SPINLACE manufacturing conventional blended substrates (that are not multi-layer), which are at significantly lower line production speeds. Increased line speed results in decreased contact time (all else being equal). To provide the desired good bonding, higher line speed may be accommodated by increasing web surface temperature (so shorter contact time is needed), increasing the roller diameter (thus increasing contact time), or increasing applied pressure (nip pressure). By way of example, for every 25 m/min increase in line speed, temperature can be increased by about 5% (in ° C.) to maintain bonding level). With respect to embossed textures, it was observed that “pin” textures (e.g., associated with fine dots) can result in tearing of the top and bottom surface layers, as the fibers get caught on the pins. Thus, textures that are formed using more of a “flat bar” type contact versus a sharp “pin” may be preferred; as such larger features do not result in such tearing. In addition, it was observed that when manufacturing such substrates through a calendaring operation, that the thermoplastic “cheese” layer should be narrower in width than the top and bottom surface “bread” layers in order to further minimize complications during manufacture. From such a processed multi-layer laminated web, individual sized wipes may be cut to the desired size. Edges of the web that may not include the thermoplastic “cheese” layer could be cut away during such cutting, if desired. The present substrates also provide for the ability to modulate the substrate stiffness by changing the pattern applied during calendaring (e.g., see the various patterns ofFIG.1E or7A-7F), as well as the ability to modulate stiffness and tensile strength characteristics by providing texturing on one or both of the substrate faces, the ability to provide for relatively higher quat release even at higher pulp fractions, and more uniform lotion release, with better mileage, as described in Applicant's application Ser. No. 16/042,690, filed Jul. 23, 2018, due to the high pulp content. Table 4 below shows the results of additional testing conducted on exemplary formed multi-layer wipes including exterior pulp layers and an interior thermoplastic layer, relative to dry stiffness characteristics. As described in Applicant's application Ser. No. 16/042,690, filed Jul. 23, 2018, the stiffness characteristics of wipes that are formed to include exterior pulp layers exhibit significantly higher stiffness than conventional, currently available wipes, even those that are blended substrates, which may include, e.g., up to 60% pulp fibers. TABLE 4ExemplarysubstrateExemplaryExemplarywith Hexsubstratesubstratetexture(no(large dotComparativeComparativeComparativeComparative(Trial 1)texture)texture)Example 1Example 2Example 3Example 4CompositionTissue—Tissue—Tissue—SB-SMS-SMS-100% PETBico-TissueBico-TissueBico-Tissueloose-SBloose pulploose pulp% Pulp/% Synthetic80/2078/2278/2260/4060/4060/400/100Basis Weight58545452525252(gsm)Dry Stiffness1222379868174708662(mg · cm) Stiffness values were measured using ASTM D-1388-96. As shown in Table 4, the exemplary 3-layer substrate materials include approximately at least double the dry stiffness of wipes produced using current wipes technologies. Such increased stiffness is believed to be due at least in part to the use of fixed pulp fibers, where the pulp layers used in forming the substrates are already in structured form (e.g., as nonwoven sheets, similar to a paper towel). Additional testing was also performed to evaluate cantilever stiffness using standard techniques e.g., where a substrate to be tested is evaluated by placing it between a stationary slide base, under a axially movable slide, and advancing the substrate towards a decline where the stationary slide base drops away from the axially movable slide, at a given angle (e.g., 45°). During the test, the average length of the substrate that is required to cause the cantilevered substrate to bend so as to contact the declined portion of the stationary slide is measured. The stiffer the substrate, the longer the cantilever length that will be needed to cause the substrate to bend, so as to touch the declined surface of the stationary slide. Applicant surprisingly found that cantilever stiffness decreases with increasing bond area, which is surprising as it would be thought that by laminating the 3 layers of the substrate together, that they might act more in unison, as a composite, thicker, substrate. One hypothesis is that as the bond area is reduced by having raised features on the bonding plates or rollers, these features “break” some of the original structure of the tissue and thus lower the stiffness of the overall structure. The results for different bond areas (simply the fraction of surface area of the substrate that is bonded versus unbonded) are shown in Table 5. TABLE 5Avg. BendingBond AreaLength (mm)65%10973%94100%83 Higher bending length equates to lower stiffness (all else being equal). The data indicates that as bonding area increases, stiffness decreases, and vice-versa. In typical calendaring processes, only one of the rollers (e.g.,216a,216bofFIG.8) is embossed (e.g., one steel, one rubber or other elastomer). In addition, typical processes result in texture on only one of the two faces of the substrate, where raised texture features on one face are axially aligned with a corresponding depression feature on the opposite face. There are no substrates currently available, which are textured in the same way on both faces, so that raised texture features (bumps) on one face would be axially aligned with corresponding raised texture features (also bumps, not depressions) on the other face. With the presently described processes, it is possible to achieve such two-sided texturing. In an embodiment, two steel rollers (e.g.,216a,216b) could be used, where both include the texture to be applied to the substrate, which can result in two-sided texturing.FIG.9Aillustrates images comparing a conventional 1-sided texture (top ofFIG.9A), to a two-sided textured substrate, where the “bumps” can be provided in both faces, where the textured “bumps” are axially aligned with one another through the substrate thickness. Such may be important in providing a user of the wipe with the same hand feel and other characteristics no matter which face of the wipe is oriented towards the hand, and which face is oriented towards the surface being cleaned (both have the same tactile characteristics, rather than differing from one another). In other words, conventional wipes are not the same on one face as compared to the other, while the present processes can be implemented in a way to provide the same user tactile experience no matter the orientation of the wipe in the user's hands, where two-sided texturing is provided.FIGS.9B-9Cillustrate profilometer data for the “bumpy” face and the “other” face of a substrate without two-sided texturing, whileFIGS.9D-9Eillustrate profilometer data for the first and second faces of a substrate with two-sided texturing (both are “bumpy”).FIGS.9F-91illustrate additional profilometer data for the tested comparative one-sided versus two-sided textured samples. Without departing from the spirit and scope of this invention, one of ordinary skill can make various modifications to the invention to adapt it to various usages and conditions. As such, these changes and modifications are properly, equitably, and intended to be, within the full range of equivalence of the following claims. | 84,604 |
11858239 | DETAILED DESCRIPTION The present disclosure provides a composite structure made from a polymer with additions of graphene (referred to herein simply as “polymer-graphene” or “polymer-graphene” material). The composite structure, i.e., a component made from the polymer-graphene material, has a reduced weight and an increase in at least one mechanical property compared to a component made simply from the polymer. The composite structure can include a polymer-graphene foam core (layer) and at least one polymer-graphene solid skin (also referred to herein simply as “polymer-graphene skin”) attached or overmolded onto the polymer-graphene foam core. For example, the composite structure includes a composite structure panel with a polymer-graphene foam core sandwiched between a pair of polymer-graphene skins. And when compared to a panel having just a foam core made from the polymer (without graphene), the composite structure panel exhibits an increase in flexural strength, elastic modulus, and energy absorption. In the alternative, or in addition to, the composite structure panel has a reduced weight compared to a panel with a polymer (without graphene) solid core or a polymer-graphene solid core. Referring toFIGS.1,2, and2A, one non-limiting example of a panel10with a composite structure according to the teachings of the present disclosure is shown. Particularly, a perspective view of an interior door panel10(referred to herein simply as “door panel”) for a vehicle12is shown inFIG.1and a cross-sectional view of section2-2inFIG.1is shown inFIG.2. The door panel10has a plurality of contours “C” and features ‘F” (e.g., a handle and a door pocket, among others) that provide a desired geometric, mechanical and/or aesthetic function. It should be understood that such panels are assembled with other panels or components during the assembly line manufacture of the vehicle. In addition, such panels can serve one or more functions during use of the vehicle, e.g., energy absorption during an impact event. It should also be understood that whileFIGS.1,2, and2Arepresent a door panel, other panels such as others panels that are included in the interior of a vehicle, panels that are included in an engine compartment of a vehicle, panels that are included in a trunk compartment of a vehicle, and panels that are included within other panels or structures of a vehicle, among others, are included within the teachings of the present disclosure. Referring particularly toFIGS.2and2A, the door panel10includes a foam core100(also known as a “foam layer” or an “inner foam layer”) and at least one solid skin110,120. The foam core100includes a matrix102with a plurality of pores or cells104disposed within the matrix102. In some variations of the present disclosure the foam core100is sandwiched between a first solid skin110with an inner facing surface112(i.e., a surface facing an interior of the vehicle12) and a second solid skin120with an outer facing surface122(i.e., a surface facing an exterior of the vehicle12). The first solid skin100has a first thickness ‘t1’, the second solid skin110has a second thickness ‘t2’, and the foam core has a foam core thickness ‘tc’. The first thickness t1and the second thickness t2are between about 0.25 millimeters (mm) and about 5.0 mm. In at least one variation, the first thickness t1and the second thickness t2are between about 0.5 mm and about 4.0 mm, for example, between about 0.75 mm and about 3.0 mm. And in some variations, the first thickness t1and the second thickness t2are between about 1.0 mm and about 1.5 mm. In some variations, the first thickness t1and the second thickness t2are the about the same thickness, while in other variations the first thickness t1and the second thickness t2are different thicknesses. The foam core thickness tc is between about 1.0 mm and about 25 mm. In some variations, the foam core thickness tc is between about 2.0 mm and about 15 mm, for example, between about 2.5 mm and about 10 mm. In at least one variation, the foam core thickness tc is between about 3.0 mm and about 7.5 mm. In some variations, a ratio of foam thickness tc to total skin thickness t1+t2(hereafter referred to as a′ which equals tc/(t1+t2)×100) is between (in percent) 1% and 500%. In at least one variation, R is between 1% and 100%, and in some variations R is between 1% and 50%. In more than variation, R is between 1% and 25%, and in some variations R is between 2% and 20%. In some variations, the first solid skin110has an inner surface114in direct contact with the foam core100and the second solid skin120has an inner surface124in direct contact with the foam core100. However, it should be understood that in at least one variation one or more layers are disposed between the inner surface114of the first solid skin110and the foam core100and/or one or more layers are disposed between the inner surface124of the second solid skin120and the foam core100. In some variations, the foam core100is made from a first polymer containing a desired amount of graphene (referred to herein as “first polymer-graphene material”). Non-limiting examples of the first polymer include thermoplastics such as polypropylene (PP), polyethylene (PE), polystyrene (PS), polycarbonate (PC), polyvinyl chloride (PVC), polylactic acid (PLA), polycarbonate (PC), and mixtures thereof, among others, and thermoset resins such as polyurethane (PU), polybutylene terephthalate (PBT), polyamide 6 (PA6), polyamide 66 (PA66), and mixtures thereof, among others. In at least one variation the first polymer is PP. Also, the amount of graphene in the first polymer-graphene material is between about 0.25 weight percent (wt. %) and about 5.0 wt. % graphene. For example, in some variations the first polymer-graphene material contains between about 0.5 wt. % and about 2.5 wt. % graphene, and in at least one variation the first polymer-graphene material contains between about 0.5 wt. % and about 1.0 wt. % graphene. In some variations, the first solid skin110and/or the second solid skin120are/is made from a second polymer containing a desired amount of graphene material (referred to herein as “second polymer-graphene material”). Non-limiting examples of the second polymer include the examples noted above for the first polymer, among others. Also, the amount of graphene in the second polymer-graphene material is between about 0.25 weight percent (wt. %) and about 5.0 wt. % graphene. For example, in some variations the second polymer-graphene material contains between about 0.5 wt. % and about 2.5 wt. % graphene, and in at least one variation the second polymer-graphene material contains between about 0.5 wt. % and about 1.0 wt. % graphene. In some variations, the first polymer and the second polymer are the same polymer, while in other variations the first polymer and the second polymer are not the same polymer. Also, in at least one variation the first solid skin110and the second solid skin120are made from different polymers. Accordingly, it should be understood that the door panel10, and other panels or components disclosed herein, can be made using one polymer material, two different polymer materials, three different polymer materials, and more. Referring now toFIG.3, a method20for manufacturing the panel10according to one form of the present disclosure is shown. The method20includes injection molding the foam core100at200and then injection molding at least one of the first solid skin110and the second solid skin120onto the foam core100at210. Accordingly, in some variations the first solid skin110and/or the second solid skin120are overmolded onto the foam core100. For example, in some variations the first solid skin110and/or the second solid skin120are overmolded onto the foam core100using an overmolding injection molding process, while in other variations the first solid skin110and/or the second solid skin120are overmolded onto the foam core100using a two-shot injection molding process. It should be understood that the first polymer-graphene material and the second polymer-graphene material are supplied or fed into an injection molding machine “pre-mixed.” That is, a desired amount of graphene mixed with a polymer is fed into an injection molding machine, which in turn injection molds at least one of the foam core100, first solid skin110, and second solid skin120. Referring toFIG.4, a method30for manufacturing the panel10according to another form of the present disclosure is shown. The method30includes supercritical fluid (SCF) injection molding the foam core100at300and then injection molding at least one of the first solid skin110and the second solid skin120onto the foam core100at210. That is, the foam core100is SCF injection molded and the at least one of the first solid skin110and the second solid skin120are injection molded onto the foam core100without use or employment of SCF. It should be understood that SCF injection molding includes injecting and mixing a SCF (e.g., nitrogen or carbon dioxide) into a melt of polymer material that is in a barrel of an injection molding machine such that a combination of heat and pressure in the barrel provides a single-phase polymer/gas material. The single-phase polymer/gas material is then injected into a mold cavity (e.g., for the foam core100) where a reduction in pressure results in the gas coming out of the polymer (solution) and forming gas bubbles or pores within a polymer matrix. Samples with a range of structures and graphene contents were injected molded and used for SEM microstructure analysis and mechanical testing. The samples were made by injection molding the samples using pellets of pure PP (PP pellets), or by injection molding the samples using PP pellets mixed with pellets of a PP-graphene material (Product No. XGPP C6301F, XG Sciences, Lansing, Michigan, USA), such that samples with a desired amount of graphene were formed. A representative SEM image of a sample cross-section with a foam core100sandwiched between a first solid skin110and a second solid skin120is shown inFIG.5. Referring toFIGS.6A-6B, SEM cross-sectional images of non-limiting examples of foam cores that had a 5% reduction in weight compared to a solid core are shown. The foam core shown inFIG.6Ais a PP foam core (without graphene) and the foam core shown inFIG.6Bis a PP-1.0 wt. % graphene foam core, i.e., the foam core shown inFIG.6Bwas formed from or with PP with 1.0 wt. % graphene. The PP foam core shown inFIG.6Ahas pores “P” within a PP matrix “M” and the PP-1.0 wt. % graphene foam core shown inFIG.6Bhas pores “Pg” within a matrix “Mg” of the PP-1.0 wt. % material. In addition, and as observed from a comparison ofFIG.6AandFIG.6B, the PP-1.0 wt. % graphene foam core has a more uniform distribution of pores and a more uniform distribution of pore size that the PP foam core. Referring toFIGS.7A-7B, SEM cross-sectional images of samples with foam cores that had a 10% reduction in weight compared to a solid core are shown. The foam core shown inFIG.7Ais a PP foam core and the foam core shown inFIG.7Bis a PP-1.0 wt. % graphene foam core. The PP foam core shown inFIG.7Ahas pores P within a matrix M of the PP material and the PP-1.0 wt. % graphene foam core shown inFIG.7Bhas pores Pg within a matrix Mg of the PP-1.0 wt. % graphene material. In addition, and as observed from a comparison ofFIGS.7A and7B, the PP-1.0 wt. % graphene foam core has a reduced pore size, a more uniform distribution of pore size, and an increased pore density than the PP foam core. Particularly, image analysis of the PP foam core shown inFIG.7Adetermined an average pore size of 183.2 micrometers (μm) with a standard deviation of +/−96.8 μm and a pore density of 4.37×105pores per square millimeter (pores/mm2). In contrast, image analysis of the PP-1.0 wt. % graphene foam core shown inFIG.7Bdetermined an average pore size of 49.3 μm with a standard deviation of +/−12.8 μm and a pore density of 5.42×106pores/mm2. Accordingly, the addition of graphene in the PP material reduced the pore size by a factor of about 3.7, reduced the standard deviation of the pore size by a factor of about 7.5, and increased the pore density by a factor of about 12. Referring toFIGS.8A-8B, SEM cross-sectional images of samples with foam cores that had a 15% reduction in weight compared to a solid core are shown. The foam core shown inFIG.8Ais a PP foam core and the foam core shown inFIG.8Bis a PP-1.0 wt. % graphene foam core. The PP foam core shown inFIG.8Ahas pores P within a matrix M of the PP material and the PP-1.0 wt. % graphene foam core shown inFIG.8Bhas pores Pg within a matrix Mg of the PP-1.0 wt. % material. In addition, and as observed from a comparison ofFIGS.8A and8B, the PP-1.0 wt. % foam core has a reduced pore size, a more uniform distribution of pore size, and an increased pore density than the PP foam core. Particularly, image analysis of the PP foam core shown inFIG.8Adetermined an average pore size of 90.5 μm with a standard deviation of +/−11.9 μm and a pore density of 6.99×105pores/mm2. In contrast, image analysis of the PP-1.0 wt. % graphene foam core shown inFIG.8Bdetermined an average pore size of 49.7 μm with a standard deviation of +/−7.0 μm and a pore density of 5.1×106pores/mm2Accordingly, the addition of graphene in the PP material reduced the pore size by a factor of about 1.8, reduced the standard deviation of the pore size by a factor of about 1.7, and increased the pore density by a factor of about 7.3. A list of samples with corresponding structure, graphene content, and labels used inFIGS.9-10is shown in Table 1 below. TABLE 1Sample data for cores and skins with varying graphene content.CoreSkin% WeightWt. %ThicknessWt. %SampleTypereductiongraphene(mm)grapheneLabelAsolidN/A00N/AA: PP Solid CoreBsolidN/A0.50N/AB: PP-0.5 Gr Solid CoreCfoam500N/AC: PP Foam CoreDfoam510N/AD: PP-1 Gr Foam CoreEfoam5111E: PP-1 Gr Foam Core w/ 1.0mm PP-1 Gr SkinsFfoam50.51.50.5F: PP-0.5 Gr Foam Core w/1.5 mm PP-0.5 Gr SkinsGfoam1000N/AG: PP Foam CoreHfoam1010N/AH: PP-0.5 Gr Foam CoreIfoam100.51.511: PP-0.5 Gr Foam Core w/1.5 mm PP-1 Gr SkinsJfoam100.51.01J: PP-0.5 Gr Foam Core w/1.0 mm PP-1 Gr Skins With reference toFIG.9, graphical plots of flexure stress versus flexure strain testing for samples with a foam core having a 5% reduction in weight compared to samples with a solid foam core are shown (Samples A-F). The modulus normalized to 100 MPA, strength normalized to 100 MPa, and energy absorption normalized to 100 J (calculated from the area under the stress versus strain curve) for samples having a foam core (samples C-F) are shown in Table 2 below. In addition, percent improvement compared to the PP foam core sample C with a 5% reduction (sample C) is shown in Table 2. TABLE 2Calculated data from observations of samples C to F.NormalizedNormalized%Normalized%Energy%ModulusImprovementStrengthImprovementAbsorptionImprovementSample(MPA)(modulus)(MPA)(strength)(J)(energy)C100N/A100N/A100N/AD102.272.27109.139.13113.5913.59E109.899.89116.6716.67199.8999.89F106.936.93111.1511.15120.0720.07 For the samples tested perFIG.9, sample E: PP-1 Gr Foam Core w/ 1.0 mm PP-1 Gr Skins exhibited the largest increase in modulus (9.89%), strength (16.67%), and energy absorption (99.89%) compared to sample C:PP Foam Core. With reference toFIG.10, graphical plots of flexure stress versus flexure strain testing for samples with a foam core having a 10% reduction in weight compared to samples with a solid foam core are shown (Samples, A, B, G-J). The modulus normalized to 100 MPa, strength normalized to 100 MPa, and energy absorption normalized to 100 J (calculated from the area under the stress versus strain curve) for samples having a foam core (samples G-J) are shown in Table 3 below. In addition, percent improvement compared to the PP foam core sample with a 10% weight reduction (sample G) is shown in Table 3. TABLE 3Calculated data from observations of samples G to J.NormalizedNormalized%Normalized%Energy%ModulusImprovementStrengthImprovementAbsorptionImprovementSample(MPA)(modulus)(MPA)(strength)(J)(energy)G100N/A100N/A100N/AH106.416.41108.558.55132.5532.55I120.3820.38116.6716.67152.1052.10J118.4618.46115.4315.43115.43102.98 For the samples tested perFIG.10, sample I: PP-0.5 Gr Foam Core w/ 1.5 mm PP-1 Gr Skins exhibited the largest increase in modulus (20.38%) and strength (16.67%), and sample J: PP-0.5 Gr Foam Core w/ 1.0 mm PP-1 Gr Skins exhibited the largest increase in energy absorption (102.98%) compared to sample G: PP Foam Core. Accordingly, it should be understood that the present disclosure provides composite structures with a combination of the polymer-graphene foam core and polymer-graphene solid skins that exhibit improved mechanical properties compared to structures made simply from polymer. The preceding description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. Work of the presently named inventors, to the extent it may be described in the background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present technology. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical “or.” It should be understood that the various steps within a method may be executed in different order without altering the principles of the present disclosure. Disclosure of ranges includes disclosure of all ranges and subdivided ranges within the entire range. The headings (such as “Background” and “Summary”) and sub-headings used herein are intended only for general organization of topics within the present disclosure, and are not intended to limit the disclosure of the technology or any aspect thereof. The recitation of multiple embodiments having stated features is not intended to exclude other embodiments having additional features, or other embodiments incorporating different combinations of the stated features. As used herein the term “about” when related to numerical values herein refers to known commercial and/or experimental measurement variations or tolerances for the referenced quantity. In some variations, such known commercial and/or experimental measurement tolerances are +/−10% of the measured value, while in other variations such known commercial and/or experimental measurement tolerances are +/−5% of the measured value, while in still other variations such known commercial and/or experimental measurement tolerances are +/−2.5% of the measured value. And in at least one variation, such known commercial and/or experimental measurement tolerances are +/−1% of the measured value. As used herein, the terms “comprise” and “include” and their variants are intended to be non-limiting, such that recitation of items in succession or a list is not to the exclusion of other like items that may also be useful in the devices and methods of this technology. Similarly, the terms “can” and “may” and their variants are intended to be non-limiting, such that recitation that an embodiment can or may comprise certain elements or features does not exclude other embodiments of the present technology that do not contain those elements or features. The broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the specification and the following claims. Reference herein to one aspect, or various aspects means that a particular feature, structure, or characteristic described in connection with an embodiment or particular system is included in at least one embodiment or aspect. The appearances of the phrase “in one aspect” (or variations thereof) are not necessarily referring to the same aspect or embodiment. It should be also understood that the various method steps discussed herein do not have to be carried out in the same order as depicted, and not each method step is required in each aspect or embodiment. The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations should not be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. | 20,967 |
11858240 | DESCRIPTION OF EMBODIMENTS [Multilayer Container] A multilayer container according to the present invention includes: a polyester layer containing a polyester resin (X); and a polyamide layer containing a polyamide resin (Y), a yellowing inhibitor (A), and an oxidation accelerator (B); the content of the polyamide resin (Y) is from 0.05 to 7.0 mass % relative to the total amount of all polyamide layers and all polyester layers; the yellowing inhibitor (A) is a dye; and the content of the yellowing inhibitor (A) is from 1 to 30 ppm relative to the total amount of all polyamide layers and all polyester layers. The reason why the multilayer container of the present invention can achieve an oxygen barrier property while also suppressing yellowing of the recycled polyester is not clear, but is considered to be as follows. An oxygen barrier layer is formed by the polyamide resin, and the oxidation accelerator contributes to oxygen absorption, and therefore the oxygen barrier property can be enhanced. Furthermore, the yellowing inhibitor is a dye having a stable structure, and a small amount of the yellowing inhibitor efficiently suppresses yellowing of the recycled polyester without inhibiting the oxidation acceleration action thereof. Thus, it is thought that as a result thereof, the multilayer container of the present invention is able to achieve both of these properties. The “total amount of all polyamide layers and all polyester layers” is the total mass of all polyamide layers and all polyester layers configuring the multilayer container, and when a plurality of layers of each are present, it is the total amount of all of these layers. <Polyester Layer> The polyester layer contains a polyester resin (X). (Polyester Resin (X)) The polyester resin (X) contained in the polyester layer is preferably a polycondensation polymer of a dicarboxylic acid and a diol, and preferably includes a constituent unit derived from a dicarboxylic acid (hereinafter, also referred to as a “dicarboxylic acid unit”) and a constituent unit derived from a diol (hereinafter, also referred to as a “diol unit”). Examples of the dicarboxylic acid unit include constituent units derived from aromatic dicarboxylic acids, constituent units derived from alicyclic dicarboxylic acids, and constituent units derived from aliphatic dicarboxylic acids, and constituent units derived from aromatic dicarboxylic acids are preferred. Examples of the aromatic dicarboxylic acid include terephthalic acid, isophthalic acid, orthophthalic acid, biphenyl dicarboxylic acid, diphenyl ether dicarboxylic acid, diphenylsulfone dicarboxylic acid, diphenylketone dicarboxylic acid, 2,6-naphthalene dicarboxylic acid, 1,4-naphthalene dicarboxylic acid, and 2,7-naphthalene dicarboxylic acid. From perspectives of cost and manufacturing ease, terephthalic acid, isophthalic acid, orthophthalic acid, naphthalene dicarboxylic acid, and 4,4′-biphenyl dicarboxylic acid are preferable, and terephthalic acid, isophthalic acid, and naphthalene dicarboxylic acid are more preferable, and from the perspective of moldability, terephthalic acid and isophthalic acid are further preferable, and terephthalic acid is even more preferable. Note that as the aromatic dicarboxylic acid, a C1-4alkyl ester of an aromatic dicarboxylic acid may be used. When the multilayer container of the present invention is to be recycled, the multilayer container may be melt-kneaded with a typical monolayer container made of a polyester resin. Since the multilayer container of the present invention includes a unit derived from terephthalic acid as a dicarboxylic acid unit, miscibility of the multilayer container with a typical monolayer container is favorable, and good recyclability is obtained. As the aromatic dicarboxylic acid, a sulfophthalic acid and a metal sulfophthalate may be used. The metal sulfophthalate is a metal salt of a sulfophthalic acid, and examples of the metal atom include alkali metals and alkaline earth metals. Specifically, the sulfophthalic acid and metal sulfophthalate are represented by Formulas (I) and (I′) below, respectively. In Formula (I′) above, M is a metal atom, and n represents the valence of M. Examples of the metal atom M include alkali metals such as lithium, sodium, and potassium; and alkaline earth metals such as beryllium, magnesium, calcium, and strontium. Of these, an alkali metal is preferable, in which sodium or lithium is preferable, and sodium is more preferable. Note that when n is 2 or greater, crosslinking with other units (for example, sulfo groups in other sulfophthalic acid units or metal sulfophthalate units) through M may occur. In Formulas (I) and (I′) above, RAis a substituted or unsubstituted alkyl group or a substituted or unsubstituted aryl group, and m represents an integer of 0 to 3. Note that when m is 2 or 3, each RAmay be the same or different. Examples of the alkyl group include a methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, t-butyl group, n-octyl group, and 2-ethylhexyl group. Among these, a C1-6alkyl group is preferable, and a C1-4alkyl group is more preferable. Examples of the aryl group include a phenyl group and a naphthyl group. Among these, a C6-12aryl group is preferable, and a phenyl group is more preferable. Examples of the substituents of the alkyl group and the aryl group include halogen atoms such as a chlorine atom, a bromine atom, or an iodine atom, an alkyl group, alkenyl group, aryl group, cyano group, hydroxyl group, nitro group, alkoxy group, aryloxy group, acyl group, amino group, mercapto group, alkylthio group, and an arylthio group. Among these groups, those having a hydrogen atom may be further substituted with the substituents described above. Specific examples of the RAinclude a methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, t-butyl group, 1-methylpropyl group, 2-methylpropyl group, hydroxymethyl group, 1-hydroxyethyl group, mercaptomethyl group, methyl thioethyl group, phenyl group, naphthyl group, biphenyl group, benzyl group, and 4-hydroxybenzyl group. Of these, a methyl group, ethyl group, and benzyl group are preferable. In Formulas (I) and (I′) above, RBrepresents a hydrogen atom or an alkyl group having from 1 to 4 carbons. The preferred R A is as described above, but the sulfophthalic acid or metal sulfophthalate used in the polyester resin (X) is preferably a unit represented by Formula (Ia) or (I′a) below, respectively, where m is 0, or in other words, the benzene ring is not substituted with RA. In Formula (Ia) above, RBis the same as RBin Formula (I). Moreover, in Formula (I′a) above, RB, M, and n are the same as the RB, M, and n in Formula (I′). Furthermore, examples of the sulfophthalic acid represented by Formula (Ia) or the metal sulfophthalate represented by Formula (I′a) include phthalic acid structures in which two —CO— are bonded at the ortho position, isophthalic acid structures in which two —CO— are bonded at the meta position, and terephthalic acid structures in which two —CO— are bonded at the para position. Among these, an isophthalic acid structure is preferable. In other words, the sulfophthalic acid or metal sulfophthalate is preferably at least one of a sulfoisophthalic acid represented by Formula (Ib) below or a metal sulfoisophthalate represented by Formula (I′b) below. In Formula (Ib) above, RBis the same as RBin Formula (I). Moreover, in Formula (I′b) above, RB, M, and n are the same as the RB, M, and n in Formula (I′). The position of the sulfo group in the sulfoisophthalic acid or the metal sulfoisophthalate may be the 2-, 4-, 5-, and 6-positions, but is preferably substituted at the 5-position as represented by Formula (Ic) or (I′c) below. In Formula (Ic) above, RBis the same as RBin Formula (I). In Formula (I′c) above, RB, M, and n are the same as the RB, M, and n in Formula (I′). Examples of the sulfoisophthalic acid represented by Formula (Ic) or the metal sulfoisophthalate represented by Formula (I′c) in the polyester resin (X) include 5-sulfoisophthalic acid, sodium 5-sulfoisophthalate, lithium 5-sulfoisophthalate, potassium 5-sulfoisophthalate, calcium bis(5-sulfoisophthalate), sodium dimethyl 5-sulfoisophthalate, and sodium diethyl 5-sulfoisophthalate. In a case where the polyester resin (X) contains a constituent unit derived from at least one selected from the group consisting of sulfophthalic acids and metal sulfophthalates, the resin preferably contains at least a constituent unit derived from a metal sulfophthalate. The content of the constituent units derived from a sulfophthalic acid and a metal sulfophthalate in the polyester resin is preferably from 0.01 to 15 mol %, more preferably from 0.03 to 10.0 mol %, even more preferably from 0.06 to 5.0 mol %, and yet even more preferably from 0.08 to 2.0 mol %. Examples of the alicyclic dicarboxylic acid include cyclohexane dicarboxylic acid, norbornene dicarboxylic acid, and tricyclodecane dicarboxylic acid. Examples of the aliphatic dicarboxylic acid include malonic acid, succinic acid, adipic acid, azelaic acid, and sebacic acid. Examples of the diol unit include constituent units derived from aliphatic diols, constituent units derived from alicyclic diols, and constituent units derived from aromatic diols, and constituent units derived from aliphatic diols are preferable. Examples of the aliphatic diols include ethylene glycol, 2-butene-1,4-diol, trimethylene glycol, tetramethylene glycol, hexamethylene glycol, neopentyl glycol, methylpentanediol, and diethylene glycol. Among these, ethylene glycol is preferable. Examples of the alicyclic diols include cyclohexane dimethanol, isosorbide, spiroglycol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol, norbornene dimethanol and tricyclodecane dimethanol. Examples of the aromatic diols include bisphenol compounds and hydroquinone compounds. The polyester resin (X) may have a constituent unit derived from a hydroxycarboxylic acid. Examples of the hydroxycarboxylic acid include aliphatic hydroxycarboxylic acids, alicyclic hydroxycarboxylic acids, and aromatic hydroxycarboxylic acids. Examples of the aliphatic hydroxycarboxylic acids include 10-hydroxyoctadecanoic acid, lactic acid, hydroxyacrylic acid, 2-hydroxy-2-methylpropionic acid, and hydroxybutyric acid. Examples of the alicyclic hydroxycarboxylic acids include hydroxymethyl cyclohexane carboxylic acid, hydroxymethyl norbornene carboxylic acid, and hydroxymethyl tricyclodecane carboxylic acid. Examples of the aromatic hydroxycarboxylic acids include hydroxybenzoic acid, hydroxytoluic acid, hydroxynaphthoic acid, 3-(hydroxyphenyl)propionic acid, hydroxyphenylacetic acid, and 3-hydroxy-3-phenylpropionic acid. The polyester resin (X) may have a constituent unit derived from a monofunctional compound and a constituent unit derived from a polyfunctional compound. Examples of the monofunctional compound include monocarboxylic acids and monoalcohols, and specifically include aromatic monocarboxylic acids, aliphatic monocarboxylic acids, aromatic monoalcohols, aliphatic monoalcohols, and alicyclic monoalcohols. Examples of the polyfunctional compound include aromatic polycarboxylic acids, alicyclic polycarboxylic acids, aliphatic polyhydric alcohols, alicyclic polyhydric alcohols, and esters thereof. The polyester resin (X) preferably includes a constituent unit derived from a dicarboxylic acid containing a terephthalic acid-derived constituent unit, and a constituent unit derived from a diol containing an ethylene glycol-derived constituent unit; more preferably has a constituent unit derived from a dicarboxylic acid containing 80 mol % or greater of a terephthalic acid-derived constituent unit, and a constituent unit derived from a diol containing 80 mol % or greater of an ethylene glycol-derived constituent unit; even more preferably has a constituent unit derived from a dicarboxylic acid containing 90 mol % or greater of a terephthalic acid-derived constituent unit, and a constituent unit derived from a diol containing 90 mol % or greater of an ethylene glycol-derived constituent unit; and yet even more preferably has a constituent unit derived from a dicarboxylic acid containing 98 mol % or greater of a terephthalic acid-derived constituent unit, and a constituent unit derived from a diol containing substantially 100 mol % of an ethylene glycol-derived constituent unit. Specific examples of the polyester resin (X) include polyethylene terephthalate (PET). The polyethylene terephthalate (PET) may include a constituent unit derived from an aromatic dicarboxylic acid other than terephthalic acid. The aromatic dicarboxylic acid other than terephthalic acid is preferably one or more selected from isophthalic acid, orthophthalic acid, naphthalene dicarboxylic acid, and 4,4′-biphenyldicarboxylic acid. These aromatic dicarboxylic acids are inexpensive, and a copolymerized polyester resin containing these aromatic dicarboxylic acids is easily manufactured. Among these, isophthalic acid and naphthalene dicarboxylic acid are preferable, and isophthalic acid is more preferable. The polyethylene terephthalate containing a constituent unit derived from isophthalic acid excels in moldability, and is also excellent from the standpoint of preventing whitening of a molded article due to the low crystallization rate. In addition, a polyethylene terephthalate containing a constituent unit derived from naphthalene dicarboxylic acid increases the glass transition point of the resin, improves the heat resistance, and absorbs ultraviolet rays. Therefore, such polyethylene terephthalate is suitably used in the manufacturing of a multilayer container requiring resistance to ultraviolet rays. Note that a 2,6-naphthalene dicarboxylic acid component is preferable as the naphthalene dicarboxylic acid because it is easy to be manufactured and is highly economical. When the polyethylene terephthalate includes a constituent unit derived from an aromatic dicarboxylic acid other than terephthalic acid, the proportion of the constituent unit derived from an aromatic dicarboxylic acid other than terephthalic acid is preferably from 1 to 20 mol %, more preferably from 1 to 10 mol %, and even more preferably from 1 to 5 mol % of the dicarboxylic acid units. Among these, when the polyethylene terephthalate includes a constituent unit derived from isophthalic acid, the proportion of the constituent unit derived from isophthalic acid is preferably from 1 to 20 mol %, more preferably from 1 to 10 mol %, and even more preferably from 1 to 5 mol % of the dicarboxylic acid units. Note that one type of polyester resin (X) may be used alone, or two or more types may be combined and used. The polyester resin (X) can be manufactured through a known method such as direct esterification or transesterification. The intrinsic viscosity of the polyester resin (X) is preferably from 0.5 to 2.0 dL/g, and more preferably from 0.6 to 1.5 dL/g. When the intrinsic viscosity is 0.5 dL/g or higher, the mechanical properties of the container are excellent. Note that the intrinsic viscosity is measured by dissolving the polyester resin in a mixed solvent of phenol/1,1,2,2-tetrachloroethane (=6/4 mass ratio) to prepare 0.2, 0.4, and 0.6 g/dL solutions, and then measuring the intrinsic viscosity at 25° C. using an automatic viscosity measuring apparatus (Viscotek, available from Malvern Instruments Limited). (Other Components) The polyester layer may contain other components. Examples of the other components include thermal stabilizers, photostabilizers, moisture-proof agents, waterproofing agents, lubricants, and spreading agents. The polyester layer may contain, within a range that does not impair the effects of the present invention, a resin other than the polyester resin (X) that is a main component. The content of the polyester resin (X) is preferably from 80 to 100 mass %, and more preferably from 90 to 100 mass %, relative to the amount of resin in the entire polyester layer. <Polyamide Layer> The polyamide layer contains a polyamide resin (Y), a yellowing inhibitor (A), and an oxidation accelerator (B). Further, the content of the polyamide resin (Y) contained in the polyamide layer is from 0.05 to 7.0 mass % relative to the total amount of all polyamide layers and all polyester layers, the yellowing inhibitor (A) is a dye, and the content of the yellowing inhibitor (A) is from 1 to 30 ppm relative to the total amount of all polyamide layers and all polyester layers. Providing a polyamide layer enables a multilayer container having a high oxygen barrier property. By further containing, in the polyamide layer, the oxidation accelerator (B) and the yellowing inhibitor (A), which is a dye, the present invention is able to achieve an extremely high oxygen barrier property while also suppressing yellowing of the recycled polyester manufactured from the multilayer container. The reason why such an excellent effect is exhibited is not clear, but is thought to be as follows. In the present invention, yellowing can be effectively suppressed by containing the yellowing inhibitor (A) in a nitrogen-containing polyamide layer, which tends to cause yellowing of a recycled resin. However, when these yellowing inhibitors coexist with an oxidation accelerator, oxygen absorption is inhibited by the oxidation accelerator. In the present invention, however, a specific amount of a dye that does not easily inhibit an oxidation reaction is used as the yellowing inhibitor and is contained in the polyamide layer along with an oxidation accelerator, and it is thought that thereby, oxygen absorption performance can be enhanced while exhibiting effective yellowing suppression performance. (Polyamide Resin (Y)) Examples of the polyamide resin (Y) include xylylene group-containing polyamide resins, nylon 6, nylon 66, nylon 666, nylon 610, nylon 11, nylon 12, and mixtures thereof. Among these, xylylene group-containing polyamide resins are preferable because the gas barrier performance can be improved and the polyamide resin can be easily separated from the polyester layer when recycling. The xylylene group-containing polyamide resin is preferably a polyamide resin containing a constituent unit derived from xylylene diamine. The xylylene group-containing polyamide resin is obtained by polycondensation of a dicarboxylic acid and a diamine containing a xylylene diamine, and includes a constituent unit derived from a xylylene diamine and a constituent unit derived from a dicarboxylic acid. Furthermore, the xylylene-group containing polyamide resin preferably contains at least 50 mol %, more preferably at least 70 mol %, even more preferably from 80 to 100 mol %, and yet even more preferably from 90 to 100 mol % of a constituent unit derived from xylylene diamine from among the constituent units derived from diamine (diamine units). The xylylene diamine is preferably meta-xylylene diamine, para-xylylene diamine, or both, and is more preferably meta-xylylene diamine. Furthermore, preferably at least 50 mol %, more preferably at least 70 mol %, even more preferably from 80 to 100 mol %, and yet even more preferably from 90 to 100 mol % of the diamine units constituting the xylylene group-containing polyamide resin are constituent units derived from meta-xylylene diamine. When the amount of constituent units derived from meta-xylylene diamine in the diamine units is within the aforementioned range, the gas barrier properties of the polyamide resin are further improved. The diamine unit in the xylylene group-containing polyamide resin may include only a constituent unit derived from xylylene diamine, or may include a constituent unit derived from diamines other than xylylene diamine. Here, examples of diamines other than xylylene diamine include, but are not limited to, aliphatic diamines having a linear or branched structure, such as ethylene diamine, tetramethylene diamine, pentamethylene diamine, 2-methylpentane diamine, hexamethylene diamine, heptamethylene diamine, octamethylene diamine, nonamethylene diamine, decamethylene diamine, dodecamethylene diamine, 2,2,4-trimethyl-hexamethylene diamine, and 2,4,4-trimethyl-hexamethylene diamine; alicyclic diamines, such as 1,3-bis(aminomethyl)cyclohexane, 1,4-bis(aminomethyl)cyclohexane, 1,3-diaminocyclohexane, 1,4-diaminocyclohexane, bis(4-aminocyclohexyl)methane, 2,2-bis(4-aminocyclohexyl)propane, bis(aminomethyl)decalin, and bis(aminomethyl)tricyclodecane; and diamines having an aromatic ring, such as bis(4-aminophenyl)ether, paraphenylene diamine, and bis(aminomethyl)naphthalene. Examples of compounds that can configure the dicarboxylic acid unit in the xylylene group-containing polyamide resin include C4-20α,ω-linear aliphatic dicarboxylic acids, such as succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, undecanedioic acid, and dodecanedioic acid; alicyclic dicarboxylic acids, such as 1,4-cyclohexane dicarboxylic acid; other aliphatic dicarboxylic acids, such as dimer acids; and aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, orthophthalic acid, xylylene dicarboxylic acid, and naphthalene dicarboxylic acid, and C4-20α,ω-linear aliphatic dicarboxylic acids are preferable, adipic acid and sebacic acid are more preferable, and from the perspective of obtaining favorable barrier performance, adipic acid is even more preferable. Furthermore, the xylylene group-containing polyamide resin preferably contains at least 50 mol %, more preferably at least 70 mol %, even more preferably from 80 to 100 mol %, and yet even more preferably from 90 to 100 mol % of a constituent unit derived from adipic acid from among the constituent units derived from dicarboxylic acid (dicarboxylic acid units). In other words, the polyamide resin (Y) preferably includes a constituent unit derived from a diamine and a constituent unit derived from a dicarboxylic acid with 50 mol % or greater of the constituent unit derived from a diamine being a constituent unit derived from xylylene diamine and 50 mol % or greater of the constituent unit derived from a dicarboxylic acid being a constituent unit derived from adipic acid, and more preferably has a constituent unit derived from a diamine and a constituent unit derived from a dicarboxylic acid with 80 mol % or greater of the constituent unit derived from a diamine being a constituent unit derived from xylylene diamine and 80 mol % or greater of the constituent unit derived from a dicarboxylic acid being a constituent unit derived from adipic acid. The xylylene diamine is preferably meta-xylylene diamine. Furthermore, the remaining dicarboxylic acid units excluding adipic acid are preferably constituent units derived from C4-20α,ω-linear aliphatic dicarboxylic acids. Furthermore, examples of the preferred xylylene group-containing polyamide resin are polyamide resins in which 70 mol % or greater of the diamine units are constituent units derived from xylylene diamine (preferably meta-xylylene diamine), from 70 to 99 mol % of the dicarboxylic acid units are constituent units derived from adipic acid, and from 1 to 30 mol % of the dicarboxylic acid units are constituent units derived from isophthalic acid. The polyamide resin is more preferably a polyamide resin in which 80 mol % or greater of the diamine units are constituent units derived from meta-xylylene diamine (preferably meta-xylylene diamine), from 80 to 99 mol % of the dicarboxylic acid units are constituent units derived from adipic acid, and from 1 to 20 mol % of the dicarboxylic acid units are constituent units derived from isophthalic acid. Adding an isophthalic acid unit as a dicarboxylic acid unit reduces the melting point, and as a result, the molding processing temperature can be lowered, and therefore thermal deterioration during molding can be suppressed, and stretching moldability is improved by delaying the crystallization time. Furthermore, besides the above-mentioned diamines and dicarboxylic acids, lactams such as ε-caprolactam and laurolactam; aliphatic aminocarboxylic acids such as aminocaproic acid and aminoundecanoic acid; and aromatic aminocarboxylic acids such as p-aminomethylbenzoic acid can also be used as components constituting the xylylene group-containing polyamide resin, within a range that does not impair the effect of the present invention. The xylylene group-containing polyamide resin is preferably manufactured by a polycondensation reaction (hereinafter, also referred to as “melt polycondensation”) in a molten state. For example, the xylylene group-containing polyamide resin is preferably manufactured by a method in which a nylon salt composed of a diamine and a dicarboxylic acid is heated using a pressurization method in the presence of water, and is polymerized in a molten state while removing the water. In addition, the xylylene group-containing polyamide resin may also be manufactured by a method in which the diamine is added directly to molten dicarboxylic acid, and the contents are polycondensed under atmospheric pressure. In this case, in order to maintain the reaction system in a uniform liquid state, preferably, the diamine is continuously added to the dicarboxylic acid, and during that time, polycondensation is allowed to proceed while increasing the temperature of the reaction system such that the reaction temperature does not fall below the melting points of the produced oligoamide and polyamide. Furthermore, the molecular weight of the xylylene group-containing polyamide can also be increased by further subjecting the product obtained through melt polycondensation to solid phase polymerization as necessary. The xylylene group-containing polyamide resin is preferably subjected to polycondensation in the presence of a phosphorus atom-containing compound. When the xylylene group-containing polyamide resin is subjected to polycondensation in the presence of a phosphorus atom-containing compound, the processing stability during melt molding is enhanced, and coloration is readily suppressed. The phosphorous atom-containing compound is preferably a hypophosphorous acid compound or a phosphorous acid compound, and is more preferably a hypophosphorous acid compound. The phosphorus atom-containing compound is preferably an organic metal salt, and of these, alkali metal salts are more preferable. From the perspective of promoting a polymerization reaction and the perspective of preventing coloration, examples of the hypophosphorous acid compound include hypophosphorous acid, metal hypophosphites, metal phenyl phosphonites, ethyl hypophosphite, dimethyl phosphinic acid, phenyl methyl phosphinic acid, phenyl phosphonous acid, and ethyl phenyl phosphonite, and metal hypophosphites are preferable. Examples of the metal hypophosphites include sodium hypophosphite, potassium hypophosphite, lithium hypophosphite, and calcium hypophosphite, and sodium hypophosphite is more preferable. Examples of the metal phenyl phosphonites include sodium phenyl phosphonite, potassium phenyl phosphonite, and lithium phenyl phosphonite. Examples of the phosphorous acid compound include phosphorous acid, pyrophosphorous acid, metal phosphites, metal phenyl phosphonates, triethyl phosphite, triphenyl phosphite, ethyl phosphonic acid, phenyl phosphonic acid, and diethyl phenyl phosphonate. Examples of the metal phosphites include sodium hydrogen phosphite, sodium phosphite, potassium phosphite, and calcium phosphite. Examples of the metal phenyl phosphonates include sodium ethylphosphonate, potassium ethylphosphonate, sodium phenylphosphonate, potassium phenylphosphonate, and lithium phenylphosphonate. The phosphorus atom-containing compound may be one type, or two or more types may be used in combination. Furthermore, polycondensation of the xylylene group-containing polyamide resin is preferably implemented in the presence of a phosphorus atom-containing compound and an alkali metal compound. When the usage amount of the phosphorus atom-containing compound is large, there is a concern that the polyamide resin may form a gel. Therefore, from the viewpoint of adjusting the rate of the amidation reaction, an alkali metal compound preferably coexists with the phosphorus atom-containing compound. Examples of the alkali metal compound include alkali metal hydroxides and alkali metal acetates. Examples of the alkali metal hydroxide include lithium hydroxide, sodium hydroxide, potassium hydroxide, rubidium hydroxide, and cesium hydroxide, and examples of the alkali metal acetate include lithium acetate, sodium acetate, potassium acetate, rubidium acetate, and cesium acetate. When an alkali metal compound is used in polycondensation of the polyamide resin, from the viewpoint of suppressing the formation of a gel, the usage amount of the alkali metal compound is in a range in which a value obtained by dividing the number of moles of the alkali metal compound by the number of moles of the phosphorus atom-containing compound is preferably from 0.5 to 1, more preferably from 0.55 to 0.95, and even more preferably from 0.6 to 0.9. The number average molecular weight of the polyamide resin is selected, as appropriate, according to the application and molding method of the multilayer container, but from the perspectives of moldability and strength of the multilayer container, the number average molecular weight is preferably from 10000 to 60000, and more preferably from 11000 to 50000. Note that the number average molecular weight of the polyamide resin is calculated from the following equation (X). Number average molecular weight=2×1000000/([COOH]+[NH2]) (X) (where [COOH] represents the terminal carboxyl group concentration (μmol/g) in the polyamide resin, and [NH2] represents the terminal amino group concentration (μmol/g) in the polyamide resin.) Here, the terminal amino group concentration is a value that is calculated by using a diluted hydrochloric acid aqueous solution to neutralize and titrate a solution obtained by dissolving the polyamide resin in a phenol/ethanol mixed solution, and the terminal carboxyl group concentration is a value that is calculated by using an aqueous sodium hydroxide solution to neutralize and titrate a solution obtained by dissolving the polyamide in benzyl alcohol. The content of the polyamide resin (Y) contained in the polyamide layer is from 0.05 to 7.0 mass % relative to the total amount of all polyamide layers and all polyester layers. From the perspectives of gas barrier properties and suppressing yellowing of the recycled polyester, the content thereof is preferably from 0.5 to 6.0 mass %, more preferably from 1.0 to 5.0 mass %, and even more preferably from 1.5 to 4.5 mass %. (Yellowing Inhibitor (A)) The polyamide layer of the multilayer container contains a yellowing inhibitor (A). The yellowing inhibitor (A) is a dye, and the content of the yellowing inhibitor (A) is from 1 to 30 ppm relative to the total amount of all polyamide layers and all polyester layers. The content of the yellowing inhibitor (A) is from 1 to 30 ppm relative to the total amount of all polyamide layers and all polyester layers. From the perspective of effectively suppressing yellowing of the recycled polyester, the content thereof is preferably from 1.5 to 25 ppm, and from the perspective of mixability and moldability during manufacturing, the content thereof is more preferably from 2 to 22 ppm, even more preferably from 3 to 20 ppm, and yet even more preferably from 8 to 20 ppm. Note that “ppm” in the present invention indicates parts per million by mass. From the perspective of effectively suppressing yellowing of the recycled polyester, the content of the yellowing inhibitor (A) in the polyamide layer is preferably from 0.001 to 1.0 mass %, more preferably from 0.005 to 0.5 mass %, even more preferably from 0.008 to 0.1 mass %, yet even more preferably from 0.01 to 0.08 mass %, and still even more preferably from 0.03 to 0.08 mass %. From the perspective of transparency, the yellowing inhibitor (A) is a dye, and of the dyes, a blue dye is preferable. Yellowing of the recycled polyester obtained from the multilayer container of the present invention can be suppressed by using an extremely small amount of a dye. Further, a recycled polyester having excellent transparency can be obtained. Here, a “dye” is a colorant that is soluble in a solvent. Examples of the dye include anthraquinone-based dyes, pyrazolone-based dyes, coumarin-based dyes, perinone-based dyes, methine-based dyes, and quinophthalone-based dyes, and anthraquinone-based dyes are preferable. Examples of the anthraquinone-based dyes include anthraquinone-based dyes in which a hydrogen atom of the aromatic ring is substituted with an aromatic amine, an aliphatic amine, or a halogen, and an anthraquinone-based dye in which a hydrogen atom of the aromatic ring is substituted with an aromatic amine is preferable. Yellowing of the recycled polyester can be suppressed by using such an anthraquinone-based dye. The anthraquinone-based dye is preferably an anthraquinone-based dye in which a hydrogen atom of the aromatic ring is not substituted with a hydroxyl group. By using such an anthraquinone-based dye, a high oxygen barrier property is obtained in the multilayer container of the present invention. Yellowing of the recycled polyester obtained from the multilayer container of the present invention can be suppressed by using an extremely small amount of an anthraquinone-based dye. The anthraquinone-based dye is more preferably an anthraquinone-based blue dye. The anthraquinone-based dye is preferably a compound represented by Formula (1) below. (Where n represents the number of R, and the two n are each independently from 1 to 5. Each R of the quantity of 2n independently represents a C1-4alkyl group.) In Formula (1), n is from 1 to 5, preferably from 2 to 5, and more preferably from 2 to 3. Yellowing (Δb* value) of the recycled polyester can be suppressed by setting n to the range described above. Each R is independently a C1-4alkyl group, and is preferably at least one selected from the group consisting of a methyl group and an ethyl group. R is preferably substituted at least at the ortho position or the para position relative to the amino group, is preferably substituted at least at the para position, is more preferably substituted at least at the ortho position, and is even more preferably substituted at the ortho position and the para position. Specific examples of the compounds represented by Formula (1) include 1,4-bis[(2-ethyl-6-methylphenyl)amino]anthraquinone, Solvent Blue 97, Solvent Blue 104, and Solvent Green 3, and 1,4-bis[(2-ethyl-6-methylphenyl)amino] anthraquinone, Solvent Blue 97, and Solvent Blue 104 are preferable. Examples of commercially available products of the yellowing inhibitor (A) include MACROLEX Blue 3R (1,4-bis[(2-ethyl-6-methylphenyl)amino]anthraquinone, anthraquinone-based dye, available from Lanxess AG), MACROLEX Blue RR Gran (anthraquinone-based dye, available from Lanxess AG), Oracet Blue 690 (anthraquinone-based dye, available from BASF SE), and Quinizarin Green SS (anthraquinone-based dye, available from Tokyo Chemical Industry Co., Ltd.). (Oxidation Accelerator (B)) In the multilayer container of the present invention, the polyamide layer contains an oxidation accelerator (B) for the purpose of inducing an oxidation reaction of the polyamide resin (Y) to increase the oxygen absorption function and further enhance the gas barrier properties. The oxidation accelerator (B) is preferably a compound containing a transition metal, and is more preferably at least one selected from the group consisting of simple transition metal substances, oxides, inorganic acid salts, organic acid salts, and complexes. Examples of the inorganic acid salts include carbonates, sulfates, nitrates, phosphates, silicates, and halides such as chloride and bromide. Examples of the organic acid salts include carboxylates, sulfonates, and phosphonates. Examples of the complexes include complexes with a β-diketone or a β-keto acid ester. The transition metal is preferably a Group VIII transition metal of the periodic table of elements, and from the perspective of expressing oxygen absorption performance, the transition metal is more preferably at least one selected from the group consisting of cobalt, iron, manganese, and nickel, and is even more preferably cobalt. From the perspective of favorably expressing oxygen absorption performance, among the compounds containing a transition metal, the compound is preferably one selected from the group consisting of transition metal-containing carboxylates, carbonates, acetylacetonate complexes, oxides and halides, is more preferably at least one selected from octanoates, neodecanoates, naphthenates, stearates, acetates, carbonates, and acetylacetonate complexes, and is even more preferably a cobalt carboxylate such as cobalt octanoate, cobalt naphthenate, cobalt acetate, cobalt neodecanoate, and cobalt stearate. One type of the oxidation accelerator (B) may be used alone, or two or more types may be used in combination. From the perspectives of increasing gas barrier properties and suppressing yellowing of the recycled polyester resin, the content of the oxidation accelerator (B) is preferably from 0.0001 to 1.0 mass %, more preferably from 0.01 to 0.8 mass %, and even more preferably from 0.05 to 0.6 mass %, relative to the polyamide layer. Additionally, from the perspectives of increasing gas barrier properties and suppressing yellowing of the recycled polyester resin, the content of the oxidation accelerator (B) is preferably from 0.0001 to 1.0 parts by mass, more preferably from 0.01 to 0.8 parts by mass, and even more preferably from 0.05 to 0.6 parts by mass, relative to 100 parts by mass of the polyamide resin (Y). Moreover, from the perspectives of increasing gas barrier properties and suppressing yellowing of the recycled polyester resin, the content of the transition metal of the oxidation accelerator (B) is preferably from 0.00001 to 0.1 mass %, more preferably from 0.0001 to 0.08 mass %, and even more preferably from 0.0003 to 0.06 mass %, relative to the polyamide layer. Further, from the perspectives of increasing gas barrier properties and suppressing yellowing of the recycled polyester resin, the content of the transition metal of the oxidation accelerator (B) is preferably from 0.00001 to 0.1 parts by mass, more preferably from 0.0001 to parts by mass, and even more preferably from 0.0003 to 0.06 parts mass, relative to 100 parts by mass of the polyamide resin (Y). Note that when a carboxylate containing a transition metal is used as the oxidation accelerator (B), the content of the transition metal refers to the content of the transition metal itself in the compound containing the transition metal. (Greening Inhibitor (C)) The polyamide layer of the multilayer container preferably contains a greening inhibitor (C). The greening inhibitor (C) suppresses green color in a −a* direction as measured with a color difference meter when the multilayer container of the present invention is recycled to obtain recycled polyester. The content of the greening inhibitor (C) is from 1 to 30 ppm relative to the total amount of all polyamide layers and all polyester layers. From the perspective of effectively suppressing greening of the recycled polyester, the content thereof is preferably from 1.5 to 25 ppm, and from the perspectives of mixability and moldability during manufacturing, the content thereof is more preferably from 2 to 22 ppm, and even more preferably from 3 to 20 ppm. Note that “ppm” in the present invention indicates parts per million by mass. From the perspective of effectively suppressing greening of the recycled polyester, the content of the greening inhibitor (C) in the polyamide layer is preferably from 0.001 to 1.0 mass %, more preferably from 0.005 to 0.5 mass %, even more preferably from 0.008 to 0.1 mass %, and yet even more preferably from 0.01 to 0.08 mass %. A mass ratio [(A)/(C)] of the yellowing inhibitor (A) to the greening inhibitor (C) in the polyamide layer of the multilayer container of the present invention is preferably from 20/80 to more preferably from 30/70 to 70/30, and even more preferably from 40/60 to 60/40. When the mass ratio is within this range, the hue change of the recycled polyester obtained after recycling is small, and in particular, a polyester having excellent achromaticity is obtained. The greening inhibitor (C) is preferably a dye from the perspective of transparency. Among the dyes, the greening inhibitor (C) is preferably at least one selected from the group consisting of anthraquinone-based dyes and azo-based dyes, and from the perspective of thermal resistance, an anthraquinone-based dye is more preferable. Here, a “dye” is a colorant that is soluble in a solvent. The anthraquinone-based dye is preferably an anthraquinone-based dye in which a hydrogen atom of the aromatic ring is not substituted with a hydroxyl group. By using such an anthraquinone-based dye, a high oxygen gas barrier property is obtained in the multilayer container of the present invention. Furthermore, the greening inhibitor (C) is preferably a red dye, is more preferably at least one selected from the group consisting of anthraquinone-based red dyes and azo-based red dyes, and from the perspective of thermal resistance, is even more preferably an anthraquinone-based red dye. Greening of the recycled polyester obtained from the multilayer container of the present invention can be suppressed by using an extremely small amount of an anthraquinone-based red dye and an azo-based red dye. The anthraquinone-based dye is preferably a compound represented by Formula (2) below. (In Formula (2), the two Y are each independently a hydrogen atom or a group represented by Formula (2a). However, at least one Y is a group represented by Formula (2a). Furthermore, in Formula (2a), R represents a C1-4 alkyl group.) In Formula (2), each of the two Y independently represents a hydrogen atom or a group represented by Formula (2a), but at least one Y is a group represented by Formula (2a). Preferably, one Y is a group represented by Formula (2a), and the other Y is a hydrogen atom. In Formula (2a), R represents a C1-4 alkyl group and is preferably at least one selected from the group consisting of a methyl group and an ethyl group. Note that when the two Y are both groups represented by Formula (2a), the two R in the groups represented by Formula (2a) may be the same or different. R is preferably substituted at the para position with respect to the amino group. Specific examples of the compound represented by Formula (2) include Solvent Violet 36. One type of the greening inhibitor (B) may be used alone, or two or more types may be used in combination. Examples of commercially available products of the greening inhibitor (B) include MACROLEX Violet 3R Gran (anthraquinone-based dye, available from Lanxess AG), MACROLEX Red Violet R Gran (Disperse Violet 31, Disperse Violet 26, Solvent Violet 59, anthraquinone-based dye, available from Lanxess AG), MACROLEX RED 5B Gran (Disperse Violet 31, Disperse Violet 26, Solvent Violet 59, anthraquinone-based dye, available from Lanxess AG), and MACROLEX Red B (Solvent Red 195, azo-based dye, available from Lanxess AG). (Polyester Resin (Z)) The polyamide layer of the multilayer container preferably contains a polyester resin (Z) from the perspectives of suppressing yellowing of the recycled polyester and improving the impact resistance. The polyester resin (Z) used in the polyamide layer is preferably a polyester resin described in the Polyester resin (X) section describing polyester resins (X) contained in the polyester layer, and the same applies to suitable polyester resins. Specifically, the polyester resin (Z) is preferably polyethylene terephthalate (PET). The polyethylene terephthalate may include a constituent unit derived from an aromatic dicarboxylic acid other than terephthalic acid, and as the constituent unit derived from an aromatic dicarboxylic acid other than terephthalic acid, a constituent unit derived from a sulfophthalic acid or a metal sulfophthalate is preferable. The metal sulfophthalate is a metal salt of a sulfophthalic acid, and examples of the metal atom include alkali metals and alkaline earth metals. When the polyester resin (Z) is contained in the polyamide layer, yellowing of the recycled polyester obtained by recycling is suppressed, and impact resistance of the multilayer container becomes favorable because adhesiveness between the polyamide layer and the polyester layer is improved. (Other Components) The polyamide layer may contain other components. Examples of the other components include thermal stabilizers, photostabilizers, moisture-proof agents, waterproofing agents, lubricants, and spreading agents. The polyamide layer may contain, within a range that does not impair the effects of the present invention, a resin other than the polyamide resin (Y) that is the main component. In particular, when the yellowing inhibitor (A) is mixed by the masterbatch method described below, it is preferable to contain the polyamide resin or polyester resin used in the masterbatch. In this case, the content of the polyamide resin or polyester resin used in the masterbatch is preferably from 1 to 20 mass % and more preferably from 3 to 15 mass % relative to the amount of resin in the entire polyamide layer. (Resin Composition in Polyamide Layer) From the perspective of gas barrier properties, the content of the polyamide resin (Y) in the polyamide layer is preferably from 80 to 100 mass %, and more preferably from 90 to 100 mass % relative to the amount of resin in the entire polyamide layer. Also, when the polyester resin (Z) is contained in the polyamide layer, from the perspectives of impact resistance and gas barrier properties, the content of the polyester resin (Z) in the polyamide layer is preferably from 5 to 70 mass %, more preferably from 10 to 65 mass %, even more preferably from 20 to 65 mass %, and still even more preferably from 40 to 65 mass %. When the content of the polyester resin (Z) is within the range described above, the multilayer container of the present invention suppresses yellowing of the recycled polyester obtained through recycling, adhesiveness between the polyamide layer and the polyester layer is improved, and the impact resistance is excellent. <Multilayer Container Structure and Characteristics> The multilayer container of the present invention has a multilayer structure including a polyester layer containing the polyester resin (X), and a polyamide layer containing the polyamide resin (Y), the yellowing inhibitor (A), and the oxidation accelerator (B). A resin layer other than the polyester layer and the polyamide layer may be included in the multilayer container of the present invention, but from the perspectives of facilitating separation during recycling and improving the yellowing suppression effect, the content of the resin layer other than the polyester layer and the polyamide layer is preferably low, and more preferably, the multilayer container of the present invention is substantially free of a resin layer other than the polyester layer and the polyamide layer. Additionally, an adhesive layer made from an adhesive or an inorganic layer made from an inorganic material may be provided, but from the perspectives of facilitating separation during recycling and improving the yellowing suppression effect, the content of the adhesive layer or the inorganic layer is preferably low, and more preferably, the multilayer container of the present invention is substantially free of an adhesive layer or an inorganic layer. The multilayer container of the present invention preferably has a multilayer structure of two or more layers, preferably has a structure of from two to five layers, more preferably has a structure of from three to five layers, even more preferably has a three layer structure or a five layer structure, and yet even more preferably has a three layer structure. The outermost layer of the multilayer container of the present invention is preferably a polyester layer. Furthermore, the innermost layer is also preferably a polyester layer, and more preferably the outermost layer and the innermost layer are both polyester layers. When the outermost layer is a polyester layer, the multilayer container excels in impact resistance, appearance and design properties. Here, the “outermost layer” is the layer present on the outer surface of the multilayer container, and is a layer in contact with a packaging material, a gripping tool, or the like during transportation, and is a layer associated with the appearance of the container. The “innermost layer” is the layer present on the inner surface of the multilayer container, and is a layer in contact with the contents, preferably a liquid. Therefore, as the structure of the multilayer container, the multilayer container preferably has a structure of from two to five layers with the outermost layer being a polyester layer, and more preferably has a structure of from three to five layers with the outermost layer and the innermost layer being polyester layers. In the case of a two-layer structure, the structure is preferably, in order from the innermost layer, a polyamide layer/polyester layer, in the case of a three-layer structure, the structure is preferably, in order from the innermost layer, a polyester layer/polyamide layer/polyester layer, and in the case of a five-layer structure, the structure is preferably, in order from the innermost layer, a polyester layer/polyamide layer/polyester layer/polyamide layer/polyester layer. The multilayer container of the present invention is preferably a hollow container, and when the multilayer container is a hollow container, the trunk section thereof has at least a multilayer structure. A ratio (thickness ratio W/S) of a thickness (W) of the polyester layer to a thickness (S) of the polyamide layer of the trunk section is preferably from 2.5 to 200. Note that the thickness of the polyester layer refers to the average thickness, and when a plurality of polyester layers are present in the trunk section, the thicknesses of the plurality of layers are averaged, and the average thickness per layer is determined. The same applies to the thickness of the polyamide layer. The thickness ratio W/S is preferably 2.5 or greater because at such ratio, the polyamide resin is easily separated from the polyester resin in a separation step of a method for manufacturing recycled polyester, and particularly in air elutriation or specific gravity separation. When the thickness ratio W/S is 200 or less, the gas barrier properties of the hollow container are excellent, and the contents can be stored for a long period of time. From the perspective of improving the gas barrier properties of the hollow container while increasing the separation ease in the separation step, the thickness ratio (W/S) is more preferably from 3 to 50, and even more preferably from 4 to 15. Additionally, when the multilayer container is a hollow container, the total thickness of the trunk section of the hollow container (that is, the total thickness of all layers of the trunk section) is preferably from 100 μm to 5 mm, more preferably from 150 μm to 3 mm, and even more preferably from 200 μm to 2 mm. Additionally, the thickness (W) of each polyester layer is preferably from 30 μm to 2 mm, more preferably from 40 μm to 1 mm, and even more preferably from 50 μm to 500 μm. The thickness (S) of each polyamide layer is preferably from 1 to 200 μm, more preferably from 3 to 100 μm, and even more preferably from 8 to 50 μm. In the present invention, when the thickness of the polyamide layer is within this range, the polyamide layer is easily separated from the polyester in a separation step while ensuring gas barrier properties. When the multilayer container is a hollow container, from the perspective of obtaining favorable gas barrier properties, the polyamide layer is preferably present at 50% or greater of the surface area of the outer surface of the container, is more preferably present at 70% or greater of the surface area of the outer surface of the container, is even more preferably present at 90% or greater of the surface area of the outer surface of the container, is yet even more preferably present at 99% or greater of the surface area of the outer surface of the container, is still even more preferably present substantially at 100% of the surface area of the outer surface of the container, and is still even more preferably present at 100% of the surface area of the outer surface of the container. When the multilayer container of the present invention is a hollow container, the multilayer container is preferably a liquid packaging container used by filling the inside of the hollow container with a liquid, and is even more preferably a beverage packaging container. Examples of the liquid to be filled inside include beverages, liquid seasonings, chemicals, pharmaceuticals, and detergents, and beverages for which deterioration due to oxygen can be effectively prevented by the multilayer container of the present invention are preferable. Examples of the beverages include water, carbonated water, oxygenated water, hydrogen water, milk, milk products, juices, coffee, coffee beverages, carbonated soft drinks, teas, and alcoholic beverages. Examples of the liquid seasonings include sauces, soy sauce, syrups, rice wine seasonings, and dressings. Examples of the chemicals include agricultural chemicals and pesticides. The oxygen barrier property of the multilayer container of the present invention can be evaluated through an oxygen permeability test by the MOCON method in accordance with ASTM D3985. The oxygen permeability (cc/(bottle·0.21 atm·day)) of the multilayer container of the present invention is preferably 0.020 or less, more preferably 0.010 or less, and even more preferably 0.005 or less when a total amount of 25 g of resin is formed into a three-layer hollow container having an internal volume of 500 mL with a mass ratio of the polyester layer to the polyamide layer being 97:3. Note that the three-layer hollow container can be manufactured according to the method described in the examples. For the measurements, the OX-TRAN 2/61 available from MOCON, Inc. is used. The 500 mL container is filled with 100 mL of water, nitrogen at 1 atm is circulated inside the container at a rate of 20 mL/min under conditions including an oxygen partial pressure of 0.21 atm, a temperature of 23° C., a container internal humidity of 100% RH, and an external humidity of 50% RH, and oxygen contained in the nitrogen after circulating inside the container is detected by a coulometric sensor, and thereby the oxygen permeability is measured. [Method for Manufacturing Multilayer Container] The method for manufacturing the multilayer container of the present invention is not particularly limited, but the multilayer container thereof is preferably manufactured by the following method. The method for manufacturing the multilayer container of the present invention is preferably a method for manufacturing a multilayer container including: a polyester layer containing a polyester resin (X); and a polyamide layer containing a polyamide resin (Y), a yellowing inhibitor (A), and an oxidation accelerator (B); the content of the polyamide resin (Y) being from 0.05 to 7.0 mass % relative to the total amount of all polyamide layers and all polyester layers; the yellowing inhibitor (A) being a dye; and the content of the yellowing inhibitor (A) being from 1 to 30 ppm relative to the total amount of all polyamide layers and all polyester layers; and the manufacturing method including: a step 1 of mixing the polyamide resin (Y), the yellowing inhibitor (A), and the oxidation accelerator (B) to prepare a polyamide resin mixture; a step 2 of co-injection molding the polyamide resin mixture and a polyester resin composition containing the polyester resin (X), and thereby obtaining a multilayer preform; and a step 3 of blow molding the multilayer preform. <Step 1 (Step of Preparing Polyamide Resin Mixture)> In step 1, the polyamide resin (Y), the yellowing inhibitor (A), and the oxidation accelerator (B) are mixed to prepare a polyamide resin mixture. Typically, equipment for stirring and mixing or kneading the yellowing inhibitor and all the resins is necessary in order to spread the yellowing inhibitor throughout the container. However, in the method for manufacturing a multilayer container of the present invention, the yellowing inhibitor (A) and the oxidation accelerator (B) are mixed into a small amount of the polyamide resin (Y), and thereby the yellowing inhibitor (A) and the oxidation accelerator (B) can be efficiently spread throughout the entire container by mixing on a small scale for a short period of time, and thus the manufacturing method of the present invention excels in productivity. The method of mixing these materials may be dry blending or melt blending (melt kneading), but from the perspectives of reducing the thermal history and preventing degradation of the resin or yellowing inhibitor, dry blending and melt blending with the masterbatch method are preferable. Further, from the perspective of preventing the yellowing inhibitor from adhering to and remaining on a molding machine or around the molding machine in step 2, melt blending is preferable, and of the melt blending techniques, the masterbatch method is preferable from the perspective of reducing the thermal history and preventing degradation of the resin and yellowing inhibitor. In step 1, the pellet-shaped polyamide resin (Y), the yellowing inhibitor (A), and the oxidation accelerator (B) are preferably mixed at a temperature of 230° C. or lower, are more preferably mixed at a temperature of 150° C. or lower, and are even more preferably mixed at a temperature of 100° C. or lower. When mixing is implemented at a temperature of 230° C. or lower, the thermal history can be reduced, and degradation of the resin or yellowing inhibitor can be prevented. It is thought that this is achieved because the polyamide resin can maintain the pellet shape, and therefore thermal degradation is minimal. Dry blending is preferably implemented when mixing at a temperature of 230° C. or lower. The yellowing inhibitor (A) suitably used in step 1 is the same as the yellowing inhibitor (A) described in the Yellowing inhibitor (A) section, is a dye, and is more preferably an anthraquinone-based dye. Furthermore, the yellowing inhibitor (A) is preferably in the form of a powder, a dispersion, or a solution, and is more preferably in the form of a powder. The yellowing inhibitor (A) in these forms can be more easily and uniformly mixed with the polyamide resin (Y). The oxidation accelerator (B) suitably used in step 1 is the same as the oxidation accelerator (B) described in the Oxidation accelerator (B) section. Specifically, the oxidation accelerator (B) is preferably a compound containing a transition metal, is preferably one selected from the group consisting of transition metal-containing carboxylates, carbonates, acetylacetonate complexes, oxides and halides, is more preferably at least one selected from octanoates, neodecanoates, naphthenates, stearates, acetates, carbonates, and acetylacetonate complexes, and is even more preferably a cobalt carboxylate such as cobalt octanoate, cobalt naphthenate, cobalt acetate, cobalt neodecanoate, and cobalt stearate. In addition, the greening inhibitor (C) is preferably further mixed in step 1. The greening inhibitor (C) suitably used in step 1 is the same as the greening inhibitor described in the above Greening inhibitor (C) section, and is preferably at least one selected from the group consisting of dyes and pigments, is more preferably at least one selected from the group consisting of anthraquinone-based dyes and azo-based dyes, is even more preferably at least one selected from the group consisting of anthraquinone-based red dyes and azo-based red dyes, and from the perspective of thermal resistance, is yet even more preferably an anthraquinone-based red dye. Furthermore, the greening inhibitor (C) is preferably in the form of a powder, a dispersion, or a solution, and is more preferably in the form of a powder. The greening inhibitor (C) in these forms can be more easily and uniformly mixed with the polyamide resin (Y). Furthermore, the polyester resin (Z) is preferably mixed in step 1. The polyester resin (Z) suitably used in step 1 is the same as the polyester resin (Z) described in the Polyester resin (Z) section. When mixed by dry blending, the polyester resin (Z) is preferably mixed in a pellet form. Examples of the mixing device used in the dry blending include a tumbler mixer, a ribbon mixer, a Henschel mixer, and a Banbury mixer. Examples of the method for mixing the polyamide resin (Y), the yellowing inhibitor (A), and the oxidation accelerator (B) by melt blending in step 1 include the masterbatch method and a full compounding method, and the masterbatch method is preferable. The masterbatch method is a method of kneading a polyamide resin or polyester resin with the yellowing inhibitor (A) and the oxidation accelerator (B), and then mixing with the polyamide resin (Y) in step 1. The masterbatch method is a method of kneading a small amount of polyamide resin or polyester resin with the yellowing inhibitor (A) and the oxidation accelerator (B) to form a masterbatch, and then mixing the master batch with the remaining polyamide resin (Y) in step 1. Further, when obtaining a masterbatch, the greening inhibitor (C) can also be kneaded at the same time. In other words, preferably, in step 1, the polyamide resin or the polyester resin and the yellowing inhibitor (A) and the oxidation accelerator (B) are kneaded and then mixed with the polyamide resin (Y), and more preferably, in step 1, the polyamide resin or polyester resin, the yellowing inhibitor (A), the oxidation accelerator (B), and the greening inhibitor (C) are kneaded and then mixed with the polyamide resin (Y). A polyamide resin or a polyester resin is preferably used in the masterbatch, and from the perspective of miscibility with the polyamide resin (Y), a polyamide resin is preferably used, and from the perspective of suppressing yellowing due to thermal history, a polyester resin is preferably used. Note that these materials may be mixed and used. In particular, the yellowing inhibitor (A) is more preferably a masterbatch kneaded with a polyamide resin (a masterbatch containing a polyamide resin and a yellowing inhibitor (A); a polyamide resin composition), and the oxidation accelerator (B) is more preferably a masterbatch kneaded with a polyester resin (a masterbatch containing a polyester resin and an oxidation accelerator (B); a polyester resin composition). The greening inhibitor (C) is preferably a masterbatch kneaded with a polyamide resin (a masterbatch containing a polyamide resin, a yellowing inhibitor (A), and a greening inhibitor (C); a polyamide resin composition). The polyamide resin used in the masterbatch is preferably a polyamide resin (Y), and is more preferably the same as the remaining polyamide resin (Y). The polyester resin used in the masterbatch is preferably a polyester resin (Z). Also, a polyester resin that is the same as the polyester resin (X) may be used, or a polyester resin that is the same as the polyester resin (X) of the polyester layer may be used. The amount of the polyamide resin or the polyester resin used in the masterbatch is preferably from 1 to 20 mass %, and more preferably from 3 to 15 mass % relative to the amount of resin in the entire polyamide layer. When a polyamide resin or a polyester resin, the yellowing inhibitor (A), and the oxidation accelerator (B) are kneaded as the method for obtaining a masterbatch, if the melting point of the resin used in the masterbatch is denoted by Tm, the kneading temperature (° C.) is preferably from Tm+5 to Tm+60, more preferably from Tm+10 to Tm+50, and even more preferably from Tm+15 to Tm+40 from the perspective of sufficient mixing. Specifically, the kneading temperature is even more preferably from 245 to 300° C., yet even more preferably from 250 to 290° C., and still even more preferably from 255 to 280° C. In addition, from the perspective of sufficiently kneading, the kneading time is preferably from 10 to 600 seconds, more preferably from 20 to 400 seconds, and even more preferably from 30 to 300 seconds. Examples of the device used for kneading include an open type mixing roll, a non-open type device such as Banbury mixer, a kneader, and a continuous kneader (such as a single-screw kneader, a twin-screw kneader, and a multi-screw kneader). Furthermore, examples of methods for mixing the masterbatch and the remaining polyamide resin (Y) include dry blending and a kneading method, and dry blending is preferable from the perspective of reducing the thermal history. For the dry blending, preferably pellets of the masterbatch are mixed with pellets of the remaining polyamide resin (Y) using a mixing device such as a tumbler mixer. When a polyester resin (Z) is contained in the polyamide layer of the multilayer container to be obtained, examples of methods for mixing with the masterbatch, the remaining polyamide resin (Y), and the remaining polyester resin (Z) include dry blending and a kneading method, and dry blending is preferable. For the dry blending, preferably pellets of the masterbatch, pellets of the remaining polyamide resin (Y), and pellets of the remaining polyester resin (Z) are mixed using a mixing device such as a tumbler mixer. The full compounding method is a method of kneading and mixing the total amount of the polyamide resin (Y), the yellowing inhibitor (A), and the oxidation accelerator (B) used in the polyamide layer. Note that when a polyester resin (Z) is contained in the polyamide layer of the multilayer container to be obtained, the total amount of the polyamide resin (Y), the total amount of polyester resin (Z), the yellowing inhibitor (A), and the oxidation accelerator (B) used in the polyamide layer are kneaded and mixed. From the perspective of sufficient mixing, the kneading temperature is preferably from 245 to 300° C., more preferably from 250 to 290° C., and even more preferably from 255 to 280° C. In addition, from the perspective of sufficiently kneading, the kneading time is preferably from 10 to 600 seconds, more preferably from 20 to 400 seconds, and even more preferably from 30 to 300 seconds. Examples of the device used for kneading include an open type mixing roll, a non-open type Banbury mixer, a kneader, and a continuous kneader (such as a single-screw kneader, a twin-screw kneader, and a multi-screw kneader). The composition of the polyamide resin mixture obtained in this step is preferably a composition similar to that described in the Polyamide layer section above. <Step 2 (Step of Obtaining Multilayer Preform)> In step 2, the polyamide resin mixture and a polyester resin composition containing a polyester resin (X) are co-injection molded to obtain a multilayer preform. The polyester resin composition is preferably a composition similar to that described in the Polyester layer section above. Also, in the co-injection molding, the polyester resin and the polyamide resin mixture are extruded in molds, respectively, and then co-injection molded to form a multilayer preform. <Step 3 (Blow Molding Step)> In step 3, the multilayer preform is blow molded. In the method for manufacturing a multilayer container of the present invention, the multilayer preform (multilayer parison) obtained in step 2 is preferably molded by stretch blowing. Among these, in step 2, the multilayer preform obtained by co-injection molding is preferably stretch-blow molded, and more preferably, the multilayer preform obtained by co-injection molding is biaxially stretch-blow molded. The conditions for biaxial stretch-blow molding preferably include a preform heating temperature of from 95 to 110° C., a primary blow pressure of from 0.5 to 1.2 MPa, and a secondary blow pressure of from 2.0 to 2.6 MPa. The occurrence of uneven thickness and uneven stretching is suppressed through biaxial stretch-blow molding under these conditions, and therefore a multilayer container having excellent strength can be obtained. [Method for Manufacturing Recycled Polyester] The multilayer container of the present invention is suitable for recycling as described above, and recycled polyester can be manufactured using the multilayer container of the present invention as a raw material. The method for manufacturing recycled polyester of the present invention preferably includes recovering polyester from the multilayer container. That is, the method for manufacturing recycled polyester of the present invention preferably includes recovering polyester from a multilayer container that includes: a polyester layer containing a polyester resin (X); and a polyamide layer containing a polyamide resin (Y), a yellowing inhibitor (A), and an oxidation accelerator (B); the content of the polyamide resin (Y) being from 0.05 to 7.0 mass % relative to the total amount of all polyamide layers and all polyester layers; the yellowing inhibitor (A) being a dye, and the content of the yellowing inhibitor (A) being from 1 to 30 ppm relative to the total amount of all polyamide layers and all polyester layers. The method for manufacturing recycled polyester from the multilayer container preferably includes removing all or a portion of the polyamide layer from the multilayer container, recovering the polyester constituting the polyester layer, and using the recovered polyester as recycled polyester. Note that the method for manufacturing recycled polyester from the multilayer container is not limited to the above-described method, and may be a method of manufacturing recycled polyester without passing through the step of removing the polyamide resin. The recycled polyester obtained by the present manufacturing method can be used in various applications such as resin molded articles and fibers. Details of the method for manufacturing recycled polyester of the present invention will be described below. In the present manufacturing method, a used multilayer container is ordinarily used as the multilayer container, but an unused multilayer container may also be used. Examples of the used multilayer container include those that have been distributed in the market and then collected. In the present manufacturing method, first, if a lid is attached to the multilayer container, the lid is preferably removed from the multilayer container. Next, the container is ground, washed as needed, and then subjected to separation to selectively remove the polyester as needed, and thereby the polyester is recovered as recycled polyester (recovery step). Next, if necessary, the polyester is granulated to obtain pellets (granulation step). Further, if necessary, a crystallization step and a solid phase polymerization step are implemented (crystallization/solid phase polymerization step). Each step is described below. <Recovery Step> The recovery step is a step of grinding the multilayer container to recover recycled polyester. In this step, after the multilayer container is ground, preferably, all or a portion of the polyamide layer is removed, and the polyester is selectively retrieved, and more preferably, the polyester and the polyamide resin constituting the polyamide layer are separated. The multilayer container can be ground using a grinder such as a single-screw grinder, a twin-screw grinder, a three-screw grinder, or a cutter mill. The ground product obtained by grinding is formed into, for example, a flake shape, a powdered shape, or a bulk shape. However, a large portion of the multilayer container has a thin multilayer laminated structure with a thickness of several mm or less, such as the trunk section, and therefore most of the ground product is ordinarily flake-shaped. Note that the flake-shaped ground product refers to a flaky or flat shaped product having a thickness of approximately 2 mm or less. Additionally, in the multilayer container, the polyester layer and the polyamide layer are structurally integrated, but these layers are usually not adhered to each other, and in the grinding step, the polyester and the polyamide resin are easily separated as separate ground products. In addition, by forming the ground product in flake shapes, the ground product is more likely to be blown up and separated by the air flow of the air elutriation described below. However, the polyester and the polyamide resin are not necessarily materials that can be completely separated in the grinding step, and the ground product is separated into a ground product having a relatively high content percentage of polyester and a ground product having a relatively low content percentage of polyester resin and a relatively high content percentage of polyamide. Note that in the following, for convenience of explanation, the ground product having a relatively high content percentage of polyester is referred to simply as polyester, and the ground product having a relatively high content percentage of polyamide resin is referred to simply as polyamide resin. The ground product that has been ground as described above is separated into polyester and polyamide resins (separation step). As the separation method, specific gravity sorting using the difference in the specific gravities of the polyester and the polyamide resins is preferably used. In other words, the polyamide layer is preferably removed by air elutriation after the multilayer container has been ground. A specific example of specific gravity sorting is air elutriation in which the ground product is sorted through wind force. An example of air elutriation includes a method in which the ground product is subjected to an airflow generated by a separation device that can internally generate a rotating airflow, and the ground product is separated into: a ground product that has a large specific gravity or a small specific surface area and naturally descends due to the weight of the ground product itself; and a ground product that has a small specific gravity or a large specific surface area and is blown upward by the airflow, and the separated ground products are recovered. With this method, the ground product of polyester naturally descends under its own weight, whereas the ground product of the polyamide resin is blown upward, and through this, the polyester and polyamide resin can be separated and recovered. In this type of air elutriation, a similar operation may be repeated for the same ground product. For example, the naturally descended ground product may be once again subjected to air elutriation to increase the content percentage of polyester in the recycled polyester. Note that the separation method is not limited to air elutriation, and other examples include a method of immersing the ground product in a liquid such as water and separating based on differences in specific gravity of the ground product with respect to the liquid, and a method of applying a constant level of vibration to the ground product and separating ground products of different specific gravities. <Granulation Step> The recycled polyester that is recovered is preferably granulated and formed into pellets in order to simplify handling during molding and the like. The granulation may be implemented before or after the below-described crystallization/solid phase polymerization step, but it is preferable to implement granulation before the crystallization/solid phase polymerization step. When granulation is implemented before the crystallization/solid phase polymerization step, handling ease in the crystallization/solid phase polymerization step is favorable. In the granulation step, it is preferable to plasticize and granulate the ground product through melt blending. Examples of the granulation device for plasticization and granulation include a single-screw extruder, a twin-screw extruder, and a multi-screw extruder, but any known granulation device can be used. The shape of the pellets is preferably cylindrical, spherical, or elliptical. The granulation preferably includes, for example, extruding the plasticized recycled polyester into a strand, and cutting the strand into pellets using a pelletizer while cooling in a water tank. Pellets removed from the water tank are usually dried to remove moisture adhered to the surface. <Crystallization/Solid Phase Polymerization Step> After the above-described step of recovering the polyester, it is preferable to implement one or more steps selected from a crystallization step and a solid phase polymerization step, and it is more preferable to implement both the crystallization step and the solid phase polymerization step. The crystallization/solid phase polymerization step is preferably implemented on the pelletized polyester described above, but may be implemented on a non-pelletized polyester (for example, the ground product). Note that when crystallization and solid phase polymerization are both implemented, the polyester is preferably crystallized and then subjected to solid phase polymerization. Crystallization of the polyester is implemented by maintaining the polyester under constant heating. The crystallization is preferably implemented by heating the polyester at a temperature of from 100 to 230° C., for example. The polyester is crystallized, and thereby mutual fusing of the polyester and adhering of the polyester to the inner surface of the device during solid phase polymerization and molding are prevented. The solid phase polymerization is preferably implemented by maintaining at a temperature of from the (polyester melting point—80° C.) to less than the melting point of the polyester for a certain duration of time. By implementing the solid phase polymerization at a temperature lower than the melting point, melting of the polyester is prevented, and for example, adhering of the polyester to the device surface, which results in a decrease in work efficiency, is prevented. Also, by implementing the solid phase polymerization at a temperature of equal to or higher than the (melting point—80° C.), the polymerization proceeds at a sufficient polymerization rate, and the desired physical properties are easily obtained. Solid phase polymerization may be implemented under vacuum conditions, and may be implemented under an inert gas stream such as nitrogen or argon. If solid phase polymerization is implemented under vacuum conditions, the vacuum pressure is preferably 1.0 torr or less, more preferably 0.5 torr or less, and even more preferably 0.1 torr or less. Furthermore, under both vacuum conditions and an inert gas stream such as nitrogen or argon, the oxygen concentration remaining in the system is preferably reduced as much as possible, and the oxygen concentration is preferably 300 ppm or less, and more preferably 30 ppm or less. When the oxygen concentration is set to 30 ppm or less, appearance defects such as yellowing are less likely to occur. Furthermore, when the solid phase polymerization is implemented under vacuum conditions, it is preferable to uniformly maintain heat transfer while constantly repeating the stirring or mixing of the polyester. When the solid phase polymerization is implemented in the presence of an inert gas, it is preferable to keep the surface of the polyester in contact with a dry gas at all times under a stream of the dry gas. Examples of the solid-phase polymerization device for implementing the crystallization/solid phase polymerization step include a tumbler-type batch device equipped with a heating jacket, a dry silo-type device provided with inert gas stream equipment, a crystallization device provided internally with a stirrer blade and a discharging screw, and a reactor internally with a stirrer blade and a discharging screw. Note that the crystallization and solid phase polymerization are preferably implemented consecutively or simultaneously in the same device. The heating time for the solid phase polymerization is determined in a timely manner based on the device and other conditions, but the time may be any time as long as the polyester obtains sufficient physical properties. The solid phase polymerization maintains the polyester at a high temperature for a long period of time, and therefore impurities present in the polyester may deteriorate the quality such as the color tone. In the removal step described above, a large portion of the polyamide resin is preferably removed, and in this case, the deterioration of quality that may occur during solid phase polymerization is minimized. In the method for manufacturing recycled polyester of the present invention, steps in addition to the steps described above may be implemented, and a washing step may be implemented to remove contents adhering to the interior of the multilayer container. The washing is preferably implemented by rinsing with a liquid, and may be washing with water, washing with an alkaline aqueous solution, or both. Furthermore, the washing may be implemented before the multilayer container is ground into a ground product, or may be implemented after grinding, but the washing is preferably implemented before any of granulation, crystallization, and solid phase polymerization are implemented. Furthermore, the washing step may be implemented simultaneously with the grinding step using a grinder called a wet grinder that simultaneously carries out washing and grinding. In addition, when the washing step is implemented, a drying step may be implemented after the washing step. By implementing the drying step, the amount of moisture in the recycled polyester obtained by the present method can be reduced, and therefore high quality recycled polyester can be provided with high thermal stability and the like. The drying step can be implemented, for example, through air blowing or hot air using a dryer. When the method for manufacturing recycled polyester includes a step of removing the polyamide resin, the content of the polyamide resin in the obtained recycled polyester is preferably less than 1 mass %, more preferably less than 0.8 mass %, and even more preferably less than 0.6 mass %. By reducing the content of the polyamide resin in this manner, the quality of the recycled polyester becomes favorable. EXAMPLES The present invention will be described more specifically hereinafter using examples and comparative examples, but the present invention is not limited to these examples. [Raw Materials] The polyester resins, yellowing inhibitors, oxidation accelerators, and greening inhibitors used in the examples and comparative examples were as follows. Furthermore, a polyamide resin manufactured in the following Manufacturing Example 1 was used as the polyamide resin. <Polyester Resin (X1)> Isophthalic acid copolymerized polyethylene terephthalate (intrinsic viscosity: 0.83 dL/g, melting point: 248° C.), isophthalic acid-modification ratio: 1.5 mol % (in dicarboxylic acid units), trade name: BK2180, available from Mitsubishi Chemical Corporation <Yellowing Inhibitor> Blue RR: Solvent Blue 97 (anthraquinone-based dye), trade name: MACROLEX Blue RR Gran, available from Lanxess AG K6907: Pigment Blue 15:1 (α-type copper phthalocyanine pigment), trade name: HELIOGEN BLUE K6907, available from BASF SE, form: powdered <Oxidation Accelerator> Cobalt(II) stearate: available from Tokyo Chemical Industry Co., Ltd. Cobalt(II) neodecanoate: available from Nippon Kagaku Sangyo Co., Ltd. <Greening Inhibitor> Violet 3R: Solvent Violet 36 (anthraquinone-based dye), trade name: MACROLEX Violet 3R Gran, available from Lanxess AG K4535: Pigment Red 202 (quinacridone pigment), trade name: Cinquasia Magenta K4535, available from BASF SE <Polyester Resin (Z1)> Isophthalic acid copolymerized polyethylene terephthalate (intrinsic viscosity: 0.83 dL/g, melting point: 248° C.), trade name: BK2180, available from Mitsubishi Chemical Corporation <Polyamide Resin (Y1)> Manufacturing Example 1 (Manufacturing of Polyamide Resin (Y1)) A reaction container having an internal volume of 50 liters and equipped with a stirrer, a partial condenser, a total condenser, a thermometer, a dropping funnel, a nitrogen introduction tube, and a strand die was filled with precisely weighed materials containing 15000 g (102.6 mol) of adipic acid, 13.06 g (123.3 mmol, 151 ppm as a phosphorus atom concentration in the polyamide) of sodium hypophosphite monohydrate (NaH2PO2·H2O), and 6.849 g (83.49 mmol, 0.68 as a ratio of the number of moles with respect to the sodium hypophosphite monohydrate) of sodium acetate, and then sufficiently subjected to nitrogen purging. The system was then heated to 170° C. while stirring under a stream of a small amount of nitrogen. Next, 13896 g (102.0 mol, 0.994 as a charged molar ratio) of meta-xylylenediamine was added dropwise under stirring, and the temperature inside the system was continuously increased while removing condensed water that was produced to outside of the system. After the completion of dropwise addition of the meta-xylylenediamine, the reaction was continued for 40 minutes at an internal temperature of 260° C. Subsequently, the inside of the system was pressurized with nitrogen, and the obtained polymer was removed from the strand die and pelletized to obtain approximately 24 kg of polyamide. Next, the polyamide was inserted into a jacketed tumble dryer provided with a nitrogen gas introduction tube, a vacuum line, a vacuum pump, and a thermocouple for measuring the internal temperature, and the inside of the tumble dryer was sufficiently purged with nitrogen gas having a purity of 99 vol % or higher while the tumble dryer was rotated at a constant speed. Subsequently, the tumble dryer was heated under the same nitrogen gas stream, and the temperature of the pellet was increased to 150° C. over approximately 150 minutes. When the temperature of the pellet reached 150° C., the pressure inside the system was reduced to 1 torr or less. Heating was once again continued, and after the temperature of the pellet was increased to 200° C. over approximately 70 minutes, the temperature was maintained at 200° C. for 30 to 45 minutes. Next, nitrogen gas having a purity of 99 vol % or higher was introduced into the system, and the tumble dryer was cooled while being rotated, and a polyamide resin (Y1) was obtained. Evaluation The multilayer container of the present invention was evaluated by the following method. <Oxygen Permeability (Evaluation of Oxygen Barrier Property)> The oxygen permeability was evaluated by the following method. An oxygen permeability test by the MOCON method was conducted in accordance with ASTM D3985. The oxygen permeability was measured using the OX-TRAN 2/61 available from MOCON, Inc. A 500 mL bottle obtained in each of the examples and comparative examples was filled with 100 mL of water, nitrogen at 1 atm was circulated inside the bottle at a rate of 20 mL/min under conditions including an oxygen partial pressure of 0.21 atm, a temperature of 23° C., a bottle internal humidity of 100% RH, and an external humidity of 50% RH, and oxygen contained in the nitrogen after circulating inside the bottle was detected by a coulometric sensor, and thereby the oxygen permeability was measured. The lower measurement limit was set to cc/(bottle·day·0.21 atm). The oxygen permeability was determined using a value for the amount of oxygen permeation after the passage of 7 days from the startup of measurements. A smaller oxygen permeation amount indicates a better oxygen barrier property. <Yellow Chromaticity Δb* (Evaluation of Yellowing Suppression Performance)> The yellow chromaticity Δb*of recycled polyester pellets obtained in the below-described Manufacturing of recycled polyester section was measured according to the following method and evaluated by the following criteria. In accordance with JIS Z 8722, the pellets were poured into a 30 mmφ cell container, and the color tone of the pellets was measured four times by the reflection method using the color difference meter ZE-2000 (a 12 V, 20 W halogen lamp light source available from Nippon Denshoku Industries Co., Ltd.), and an average value was determined as used as the color tone. Note that the b* value represents the chromaticity. A +b* represents a yellow direction, and a −b*represents a blue direction. Also, a smaller absolute value of the Δb* value means a greater suppression of yellowing. The smaller absolute value also means a higher level of achromaticity. The Δb* value indicates a difference between the b* value of a sample from the following examples and comparative examples and the b* value of the polyester resin alone, subjected to the same treatment as in the examples and comparative examples. <Green Chromaticity Δa*> The green chromaticity Δa* of recycled polyester pellets obtained in the below-described Manufacturing of recycled polyester section was measured according to the following method and evaluated by the following criteria. In accordance with JIS Z 8722, the pellets were poured into a 30 mmφ cell container, and the color tone of the pellets was measured four times by the reflection method using the color difference meter ZE-2000 (a 12 V, 20 W halogen lamp light source available from Nippon Denshoku Industries Co., Ltd.), and an average value was determined as used as the color tone. Note that the a* value represents the chromaticity. A +a* represents a red direction, and a −a* represents a green direction. Also, a smaller absolute value of the Δa* value means a greater suppression of greening. The smaller absolute value also means a higher level of achromaticity. The Δa* value indicates a difference between the a* value of a sample from the following examples and comparative examples and the a* value of the polyester resin alone, subjected to the same treatment as in the examples and comparative examples. [Manufacturing of Polyamide Resin Mixture by the Masterbatch Method] Manufacturing Example 2 An amount of 95.35 mass % of the polyamide resin (Y1), 0.20 mass % of Blue RR as the yellowing inhibitor, 4.25 mass % of cobalt(II) stearate as the oxidation accelerator, and 0.20 mass % of Violet 3R as the greening inhibitor were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch A was obtained. Next, a polyamide resin mixture was prepared by mixing the obtained masterbatch A and the remaining polyamide resin (Y1) at the mass ratio (masterbatch A/remaining polyamide resin=10/90) indicated in Table 1. Manufacturing Example 3 An amount of 94.95 mass % of the polyamide resin (Y1), 0.40 mass % of Blue RR as the yellowing inhibitor, 4.25 mass % of cobalt(II) stearate as the oxidation accelerator, and 0.40 mass % of Violet 3R as the greening inhibitor were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch B was obtained. Next, a polyamide resin mixture was prepared by mixing the obtained masterbatch B and the remaining polyamide resin (Y1) at the mass ratio (masterbatch B/remaining polyamide resin=10/90) indicated in Table 1. Manufacturing Example 4 An amount of 96.48 mass % of the polyamide resin (Y1), 0.40 mass % of Blue RR as the yellowing inhibitor, 2.72 mass % of cobalt(II) neodecanoate as the oxidation accelerator, and 0.40 mass % of Violet 3R as the greening inhibitor were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch C was obtained. Next, a polyamide resin mixture was prepared by mixing the obtained masterbatch C and the remaining polyamide resin (Y1) at the mass ratio (masterbatch C/remaining polyamide resin=10/90) indicated in Table 1. Manufacturing Example 5 An amount of 97.08 mass % of the polyamide resin (Y1), 0.40 mass % of Blue RR as the yellowing inhibitor, 2.12 mass % of cobalt(II) stearate as the oxidation accelerator, and 0.40 mass % of Violet 3R as the greening inhibitor were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch D was obtained. Next, a polyamide resin mixture was prepared by mixing the obtained masterbatch D and the remaining polyamide resin (Y1) at the mass ratio (masterbatch D/remaining polyamide resin=10/90) indicated in Table 1. Manufacturing Example 6 An amount of 95.35 mass % of the polyamide resin (Y1), 0.40 mass % of Blue RR as the yellowing inhibitor, and 4.25 mass % of cobalt(II) stearate as the oxidation accelerator were dry blended in advance. A greening inhibitor was not added to this dry blend. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch E was obtained. Next, a polyamide resin mixture was prepared by mixing the obtained masterbatch E and the remaining polyamide resin (Y1) at the mass ratio (masterbatch E/remaining polyamide resin=10/90) indicated in Table 1. Manufacturing Example 7 An amount of 94.95 mass % of the polyester resin (X1), 0.40 mass % of Blue RR as the yellowing inhibitor, 4.25 mass % of cobalt(II) stearate as the oxidation accelerator, and 0.40 mass % of Violet 3R as the greening inhibitor were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch F was obtained. Next, a polyamide resin mixture was prepared by mixing the obtained masterbatch F and the remaining polyamide resin (Y1) at the mass ratio (masterbatch F/remaining polyamide resin=10/90) indicated in Table 1. Manufacturing Example 8 An amount of 93.75 mass % of the polyamide resin (Y1), 0.40 mass % of the pigment K6907 as the yellowing inhibitor, 4.25 mass % of cobalt(II) stearate as the oxidation accelerator, and 1.60 mass % of the pigment K4535 as the greening inhibitor were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch G was obtained. Next, a polyamide resin mixture was prepared by mixing the obtained masterbatch G and the remaining polyamide resin (Y1) at the mass ratio (masterbatch G/remaining polyamide resin=10/90) indicated in Table 1. Manufacturing Example 9 An amount of 95.75 mass % of the polyamide resin (Y1) and 4.25 mass % of cobalt(II) stearate as the oxidation accelerator were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch H was obtained. Next, a polyamide resin mixture was prepared by mixing the obtained masterbatch H and the remaining polyamide resin (Y1) at the mass ratio (masterbatch H/remaining polyamide resin=10/90) indicated in Table 1. [Manufacturing of Polyamide Resin Mixture Containing Polyester Resin] Manufacturing Example 10 (Polyamide Resin Composition (Y2)) An amount of 99.2 mass % of the polyamide resin (Y1), 0.4 mass % of Blue RR as the yellowing inhibitor, and 0.4 mass % of Violet 3R as the greening inhibitor were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a polyamide resin composition (Y2) was obtained. Manufacturing Example 11 (Polyester Resin Composition (Z2)) An amount of 95.75 mass % of the polyester resin (Z1) and 4.25 mass % of cobalt(II) stearate as the oxidation accelerator were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 280° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a polyester resin composition (Z2) was obtained. Manufacturing Examples 12 to 18 (Polyamide Resin Mixture Containing Polyester Resin) Polyamide resin mixtures were prepared by mixing the polyamide resin (Y1), the polyamide resin composition (Y2), the polyester resin (Z1), and the polyester resin composition (Z2) at the mass ratios indicated in Table 2. In Table 2, each polyamide resin mixture is indicated by a manufacturing example number. [Manufacturing of Multilayer Container] Examples 1 to 13 and Comparative Examples 1 to 4 <Preform Molding> An injection molding machine (model DU130CI, available from Sumitomo Heavy Industries, Ltd.) having two injection cylinders, and a two-piece mold (available from Kortec, Inc.) were used. The polyester resin (X1) was injected from one injection cylinder, a polyamide resin mixture obtained in Manufacturing Examples 2 to 18 was injected from the other injection cylinder, and under the conditions presented below, a three-layer preform (25 g equivalent setting per preform) formed from a polyester layer/polyamide layer/polyester layer was injection molded and manufactured such that the mass of the polyamide layer relative to the entire preform was as described in Table 1 or 2. The shape of the preform included an overall length of 95 mm, an outer diameter of 22 mm, and a wall thickness of 4.0 mm. The molding conditions for the three-layer preform were as presented below.Skin-side injection cylinder temperature: 285° C.Core-side injection cylinder temperature (only for three-layer preform): 265° C.Resin flow path temperature in the mold: 285° C.Mold cooling water temperature: 15° C.Cycle time: 40 seconds <Bottle Molding> The preform obtained above was biaxially stretch-blow molded using a blow molding device (EFB1000ET, available from Frontier Inc.), and a bottle (hollow multilayer container) was obtained. The overall length of each bottle was 223 mm, the outer diameter was 65 mm, and the internal volume was 500 mL, and the bottom part was petaloid shaped. No dimples were provided in the trunk section. The biaxial stretch-blow molding conditions are as shown below. The oxygen permeability was evaluated using the bottles obtained in Examples 1 to 7 and Comparative Examples 1 and 2. The results are shown in Table 1.Preform heating temperature: 103° C.Stretching rod pressure: 0.7 MPaPrimary blow pressure: 1.1 MPaSecondary blow pressure: 2.5 MPaPrimary blow delay time: 0.30 secondsPrimary blow time: 0.30 secondsSecondary blow time: 2.0 secondsBlow exhaust time: 0.6 secondsMold temperature: 30° C. [Manufacturing of Recycled Polyester] <Recovery and Granulation Step> Ten kilograms of the hollow multilayer containers obtained in Examples 1 to 13 and Comparative Examples 1 to 4 were ground with a grinder having a mesh diameter of 8 mm, and the resulting flake-shaped ground product was recovered as recycled polyester. The recovered recycled polyester was extruded and formed into a strand shape by a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.) at a heater temperature of 270° C. and a discharge rate of 20 kg/hr, and then cut with a pelletizer and formed into pellets while being cooled in a water tank. Note that in Examples 1 to 13 and Comparative Examples 1 to 4, air elutriation of the polyamide layer was not implemented. <Crystallization/Solid Phase Polymerization Step> The pellets obtained in the granulation step were heated at 200° C. for 7 hours under vacuum conditions with the pressure reduced to 1 torr or less. The pellets were removed after the heating treatment, and the yellow chromaticity Δb* and the green chromaticity Δa* were evaluated. The results are shown in Tables 1 and 2. TABLE 1ComparativeExamplesExamples123456712PolyamideManufacturing Example No233456789resinMasterbatchPolyamidePolyamide9.5359.4959.4959.6489.7089.535—9.3759.575mixtureresinresin (Y1)(mass %)PolyesterPolyester——————9.495——resinresin (X1)(mass %)YellowingBlue RR0.020.040.040.040.040.040.04——inhibitorK6907———————0.04—(mass %)OxidationCobalt (II)0.4250.4250.425—0.2120.4250.4250.4250.425acceleratorstearate(mass %)Cobalt (II)———0.272—————neodecanoateGreeningViolet 3R0.020.040.040.040.04—0.04——inhibitorK4535———————0.16—(mass %)Polyamide resin (Y1) (mass %)909090909090909090Total (mass %)100100100100100100100100100MultilayerPolyamide layerPolyamide335555555container(mass %)resinmixturePolyester layerPolyester979795959595959595(mass %)resin (X1)Total (mass %)100100100100100100100100100Yellowing inhibitor(ppm)6122020202020200amountEvaluationOxygen permeability<0.001<0.001<0.001<0.001<0.001<0.001<0.0010.002<0.001(cc/(bottle · day · 0.21 atm))Yellow chromaticity Δb*7.10.50.90.80.61.21.11.723.3Green chromaticity Δa*1.20.81.21.31.015.41.31.41.9 As shown in Table 1, the multilayer containers of the examples can exhibit an excellent oxygen barrier property, and by containing even a small amount of a yellowing inhibitor, the multilayer containers thereof can suppress yellowing of the recycled polyester when recycling. TABLE 2ComparativeExamplesExamples891011121334PolyamideManufacturing Example No1213141512161718resin mixturePolyamidePolyamide8073238480309040resin (Y1)resin (Y1)(mass %)PolyamidePolyamide10171761010——resinresin (Y1) +compositionyellowing(Y2) (mass %)inhibitor(BlueRR) 0.4% +greeninginhibitor(Violet 3R)0.4%Polyester resinPolyester——50——50—50(X1) (mass %)resin (X1)Polyester resinPolyester1010101010101010compositionresin (Z1) +(Z2) (mass %)oxidationaccelerator(cobalt(II)stearate) 4.25%Total (mass %)100100100100100100100100MultilayerPolyamidePolyamide33355555resinmixturecontainerlayer (mass %)Oxidation0.4250.4250.4250.4250.4250.4250.4250.425acceleratoramount(mass %) (inresin mixture)Polyester layerPolyester9797979595959595(mass %)resin (X1)Total (mass %)100100100100100100100100Yellowing(ppm)12202012202000inhibitoramountGreening(ppm)12202012202000inhibitoramountEvaluationYellow0.40.50.21.50.81.220.09.4chromaticityΔb*Green0.40.60.40.80.90.51.20.5chromaticityΔa* Further, as shown in Table 2, even when the polyamide layer contains a polyester resin, by using a small amount of a yellowing inhibitor, the multilayer containers of the examples can suppress yellowing of the recycled polyester when recycling. [Manufacturing of Polyamide Resin Mixture or Polyamide Resin Mixture] Manufacturing Example 19 (Manufacturing of Polyamide Resin Mixture) An amount of 94.95 mass % of the polyamide resin (Y1), 0.40 mass % of Blue RR as the yellowing inhibitor, 4.25 mass % of cobalt(II) stearate as the oxidation accelerator, and 0.40 mass % of Violet 3R as the greening inhibitor were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch I was obtained. Next, a polyamide resin mixture was prepared by mixing the obtained masterbatch I and the remaining polyamide resin (Y1) at the mass ratio (masterbatch I/remaining polyamide resin=indicated in Table 3. Manufacturing Example 20 (Manufacturing of Polyamide Resin Mixture) An amount of 95.75 mass % of the polyamide resin (Y1) and 4.25 mass % of cobalt(II) stearate as the oxidation accelerator were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch J was obtained. Next, a polyamide resin mixture was prepared by mixing the obtained masterbatch J and the remaining polyamide resin (Y1) at the mass ratio (masterbatch J/remaining polyamide resin=indicated in Table 3. Manufacturing Example 21 (Manufacturing of Polyester Resin Mixture) An amount of 97.60 mass % of the polyester resin (X1), 1.20 mass % of Blue RR as the yellowing inhibitor, and 1.20 mass % of Violet 3R as the greening inhibitor were dry blended in advance. Next, the dry blended mixture was melt-kneaded at 260° C. using a twin-screw extruder (TEM26SX available from Toshiba Machine Co., Ltd.), and masterbatch pellets were obtained. Subsequently, the pellets were dried in a vacuum dryer at 150° C. for 5 hours, and a masterbatch K was obtained. Next, a polyester resin mixture was prepared by mixing the obtained masterbatch K and the remaining polyester resin (X1) at the mass ratio (masterbatch K/remaining polyester resin=indicated in Table 3. [Manufacturing of Multilayer Container] Example 14 and Comparative Example 5 <Preform Molding> An injection molding machine (model DU130CI, available from Sumitomo Heavy Industries, Ltd.) having two injection cylinders, and a two-piece mold (available from Kortec, Inc.) were used. The polyester resin (X1) (Example 14) or the polyester resin mixture (Comparative Example 5) obtained in Manufacturing Example 21 was injected from one injection cylinder, the polyamide resin mixture (Example 14) obtained in Manufacturing Example 19 or the polyamide resin mixture (Comparative Example 5) obtained in Manufacturing Example 20 was injected from the other injection cylinder, and under the conditions presented below, a three-layer preform (25 g equivalent setting per preform) formed from a polyester layer/polyamide layer/polyester layer was injection molded and manufactured such that the mass of the polyamide layer relative to the entire preform was as described in Table 3. The shape of the preform included an overall length of 95 mm, an outer diameter of 22 mm, and a wall thickness of 4.0 mm. The molding conditions for the three-layer preform were as presented below.Skin-side injection cylinder temperature: 285° C.Core-side injection cylinder temperature (only for three-layer preform): 265° C.Resin flow path temperature in the mold: 285° C.Mold cooling water temperature: 15° C.Cycle time: 40 seconds <Bottle Molding> The preform obtained above was biaxially stretch-blow molded using a blow molding device (EFB1000ET, available from Frontier Inc.), and a bottle (hollow multilayer container) was obtained. The overall length of each bottle was 223 mm, the outer diameter was 65 mm, and the internal volume was 500 mL, and the bottom part was petaloid shaped. No dimples were provided in the trunk section. The biaxial stretch-blow molding conditions are as shown below.Preform heating temperature: 103° C.Stretching rod pressure: 0.7 MPaPrimary blow pressure: 1.1 MPaSecondary blow pressure: 2.5 MPaPrimary blow delay time: 0.30 secondsPrimary blow time: 0.30 secondsSecondary blow time: 2.0 secondsBlow exhaust time: 0.6 secondsMold temperature: 30° C. [Manufacturing of Recycled Polyester Including Air Elutriation Step] <Recovery, Air Elutriation, and Granulation Step> Ten kilograms of the hollow multilayer containers obtained in Example 14 and Comparative Example 5 were ground into flakes with a grinder having a mesh diameter of 8 mm, and then the flakes were washed with water. Subsequently, a material having a heavy specific gravity and dropped into a lower receptacle was collected using the froth separator CFS-150 (available from Aco KK) at a feed rate of 10 kg/hr with a suction blower having a frequency of 35 Hz and a secondary blower having a frequency of 30 Hz. The flake-shaped ground product that was ultimately dropped into the lower receptacle was recovered as recycled polyester. The recovered recycled polyester was extruded and formed into a strand shape by a twin-screw extruder (TEM26SX, available from Toshiba Machine Co., Ltd.) at a heater temperature of 270° C. and a discharge rate of 20 kg/hr, and then cut with a pelletizer and formed into pellets while being cooled in a water tank. <Crystallization/Solid Phase Polymerization Step> The pellets obtained in the granulation step were heated at 200° C. for 7 hours under vacuum conditions with the pressure reduced to 1 torr or less. The pellets were removed after the heating treatment, and the yellow chromaticity Δb* and the green chromaticity Δa* were evaluated. The results are shown in Table 3. TABLE 3ExampleComparative14Example 5PolyamideManufacturing Example No1920resin mixtureMasterbatchPolyamide resin (mass %)Polyamide resin (Y1)9.4959.575Yellowing inhibitorBlue RR0.04—(mass %)Oxidation acceleratorCobalt (II) stearate0.4250.425(mass %)Greening inhibitorViolet 3R0.04—(mass %)Polyamide resin (Y1) (mass %)9090Total (mass %)100100PolyesterManufacturing Example No—21resin mixtureMasterbatchPolyester resin (mass %)Polyester resin (X1)—4.88Yellowing inhibitorBlue RR—0.060(mass %)Greening inhibitorViolet 3R—0.060(mass %)Polyester resin (X1) (mass %)10095Total (mass %)100100MultilayerPolyamide layer (mass %)Polyamide resin mixture or77containerpolyamide resin (Y1)Polyester layer (mass %)Polyester resin (X1) or polyester9393resin mixtureTotal (mass %)100100Yellowing inhibitor amount(ppm)2828EvaluationYellow chromaticity Δb*0.420.9Green chromaticity Δa*0.71.8 As shown in Table 3, the multilayer container of Example 14 demonstrated that by adding a small amount of yellowing inhibitor to the polyamide layer, yellowing of the recycled polyester can be suppressed even when the polyamide layer is removed during recycling. With the multilayer container of Comparative Example 5, for a case in which the polyamide layer was removed when recycling, the addition of the yellowing inhibitor to the polyester layer resulted in a disruption of the quantitative balance between the polyamide resin and the yellowing inhibitor contained in the recycled polyester and an increase in the Δb* value. | 112,053 |
11858241 | DETAILED DESCRIPTION OF ADVANTAGEOUS EMBODIMENTS OF THE INVENTION This object is achieved by a single-layer or multilayer transparent film composed of one or more polymeric materials having CIE colour values a* and b* such that −7≤a*≤0, −15≤b*≤0 and an optical transmission T such that 60%≤T≤95%. In addition, the object of the invention is achieved by a single-layer or multilayer transparent film composed of one or more polymeric materials having an optical transmission T such that 60%≤T≤95%, where the film contains one or more main dyes which absorb light having wavelengths in the range from 520 to 600 nm. Advantageous embodiments of the above-described films are characterized in that:−7≤a*≤−5, −6≤a*≤−4, −5≤a*≤−3, −4≤a*≤−2, −3≤a*≤−1 or −2≤a*≤0;−7≤a*≤−6, −6≤a*≤−5, −5≤a*≤−4, −4≤a*≤−3, −3≤a*≤−2, −3≤a*≤−2 or −1≤a*≤0;−15≤b*≤−11, −13≤b*≤−9, −11≤b*≤−7, −9≤b*≤−5, −7≤b*≤−3, −5≤b*≤−1 or −3≤b*≤0;−15≤b*≤−14, −14≤b*≤−13, −13≤b*≤−12, −12≤b*≤−11, −11≤b*≤−10, −10≤b*≤−9, −9≤b*≤−8, −8≤b*≤−7, −7≤b*≤−6, −6≤b*≤−5, −5≤b*≤−4, −4≤b*≤−3, −3≤b*≤−2, −2≤b*≤−1 or −1≤b*≤0;a standard deviation of the CIE value a* in the total film is ≤2;a standard deviation of the CIE value a* in the total film is ≤1;a standard deviation of the CIE value a* in the total film is ≤0.5;a standard deviation of the CIE value b* in the total film is ≤2;a standard deviation of the CIE value b* in the total film is ≤1;a standard deviation of the CIE value b* in the total film is ≤0.5;the film has an optical transmission T such that 65%≤T≤95%, 70%≤T≤95%, 75%≤T≤95%, 80%≤T≤95%, 85%≤T≤95% or 90%≤T≤95%;the film has an optical transmission T such that 60%≤T≤92%;the film has an optical transmission T such that 65%≤T≤92%, 70%≤T≤92%, 75%≤T≤92%, 80%≤T≤92%, 85%≤T≤92% or 90%≤T≤92%;the film has an optical transmission T such that 60%≤T≤85%;the film has an optical transmission T such that 65%≤T≤85%, 70%≤T≤85%, 75%≤T≤85%, 80%≤T≤85%, 85%≤T≤585% or 90%≤T≤85%;the film has a width of from 0.1 to 6 m;the film has a width of from 0.1 to 0.4 m, from 0.2 to 0.6 m, from 0.4 to 0.8 m, from 0.6 to 1.0 m, from 0.8 to 1.2 m, from 1 to 3 m, from 2 to 4 m, from 3 to 5 m or from 4 to 6 m;the film has a length of from 2 to 10 000 m;the film has a length of from 10 to 100 m, from 50 to 200 m, from 100 to 500 m, from 300 to 700 m, from 500 to 900 m, from 700 to 1100 m, from 1000 to 3000 m, from 2000 to 4000 m, from 3000 to 5000 m or from 4000 to 10 000 m;the film has a thickness of from 60 to 1400 μm;the film has a thickness of from 60 to 140 μm, from 100 to 180 μm, from 140 to 220 μm, from 180 to 300 μm, from 200 to 400 μm, from 300 to 500 μm, from 400 to 600 μm, from 500 to 700 μm, from 600 to 800 μm, from 700 to 900 μm, from 800 to 1000 μm, from 900 to 1100 μm, from 1000 to 1200 μm, or from 1100 to 1400 μm;the film is thermoformable;the film is not oriented;the film is not stretched;the film comprises one or more layers which, independently of one another, consist of a polymeric material having a proportion by weight of from 60 to 99% by weight vinyl chloride polymer (VCP), based on the total weight of the layer;the film comprises one or more layers which consist of a polymeric material having a proportion by weight of from 60 to 99% by weight of vinyl chloride polymer (VCP), based on the total weight of the layer;the film comprises one or more layers which, independently of one another, consist of a polymeric material having a proportion by weight of from 60 to 99% by weight of polyvinylidene chloride (PVdC), based on the total weight of the layer;the film comprises one or more layers which, independently of one another, consist of a polymeric material having a proportion by weight of from 60 to 99% by weight of polyvinylidene chloride (PVdC), based on the total weight of the layer, and the one or more layers have a total weight per unit area of from 40 to 360 g·m−2;the film comprises one or more layers which, independently of one another, consist of a polymeric material having a proportion by weight of from 60 to 99% by weight of polyvinylidene chloride (PVdC), based on the total weight of the layer, and the one or more layers have a total weight per unit area of from 40 to 80 g·m−2, from 60 to 100 g·m−2, from 80 to 120 g·m−2, from 100 to 140 g·m−2, from 120 to 160 g·m−2, from 140 to 180 g·m−2, from 160 to 200 g·m−2, from 180 to 220 g·m−2, from 200 to 240 g·m−2, from 220 to 260 g·m−2, from 240 to 280 g·m−2, from 260 to 300 g·m−2, from 280 to 320 g·m−2, from 300 to 340 g·m−2or from 320 to 360 g·m−2;the film comprises one or more layers which, independently of one another, consist of a polymeric material having a proportion by weight of from 60 to 99% by weight of polychlorotrifluoroethylene (PCTFE), based on the total weight of the layer;the film comprises one or more layers which, independently of one another, consist of a polymeric material having a proportion by weight of from 60 to 99% by weight of polyethylene (PE), based on the total weight of the layer;the film comprises one or more layers which, independently of one another, consist of a polymeric material having a proportion by weight of from 60 to 99% by weight of polyester, based on the total weight of the layer;the film comprises one or more layers which, independently of one another, consist of a polymeric material having a proportion by weight of from 60 to 99% by weight of polypropylene (PP), based on the total weight of the layer;the film comprises one or more layers which, independently of one another, consist of a polymeric material having a proportion by weight of from 60 to 99% by weight of cycloolefin copolymer (COC), based on the total weight of the layer;the film comprises one or more layers which, independently of one another, consist of a polymeric material having a proportion by weight of from 60 to 99% by weight of ethylene vinyl alcohol copolymer (EVOH), based on the total weight of the layer;the film comprises three adjacent layers which have the sequence PE/EVOH/PE, in each case consisting of a polymeric material having a proportion by weight of from 60 to 99% by weight of polyethylene (PE), from 60 to 99% by weight of ethylene-vinyl alcohol copolymer (EVOH) or from 60 to 99% by weight of polyethylene (PE), based on the total weight of the respective layer;the film comprises two, three, four, five, six, seven, eight, nine, ten or more layers, where at least two of the layers consist of different polymeric materials;the film comprises two, three, four, five, six, seven, eight, nine, ten or more layers and one or more bonding layers, where a bonding layer is in each case arranged between two layers of the film;the one or more main dyes absorb, independently of one another, light having wavelengths in the range from 520 to 540 nm, from 530 to 550 nm, from 540 to 570 nm, from 550 to 570 nm, from 560 to 580 nm, from 570 to 590 nm or from 580 to 600 nm;the one or more main dyes have an integrated absorption of from 20 to 100% for light having wavelengths in the range from 520 to 600 nm, in each case based on the integrated absorption thereof for light having wavelengths in the range from 380 to 780 nm;the one or more main dyes have an integrated absorption for light having wavelengths in the range from 520 to 600 nm of from 30 to 100%, from 40 to 100%, from 50 to 100%, from 60 to 100%, from 70 to 100%, from 80 to 100% or from 90 to 100%, in each case based on the integrated absorption thereof for light having wavelengths in the range from 380 to 780 nm;the one or more main dyes have a specific absorption as in the wavelength range from 520 to 600 nm of from 20 to 100%;the one or more main dyes have a specific absorption as in the wavelength range from 520 to 600 nm of from 30 to 100%, from 40 to 100%, from 50 to 100%, from 60 to 100%, from 70 to 100%, from 80 to 100% or from 90 to 100%;the one or more main dyes have an integrated absorption for light having wavelengths in the range from 520 to 600 nm which is a factor of from 2 to 300 greater than the integrated absorption thereof for light having wavelengths in the range from 420 to 500 nm;the one or more main dyes have an integrated absorption for light having wavelengths in the range from 520 to 600 nm which is a factor of from 2 to 10, from 5 to 20, from 10 to 30, from 20 to 40, from 30 to 50, from 40 to 60, from 50 to 70, from 60 to 80, from 70 to 90, from 80 to 100, from 90 to 110 or from 100 to 300, greater than the integrated absorption thereof for light having wavelengths in the range from 420 to 500 nm;one or more of the polymeric materials contain, independently of one another, one or more supplementary dyes which absorb light having wavelengths in the range from 520 to 600 nm;the one or more supplementary dyes absorb, independently of one another, light having wavelengths in the range from 520 to 540 nm, from 530 to 550 nm, from 540 to 570 nm, from 550 to 570 nm, from 560 to 580 nm, from 570 to 590 nm or from 580 to 600 nm;the one or more supplementary dyes have an integrated absorption for light having wavelengths in the range from 520 to 600 nm of from 20 to 100%, in each cased based on the integrated absorption thereof for light having wavelengths in the range from 380 to 780 nm;the one or more supplementary dyes have an integrated absorption for light having wavelengths in the range from 520 to 600 nm of from 30 to 100%, from 40 to 100%, from 50 to 100%, from 60 to 100%, from 70 to 100%, from 80 to 100% or from 90 to 100%, in each case based on the integrated absorption thereof for light having wavelengths in the range from 380 to 780 nm;the one or more supplementary dyes have a specific absorption αsin the wavelength range from 520 to 600 nm of from 20 to 100%;the one or more supplementary dyes have a specific absorption αsin the wavelength range from 520 to 600 nm of from 30 to 100%, from 40 to 100%, from 50 to 100%, from 60 to 100%, from 70 to 100%, from 80 to 100% or from 90 to 100%;the one or more supplementary dyes have an integrated absorption for light having wavelengths in the range from 520 to 600 nm which is a factor of from 2 to 300 greater than the integrated absorption thereof for light having wavelengths in the range from 620 to 700 nm;the one or more supplementary dyes have an integrated absorption for light having wavelengths in the range from 520 to 600 nm which is a factor of from 2 to 10, from 5 to 20, from 10 to 30, from 20 to 40, from 30 to 50, from 40 to 60, from 50 to 70, from 60 to 80, from 70 to 90, from 80 to 100, from 90 to 110 or from 100 to 300, greater than the integrated absorption thereof for light having wavelengths in the range from 620 to 700 nm;one or more of the polymeric materials contain, independently of one another, one or more main dyes and one or more supplementary dyes;the ratio of the integrated absorption of the one or more main dyes in the wavelength range from 520 to 600 nm to the integrated absorption of the one or more supplementary dyes in the wavelength range from 520 to 600 nm is in the range from 4:1 to 1:1;the ratio of the integrated absorption of the one or more main dyes in the wavelength range from 520 to 600 nm to the integrated absorption of the one or more supplementary dyes in the wavelength range from 520 to 600 nm is in the range from 4:1 to 2:1 or from 3:1 to 1:1;the one or more main dyes are, independently of one another, present in one or more of the layers;the one or more main dyes are, independently of one another, present in one or more of the bonding layers;the one or more main dyes are, independently of one another, present in one or more of the layers and in one or more of the bonding layers;the one or more supplementary dyes are, independently of one another, present in one or more of the layers;the one or more supplementary dyes are, independently of one another, present in one or more of the bonding layers;the one or more supplementary dyes are, independently of one another, present in one or more of the layers and in one or more of the bonding layers; and/orthe one or more main dyes and supplementary dyes are selected from the group consisting of EPOLIGHT® 5819, EPOLIGHT® 5821, EPOLIGHT® 5822, EPOLIGHT® 5391, EPOLIGHT® 5396, FDG-006®, FDG-007®, FDR-001®, HELIOGEN® Blue, Nilblue, HOSTAPRINT® Red HF2B 34, Solvent Blue 97, NOVOPERM® Red HF4B, Eosin Y, Cu-phthalocyanine, Rhodamine Blue, Rhodamine Red, Indigo carmine, Acid Blue 3, Acid Blue 25. The invention further provides shaped bodies, for example blister films or shells, which have been produced from a film as described above by means of thermoforming. The invention further provides a blister pack which comprises a blister part or a blister film which has been formed from a film as described above. The invention further provides for the use of a film as described above for producing a blister part or a blister film for a blister pack. The invention further provides a process for producing a single-layer or multilayer transparent film composed of one or more polymeric materials in one or more film plants, which comprises the steps:(a) provision of one or more polymeric materials;(b) provision of one or more dyes;(c) mixing of the one or more dyes with one or more of the polymeric materials in predetermined proportions;(d) plasticization of the one or more polymeric materials in one or more gelling apparatuses; and(e) shaping of the one or more polymeric materials to give a film by means of extrusion, coextrusion, calendering, coating, extrusion coating and/or lamination; characterized in that the one or more dyes are added in such proportions that the film has CIE colour values a* and b* such that −7≤a*≤0, −15≤b*≤0 and an optical transmission T such that 60%≤T≤95%. Advantageous embodiments of the process of the invention are characterized in that:the one or more dyes are added in such proportions that the film has a CIE colour value a* such that −7≤a*≤−5, −6≤a*≤−4, −5≤a*≤−3, −4≤a*≤−2, −3≤a*≤−1 or −2≤a*≤0;the one or more dyes are added in such proportions that the film has a CIE colour value a* such that −7≤a*≤−6, −6≤a*≤−5, −5≤a*≤−4, −4≤a*≤−3, −3≤a*≤−2, −3≤a*≤−2 or −1≤a*≤0;the one or more dyes are added in such proportions that the film has a CIE colour value b* such that −15≤b*≤−11, −13≤b*≤−9, −11≤b*≤−7, −9≤b*≤−5, −7≤b*≤−3, −5≤b*≤−1 or −3≤b*≤0;the one or more dyes are added in such proportions that the film has a CIE colour value b* such that −15≤b*≤−14, −14≤b*≤−13, −13≤b*≤−12, −12≤b*≤−11, −11≤b*≤−10, −10≤b*≤−9, −9≤b*≤−8, −8≤b*≤−7, −7≤b*≤−6, −6≤b*≤−5, −5≤b*≤−4, −4≤b*≤−3, −3≤b*≤−2, −2≤b*≤−1 or −1≤b*≤0;the one or more dyes are present in one or more colouring additives;the one or more dyes are mixed with the one or more polymeric materials in the one or more gelling apparatuses;the one or more colouring additives are mixed with the one or more polymeric materials in the one or more gelling apparatuses;the film plant is equipped with one or more regulatable metering devices for the one or more dyes;the film plant is equipped with one or more regulatable metering devices for the one or more colouring additives;the film plant is equipped with one or more devices for measuring the colour of the film;the at least one device for measuring the colour of the film comprises a digital colour camera;the at least one device for measuring the colour of the film is configured as a spectrophotometer and comprises a wavelength-dispersive optical component such as a grating or a prism;the at least one device for measuring the colour of the film is designed and configured for detecting the transmission of light through the film;the at least one device for measuring the colour of the film is designed and configured for detecting the transmission of light through the film as a function of the wavelength;the film plant is equipped with one or more transmission sensors for measuring the optical transmission of the film;the film plant is equipped with one or more spectrophotometers for measuring the optical transmission of the film;the film plant is equipped with a control for the metering of the one or more dyes;the film plant is equipped with a control for the metering of the one or more colouring additives;the spectral transmission of the film is measured and transmitted as input signal to the electronic control;the input signal of the spectral transmission of the film is evaluated digitally in the electronic control by means of a software program, converted into control signals and transmitted to the one or more metering devices for the one or more dyes;the input signal of the spectral transmission of the film is evaluated digitally in the electronic control by means of a software program, converted into control signals and transmitted to the one or more metering devices for the one or more colouring additives;the optical transmission of the film is measured and transmitted as input signal to the electronic control;the input signal of the optical transmission of the film is evaluated digitally in the electronic control by means of a software program, converted into control signals and transmitted to the one or more metering devices for the one or more dyes; and/orthe input signal of the optical transmission of the film is evaluated digitally in the electronic control by means of a software program, converted into control signals and transmitted to the one or more metering devices for the one or more colouring additives. The invention further relates to a film which can be produced by a process having one or more of the above-described features. Films according to the invention have a high transparency and are only slightly—at best hardly noticeable light blue—coloured. Even after prolonged irradiation with sunlight, which causes a yellow-orange discolouration in conventional films, no yellowing is perceptible in the films according to the invention. For the purposes of the present invention, the term “film” refers to individual pieces of a film having dimensions of from 0.1 to 1 m and also industrially produced film webs having lengths of from several hundred to some thousands of metres. For the purposes of the present invention, the term “polychlorotrifluoroethylene (PCTFE)” refers to homopolymers composed of chlorotrifluoroethylene units and copolymers containing chlorotrifluoroethylene units and, for example, vinylidene fluoride units. For the purposes of the present invention, the term “polyethylene (PE)” refers to homopolymers composed of ethene units of the type PE-HD (HDPE), PE-LD (LDPE), PE-LLD (LLDPE), PE-HMW or PE-UHMW and also mixtures of the above types. For the purposes of the present invention, the term “polypropylene (PP)” refers to homopolymers composed of propene units, copolymers composed of propene and ethene units and also mixtures of the above homopolymers and copolymers. For the purposes of the present invention, the term “cycloolefin copolymer (COC)” refers to copolymers composed of cycloolefins such as norbornene with alk-1-enes such as ethene. For the purposes of the present invention, the term “ethylene-vinyl alcohol copolymer (EVOH)” refers to copolymers of the monomers ethene and vinyl alcohol. For the purposes of the present invention, the term “polyvinylidene chloride (PVdC)” refers to homopolymers of vinylidene chloride and copolymers of vinylidene chloride and one or more comonomers. Preference is given to using PVdC copolymers which consist of vinylidene chloride and one or more comonomers selected from the group consisting of vinyl chloride, acrylates, alkyl acrylates, alkyl methacrylates and acrylonitrile. For the purposes of the present invention, the term “vinyl chloride polymers (VCP)” refers to vinyl chloride homopolymers, vinyl chloride copolymers and also mixtures of the above polymers. In particular, the term “vinyl chloride polymer” encompassespolyvinyl chlorides (PVC) produced by homopolymerization of vinyl chloride,vinyl chloride copolymers which are formed by copolymerization of vinyl chloride with one or more comonomers such as ethylene, propylene or vinyl acetate; andmixtures of the above homopolymers and copolymers. For the purposes of the present invention, the term “polyester” refers to semicrystalline or amorphous homopolyesters or copolyesters. As semicrystalline or amorphous polyester, preference is given to using glycol-modified polyethylene terephthalate (PETG) or acid-modified polyethylene terephthalate. In particular, glycol units are replaced by 1,4-cyclohexanedimethanol units in the amorphous glycol-modified polyethylene terephthalate (PETG). Such a 1,4-cyclohexane-dimethanol-modified polyethylene terephthalate is commercially available from Eastman Chemical Company (Tennessee, USA) under the product name EASTAR® Copolyester 6763. In a further advantageous embodiment of the invention, a semicrystalline or amorphous polyester having a crystallization half life of at least 5 minutes is used. Such a copolyester is described, for example, in the patent EP 1 066 339 B1 of Eastman Chemical Company. This copolyester is made up of (i) diacid moiety components and (ii) diol moiety components. The diacid moiety components (i) comprise at least 80 mol % of a diacid moiety component selected from among terephthalic acid, naphthalenedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, isophthalic acid and mixtures thereof, based on all diacid moiety components present in the copolyester (=100 mol %). The diol moiety components (ii) comprise from 80 to 100 mol % of a diol moiety component selected from among diols having from 2 to 10 carbon atoms and mixtures thereof and from 0 to 20 mol % of a modified diol selected from among 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,8-octanediol, 2,2,4-trimethyl-1,3-pentanediol, propylene glycol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol, based on all diol moieties present in the copolyester (=100 mol %). Amorphous or semicrystalline copolyesters having a crystallization half life of at least 5 minutes are well suited to conventional calendering processes. Homogeneous and virtually defect-free films can be produced from a polymeric material containing a substantial proportion, generally more than 50% by weight, of semicrystalline or amorphous copolyester having a crystallization half life of at least 5 minutes by calendering. Amorphous or semicrystalline polyesters having a crystallization half life of at least 5 minutes are commercially available from, inter alia, Eastman Chemical Company under the product name CADENCE™ Copolyester. These copolyesters are used as main component for producing polyester films, with the proportion thereof based on the total weight of the polyester film generally being from more than 40 to 70% by weight. The crystallization half life of the copolyesters used for the film is determined by means of a differential scanning calorimeter (DSC). Differential scanning calorimetry (DSC) is a standard method for measuring the thermal properties, in particular the phase transition temperatures, of solids. For the purposes of the present invention, the crystallization half life is determined by heating 15 mg of the copolyester to be measured to 290° C., subsequently cooling it in the presence of helium at a rate of 320° C. per minute to a predetermined temperature in the range from 180 to 210° C. and detecting the time to attainment of the isothermal crystallization temperature or the crystallization peak of the DSC curve. The crystallization half life is determined from the curve of crystallization against time. The crystallization half life corresponds to the time required at the predetermined temperature in the range from 180 to 210° C. after the initial phase of crystallization in order to obtain 50% of the maximum achievable crystallinity in the sample. In advantageous embodiments of the film according to the invention, two or more layers are, independently of one another, joined to one another by the same or different bonding agents. As bonding agents, preference is given to using polyurethanes or acrylates which contain hydrolysis groups, with or without crosslinking by polyisocyanates. In some production processes, for example coextrusion, it is in some cases possible to join layers of different polymers directly, i.e. without bonding agents. For the purposes of the present invention, the term “dye” refers to compounds, in particular organic molecules, which selectively absorb light having wavelengths in a prescribed region of the visible spectrum of from 380 to 780 nm. For the purposes of the present invention, the term “colouring additive” refers to viscous or solid materials, e.g. solutions, dispersions, pigments and masterbatches, which comprise one or more organic and/or polymeric carrier materials and one or more dyes dissolved or dispersed therein. For the purposes of the present invention, the term “absorption coefficient” refers to the linear attenuation coefficient of a material for electromagnetic radiation in the wavelength range of visible light from 380 to 780 nm (https://de.wikipedia.org/wiki/Absorptionskoeffizient). The absorption coefficient is, in accordance with customary terminology, abbreviated by the Greek letter “α”. According to the Lambert-Beer law, the intensity I(z) of light having an initial intensity I0decreases exponentially with the path length z after passing through an absorber having an absorption coefficient α according to the equation I(z)=I0·e−α·z. The product α·z or α·d of the absorption coefficient α and the path length z or the thickness d of a body through which light passes, in particular a film, is referred to as “optical density” or denoted by the symbol “E” (cf. de.wikipedia.org/wiki/Extinktion_(Optik)). For the purposes of the present invention, the terms “integrated absorption” and “integrated optical density” refer to the integrals of the absorption coefficient α and, respectively, the optical density E of a material, in particular a dye, over a prescribed wavelength range [λa, λb] of the visible spectrum. The ratio of the “integrated absorption” or the “integrated optical density” in a prescribed wavelength range [λa, λb] and the “integrated absorption” or “integrated optical density” over the entire visible wavelength range from 380 to 780 nm is referred to as “specific absorption αs”, where αs(λa,λb)=∫λaλbα(λ)dλ∫380nm780nmα(λ)dλ=∫λaλbE(λ)dλ∫380nm780nmE(λ)dλ and 380 nm≤λa<λb≤780 nm. The “specific absorption αs” serves to assign a dye quantitatively to a wavelength range [λa, λb] having a dominant absorption and for the purposes of the present invention replaces the customary qualitative designation by means of a colour complementary to the wavelength range [λa, λb] (de.wikipedia.org/wiki/Komplementärfarbe). For the purposes of the present invention, the colour values a* and b* of a film are measured in remission with the aid of a spectrophotometer in accordance with DIN EN ISO 11664-1:2011-07, DIN EN ISO 11664-2:2011-07 and DIN EN ISO 11664-3:2013-08 using standard light CIE D65, 10° field of view and sensitivity or tristimulus curvesx,y,zof the CIE standard valence system of 1931. For the colour measurement, the film is arranged on a calibrated, diffusely reflecting white standard scattering plate made of SPECTRALON®. In this measurement arrangement, the light emitted by the light source passes twice through the film before it enters into the spectrophotometer. For the purposes of the present invention, the term “optical transmission” refers to the total transmittanceTaveraged over the visible wavelength range: T_=1400nm∫780nm380nmT(λ)dλ where T(λ) is the total transmittance of the film at the wavelength λ. The total transmittance T(λ) as a function of the wavelength λ is determined in accordance with DIN EN ISO 13468-2:2006-07 using a spectrophotometer for detecting the transmitted light (e.g. a Shimadzu UV-3600 Plus spectrophotometer). To measure the total transmittance T(λ), a collimated beam of incident light having an intensity T0(λ) is directed in a perpendicular direction onto the surface of the film. The incident light beam is partially reflected at the two surfaces of the film. The sum of the reflected intensities, which in the case of polymer films is typically from about 8% to 10%, is referred to as IR(λ). While the incident light beam is passing through the film, the intensity is additionally decreased due to absorption IA, forward scattering IFSand backscattering IBS. In embodiments in which the surface of the film is rough, the transmitted light is scattered to a high degree. Accordingly, the measured total transmittance T(λ) can be described by the following equation T(λ)=c·[I0(λ)−IR(λ)−IBS(λ)]/I0(λ) where c is a factor which is determined by careful calibration of the instrument, e.g. by measuring the total transmittance T(λ) without film. The optical transmission, i.e. the average total transmittanceT, is obtained by averaging T(λ) over the visible wavelength range from 380 to 780 nm, according to the relationship T_=1400nm∫380nm780nmT(λ)dλ. For the purposes of the present invention, the content of a dye in a film is for practical reasons not specified in amount-based units of [% by weight] or [mol %] but instead as its optical density E(λ)=α(λ)·d, where d is the thickness of the film. The optical density E(λ) characterizes the effect of a dye independently of the nature and thickness d of the respective film. Reporting of the optical density E(λ) approaches industrial practice, in which the proportion of a dye-containing colouring additive is set with the aid of colour measurements. In the polymer processing industry, colouring additives rather than pure dyes are used virtually without exception. Colouring additives comprise one or more dyes dissolved or dispersed in an organic or polymeric carrier. Accordingly, colouring additives are classified as solution, dispersion, pigment or masterbatch. The proportion of a dye in a colouring additive in units of [% by weight] or [mol %] is usually not quantified by the producers of the colouring additives and is subject to changes. For this reason, the proportion of a colouring additive in a polymeric material is in industrial practice determined empirically by measuring the colour of an article, extrudate or film produced. The empirical determination of the proportion of a dye or colouring additive is also necessary because numerous dyes are subject to appreciable degradation at the elevated temperature in the production process. The optical density E(λ) reported in the present invention can easily be measured by means of the natural logarithm of the ratio of the spectral transmission TF(λ) of a film containing the dye or a colouring additive comprising the dye and the spectral transmission T0(λ) of a film having a thickness of d produced in the same way without the dye or without the colouring additive, according to the relationship E(λ)=ln[TF(λ)T0(λ)]. In the measurement and reporting of the optical density E(λ), the influence of the organic or polymeric carrier materials present in the colouring additives can be disregarded becausethe carrier material has a vanishingly small absorption coefficient (α˜0) in the visible wavelength range from 380 to 780 nm; andthe proportion of the colouring additive and thus of the carrier material in the polymeric material is generally less than 2% by weight. Furthermore, it has to be taken into account that polymeric films and other articles are produced industrially by means of continuous processes such as extrusion, coextrusion, calendering, coating, extrusion coating and/or lamination, with one or more polymeric materials, usually in the form of pellets, and also solid or viscous colouring additives being fed continuously into a gelling apparatus, for example a kneader or extruder. The amount of the colouring additive introduced is regulated with the aid of on-line colour measurement and an electronic control. Only continuous colour measurement in combination with regulated metering-in of the colouring additives makes it possible to adhere to colour tolerances in accordance with ISO/CIE 11664-6 of, for example, ΔE00≤2 or ΔE00≤1 (de.wikipedia.org/wiki/Delta_E) in industrially produced films having a length of up to 10 000 m per roll. For the above reasons, it is neither practicable nor advantageous to indicate the dye content of films according to the invention in amount-based units of [% by weight] or [mol %]. Instead, the optical density E(λ)=α(λ)·d is reported for the purposes of the present invention. Unless specified otherwise, the optical density E(λ) of a colouring additive or of a dye reported in the context of the present invention is based on a measurement in a three-layer film consisting of a first layer of polyvinyl chloride (PVC) having a thickness of 250 μm, a second layer of polyvinylidene chloride (PVdC) having a weight per unit area of 120 g·m−2(corresponding to a thickness of 71 μm) and a third layer of polyethylene (PE) having a thickness of 30 μm. In order to obtain an optical density E(λ) of a dye or colouring additive as specified in the present invention or deviating therefrom in any film, a person skilled in the art of polymer technology will measure the spectral transmission of two or more films havingthe same thickness with and without a prescribed proportion of the colouring additive; orthe same proportion of the colouring additive and differing thicknesses; where the films otherwise consist of identical polymeric materials. For example, a person skilled in the art will make two films F1and F2composed of PVC or PET having the same thickness d, where the first film F1does not contain any colouring additive and the second film F2contains a predetermined proportion of a colouring additive, measure the spectral transmission T1(λ) and T2(λ), respectively, thereof and calculate the optical density E(λ) of the dye or colouring additive according to the relationship E(λ)=ln[TZ(λ)T1(λ)]. With a knowledge of the thickness d, the absorption coefficient α(λ) can then be calculated according to E(λ)=α(λ)·d. The absorption coefficient α(λ) is in turn directly proportional to the proportion of the dye or colouring additive. A person skilled in the art thus has the parameters required to set the proportion of the colouring additive in a film having any composition and thickness in such a way that the film has a predetermined optical density E(λ). As an alternative, a person skilled in the art will, for example, make a film composed of PVC or PET having a predetermined proportion of a selected colouring additive and measure the thickness d thereof and also the spectral transmission and optical density E(1×d; λ), . . . , E(n×d; λ) of single and multiple film stacks having a thickness of 1×d, . . . , n×d where n=2, 3, . . . and determine the absorption coefficient α(λ) by linear regression of the optical density E(j×d; λ) as a function of the thickness j×d where 1≤j≤n. Preference is given to using, for example, polycarbonate (PC) or polymethyl methacrylate (PMMA) as polymeric material for the films F1and F2. In the visible wavelength range from 380 to 780 nm, PC and PMMA have a virtually constant transmission, i.e. a negligible absorption, for layer thicknesses of up to 10 mm and serve as “invisible” matrix for the dye or a colouring additive containing the dye. Apart from deviating temperatures in the production process and more or less severe degradation of a dye associated therewith, the values determined by the above method for the optical density E(λ) and the absorption coefficient α(λ) can readily be carried over by means of an appropriately selected correction factor for the thickness and/or the proportion to a film of any composition and thickness. In the development of the films according to the invention, it was found to be extremely difficult to find dyes or dye combinations by means of which CIE colour values a* and b* such that −7≤a*≤0, −15≤b*≤0 and at the same time a high transparency could be achieved. Dyes by means of which b* can be reduced to values in the range −15≤b*≤0 also mostly bring about a considerable reduction in a* to values of a*<−15 and thus a greenish colouration of the film which can give an observer the impression of, for example, an algal-type growth. In order to increase a* to values in the range −7≤a*≤0, it is therefore generally necessary to employ an additional dye which reduces the transparency and/or, for example, causes an undesirable violet discolouration. To discover suitable dyes and combinations thereof, the inventors have developed a method or mathematical model which is explained briefly below. The form or profile of the optical density E(λ) or of the absorption coefficient α(λ) as a function of the wavelength λ is critical for the colour effect of a dye. The inventors have developed an empirical method by means of which the change in the colour values Δa* and Δb* can be calculated to a good approximation with the aid of the optical density E(λ). The calculation method is presented briefly below: Δa*=-0.39+∫780nm380nm(1-e-2·E(λ))Fa(λ)dλ Δb*=-0.54+∫780nm380nm(1-e-2·E(λ))Fb(λ)dλwhereFa(λ)=11nm∑i=13hi2πσi2e-12(λ-μiσi)2 ihiμiσi1−17.66 6447.5918.63250.7532.3828.163−32.65608.5726.28 and Fb(λ)=11nm[k12πτ12e-12(λ-v1τ1)2+k22πτ22e-12(λ-v2τ2)2α22πτ22∫-∞λe-12α22(χ-v2)2τ22dχ] ikiνiτiα2138.35451.5920.33—2−76.42521.2357.982.44 The curve of the wavelength-dependent functions Fa(λ) and Fb(λ) is shown inFIGS.6and7and corresponds to a sequence of three symmetric Gaussian curves or a sequence of a symmetric Gaussian curve and an asymmetric Gaussian curve with alternating signs. Furthermore, it should be noted that base polymers used in industrial film production, for example vinyl chloride polymer (VCP), polyvinylidene chloride (PVdC), polyester, polychlorotrifluoroethylene (PCTFE), polyethylene (PE), polypropylene (PP), cycloolefin copolymer (COC) and ethylene-vinyl alcohol copolymer (EVOH), have a small and essentially wavelength-independent absorption coefficient in the visible wavelength range from 380 to 780 nm. The empirical calculation method for the colour change Δa* and Δb* developed by the inventors now makes it possible to check the effect of a colouring additive or dye having an optical density E(λ) and adapt it to target values. The dyes used for the purposes of the present invention are listed in Table 1. The chemical empirical formula and structural formula of each dye is indicated where known. In a number of cases, the suppliers or manufacturers of a dye do not disclose the chemical structure thereof. In these cases (and also others), the functional dependence of the optical density E(λ) or of the absorption coefficient α(λ) on the wavelength λ is therefore specified in the form of graphs (seeFIGS.8-10) and tables of values. TABLE 1No.NameEmpirical formulaStructural formula#1EPOLIGHT ®——5819#2EPOLIGHT ®——5821#3EPOLIGHT ®——5822#4EPOLIGHT ®——5391#5EPOLIGHT ®——5396#6FDG-0060 ®——#7FDG-007 ®——#8FDR-001 ®——#9HELIOGEN ® BleuC32H18N8#10NilblueC20H20N3O+#11HOSTAPRINT ® Red HF2B 34C29H25N5O5#12Solvent Blue 97C36H38N2O2#13NOVOPERM ® Red HF4BC34H28ClN5O7#14Eosin YC20H6Br4Na2O5#15Cu- phthalocyanineC32H16CuN8#16Rhodamine BlueC28H31ClN2O3#17Rhodamine RedC31H29ClN2O6S2#18Indigo carmineC16H8N2Na2O8S2#19Acid Blue 3C27H31N2O6S2Na#20Acid Blue 25C20H13N2NaO5S Colouring additives which contain dyes having the product names indicated in Table 1 above are produced and/or supplied by EPOLIGHT ®Epolin Co.FDG-006Yamada Chemical Co. Ltd.FDG-007Yamada Chemical Co. Ltd.FDR-001Yamada Chemical Co. Ltd.HELIOGEN ®BASF SEHOSTAPRINT ®Clariant SENOVOPERM ®Clariant SE Some of the dyes used have the following CAS numbers: HELIOGEN ® BlueCAS No. 574-93-6NilblueCAS No. 3625-57-8HOSTAPRINT ® Red HF2B 34CAS No. 31778-10-6Solvent Blue 97CAS No. 61969-44-6NOVOPERM ® Red HF4BCAS No. 59487-23-9Eosin YCAS No. 17372-87-1Cu-phthalocyanineCAS No. 147-14-8Rhodamine BlueCAS No. 81-88-9Rhodamine RedCAS No. 82354-19-6Indigo carmineCAS No. 860-22-0Acid Blue 3CAS No. 20262-76-4Acid Blue 25CAS No. 6408-78-2 The invention will be illustrated below with the aid of drawings and examples. The drawings show FIG.1a schematic sectional view of a film having four layers and two bonding layers; FIG.2transmission spectra of a film before and after UV irradiation in an irradiation chamber; FIG.3absorbance of a film caused by UV irradiation, presented as absorption coefficient or optical density; FIG.4absorption coefficients of an ideal dye according to the invention and also two commercial dyes; FIG.5a schematic depiction of the instrumental and visual colour measurement or perception; FIG.6the curve of a function Fa(λ) for the empirical calculation of the colour change Δa*; FIG.7the curve of a function Fb(λ) for the empirical calculation of the colour change Δb*; FIG.8-10absorption coefficients of the dyes #1 to #9; FIG.11-13optical densities of illustrative films. FIG.1shows a schematic sectional view of a film1according to the invention having four layers2,3,4,5and two bonding layers6,7which are arranged between the layers2and3and between the layers4and5. The bonding layers6,7serve to adhesively bond the layers2and3or4and5. The film1is transparent and has an optical transmission of from 60 to 95%. One or more of the layers2,3,4,5and bonding layers6,7contain one or more dyes. The one or more dyes and the respective amount or mass thereof is selected in such a way that the film has CIE colour values a* and b* such that −7≤a*≤0, −15≤b*≤0. The CIE colour values a* and b* are determined in accordance with DIN EN ISO 11664-1:2011-07, DIN EN ISO 11664-2:2011-07 and DIN EN ISO 11664-3:2013-08 using standard light CIE D65, 10° field of view and tristimulus curvesx,y,zof the CIE standard valence system of 1931. The thickness of the bonding layers6,7is a factor of from 6 to 1000 smaller than the thickness of the layers2,3,4,5. Accordingly, the contribution of the bonding layers to the total weight of the film1and their barriers towards oxygen and water vapour is negligible. Apart from establishing an adhesive bond between adjacent layers, the bonding layers6,7can also function as carriers for one or more dyes. FIG.2shows the spectral transmission of a film according to the invention in the original state (t=0 min) and after UV irradiation for 120 minutes (t=120 min) in an irradiation chamber. In a wavelength range from about 400 to 600 nm, the irradiated film has a significantly reduced transmission or increased absorption compared to the unirradiated film. FIG.3shows the absorption coefficient determined from the transmission curves depicted inFIG.2as a function of the wavelength. In a wavelength range from about 430 to 440 nm, which overlaps with the range of violet light (400 to 450 nm), the absorption coefficient displays a maximum. The colour complementary to this wavelength range is yellow-green (cf. de.wikipedia.org/wiki/Komplementärfarbe). In the range of visible light from 380 to 780 nm, i.e. without taking into account wavelengths of <380 nm, the greatest absorption (by area) is at 495.5 nm between blue and cyan. The complementary colour corresponding thereto is orange. This result is in agreement with the observation of an initially yellowish discolouration of the film which changes to brownish with increasing UV dose. Based on the above-described colour measurements on UV-weathered films and mathematical analyses, the inventors have postulated an “ideal” dye which compensates a “representative yellowing” of a film. In the context of the present invention, the term “representative” relates to a UV dose to which a film is subjected under normal use conditions. The representative UV dose corresponds to 360 KJ·m−2at a black standard temperature (BST) of 65° C. in accordance with DIN EN ISO 4892-2: 2013-06 B2. The irradiation of the films with the representative UV dose was carried out in a SUNTEST® XLS+ instrument from Atlas Material Testing Technology GmbH. The form or curve of the absorption coefficient of the “ideal” dye is shown in the graph ofFIG.4as a function of the wavelength and corresponds to a Gaussian curve having a centre at 577 nm and full width at half maximum (FWHM) of 20 nm. At an appropriately selected content or optical density of the ideal dye, a film having CIE colour values a* and b* such that −7≤a*≤0, −15≤b*≤0 is obtained. Furthermore, the absorption coefficient of the dye EPOLIGHT® 5819 from Epolin and of Cu-phthalocyanine are shown inFIG.4. Surprisingly, the same CIE colour values a* and b* as in the case of the “ideal” dye are obtained by means of combination of the dyes EPOLIGHT® 5819 and Cu-phthalocyanine having a relatively low optical density under identical conditions, i.e. in films having the same nature and thickness. It should be noted here that the scaling of the optical densities of EPOLIGHT® 5819 and Cu-phthalocyanine is increased by a factor of 2 relative to the “ideal” dye in the graph ofFIG.4. FIG.5schematically shows the measurement of the CIE colour values a* and b* of a film12according to the invention by means of a spectrophotometric colorimeter15. For this purpose, the film12is arranged or laid on a certified white scattering standard14. The white scattering standard14consists of BaSO4or SPECTRALON® (sintered polytetrafluoroethylene) and corresponds to a virtually ideal Lambert reflector. The light used for the colour measurement is produced by a light source10conforming to CIE D65 or by a light source10having a known spectral intensity distribution11. If the spectral intensity distribution11of the light source is not known, it is determined by means of a spectrophotometer (or spectrophotometric colorimeter). In the software-aided evaluation, the spectra recorded using the colorimeter are converted into spectra conforming to CIE 65 by multiplication by a wavelength-dependent factor K(λ) which corresponds to the intensity ratio of a CIE 65 standard light source and the light source actually used, i.e. K(λ)=I(CIE65;λ)I(lightsource;λ). The light emitted by the light source10impinges on the film12, passes through the latter for a first time, is diffusely reflected by the white scattering standard14, passes through the film12a second time and is detected in the colorimeter15. The colorimeter15comprises a spectrophotometer having a wavelength-dispersive optical element, in particular a grating, and a photodiode array. The diffusely reflected light from the film12is collected in combination with the white scattering standard14from a solid angle range having a conical opening angle of 10° and bundled onto the entry slit of the spectrophotometer. The light emitted by the light source10is more or less strongly absorbed or attenuated as a function of the wavelength during the double passage through the film12. The attenuation of the light in the film12is described mathematically by a wavelength-dependent transmission13. For light quanta (photons), the film12represents a transmission filter having a wavelength-dependent transmission probability. The spectrum recorded in the colorimeter15for the light reflected from the film12and the white scattering standard14is finally multiplied or convolved with tristimulus curvesx,y,zof the CIE standard valence system of 1931 (reference16inFIG.5) in order to calculate CIE colour values X, Y, Z and a*, b*. The tristimulus curvesx,y,ztake into account the spectral sensitivities or actuation probabilities of the photoreceptors in the retina of the human eye (de.wikipedia.org/wiki./CIE-Normvalenzsystem). FIG.8to10show the optical densities E(λ) or absorption coefficients α(λ) of the dyes #1 to #9 in standardized units as a function of the wavelength in the visible range from 380 to 780 nm. Numerical values corresponding thereto are shown in Table 2. TABLE 2λ[nm]#1#2#3#4#5#6#7#8#93800.000.000.000.000.000.110.080.150.513850.000.000.000.000.000.100.070.120.453900.000.000.000.000.000.100.060.110.393950.000.000.000.000.000.090.050.090.344000.000.000.000.000.000.080.050.080.294050.030.020.050.020.000.070.040.070.264100.020.020.050.020.000.060.030.060.234150.020.020.040.020.000.050.030.050.214200.010.020.040.020.000.050.020.040.194250.010.020.040.020.000.040.020.030.184300.010.030.040.020.000.040.010.020.164350.010.040.040.020.000.040.010.020.144400.000.060.040.020.000.040.010.010.134450.000.070.040.020.000.040.010.010.114500.000.090.040.020.000.040.000.010.104550.010.110.040.030.010.050.000.010.094600.010.140.030.030.030.050.000.010.094650.010.170.040.040.040.050.000.010.084700.010.210.030.050.060.050.000.000.084750.010.240.030.070.100.050.000.000.084800.010.280.040.080.150.060.000.000.084850.010.320.040.110.230.060.010.010.084900.010.380.050.140.280.070.010.010.094950.020.450.050.180.310.080.010.010.095000.020.520.060.240.340.090.010.010.105050.030.570.070.300.400.100.020.010.115100.030.610.090.340.520.110.030.020.125150.040.640.100.370.690.130.030.020.145200.050.690.130.410.880.150.040.030.175250.070.760.200.490.980.180.050.030.205300.120.850.220.610.980.220.060.040.245350.160.940.200.780.790.250.090.040.295400.140.990.190.920.560.270.130.060.355450.130.990.200.990.330.270.160.090.425500.140.930.240.980.160.290.150.130.515550.150.860.300.850.070.330.140.150.605600.170.810.350.600.020.400.150.140.705650.210.800.460.370.000.480.170.130.785700.310.840.740.220.000.570.190.140.855750.540.890.980.110.000.710.220.150.915800.900.920.920.050.000.910.330.160.975850.990.880.580.020.001.000.570.190.995900.720.750.260.010.000.900.920.281.005950.370.570.110.000.000.610.980.490.996000.160.380.050.000.000.340.710.840.986050.060.240.030.000.000.190.401.000.976100.040.130.020.000.000.090.190.750.966150.020.070.010.000.000.050.100.410.946200.020.040.010.000.000.030.050.180.926250.010.020.010.000.000.010.030.090.906300.010.010.010.000.000.010.020.050.866350.010.000.010.000.000.000.020.030.836400.000.000.010.000.000.000.010.020.796450.000.000.000.000.000.000.010.020.756500.000.000.000.000.000.000.000.020.726550.000.000.000.000.000.000.000.010.696600.000.000.000.000.000.000.000.010.676650.000.000.000.000.000.000.000.010.666700.000.000.000.000.000.000.000.010.666750.000.000.000.000.000.000.000.010.676800.000.000.000.000.000.000.000.010.686850.000.000.000.000.000.000.000.010.706900.000.000.000.000.000.000.000.010.716950.000.000.000.000.000.000.000.000.727000.000.000.000.000.000.000.000.000.717050.000.000.000.000.000.000.000.000.717100.000.000.000.000.000.000.000.000.697150.000.000.000.000.000.000.000.000.677200.000.000.000.000.000.000.000.000.657250.000.000.000.000.000.000.000.000.627300.000.000.000.000.000.000.000.000.607350.000.000.000.000.000.000.000.000.567400.000.000.000.000.000.000.000.000.537450.000.000.000.000.000.000.000.000.497500.000.000.000.000.000.000.000.000.457550.000.000.000.000.000.000.000.000.417600.000.000.000.000.000.000.000.000.377650.000.000.000.000.000.000.000.000.347700.000.000.000.000.000.000.000.000.317750.000.000.000.000.000.000.000.000.287800.000.000.000.000.000.000.000.000.26 Examples 1 to 24 A total of 25 multilayer films, hereinafter designated as Example 1 to 24 and Comparative Example 25, having a layer structure of the type 250 μm of PVC/30 μm of PE/71 μm of PVdC were produced. For this purpose, base films of PVC material comprising 92% by weight of PVC, from 6 to 8% by weight of customary industrial additives, e.g. thermal stabilizer, lubricant and impact modifier, and from 0 to 2% by weight of two colouring additives were firstly manufactured by means of a laboratory calender. The thickness of the PVC films was in each case 250 μm. A total of from 0.01 to 2% by weight of two colouring additives, each containing a dye of the type #1 to #20 as per Table 1, were added to the PVC materials of Examples 1 to 24. The proportion by weight of each colouring additive was indicated by the manufacturer or established by the inventors by means of the measured optical density or absorption coefficient of the respective dye. No colouring additive was added to the PVC material of Comparative Example 25. A 30 μm thick PE film was laminated onto each of the PVC films of Examples 1 to 24 and of Comparative Example 25. The PE layer was subsequently coated with an aqueous PVdC dispersion in each of a number of passes and the coating was dried in order to obtain an integral PVdC layer having a total weight per unit area of 120 g/m2(corresponding to a thickness of 71 μm). For each of the films of Examples 1 to 24 and the Comparative Example 25, a transmission spectrum Tn(λ) where n=1, . . . , 25 was recorded using a spectrophotometer and the colour values a* and b* were determined using a spectrophotometric colorimeter. The total optical density Em(λ) was determined from the natural logarithm of the ratio Tm(λ)/T25(λ) of the transmission spectra Tm(λ), m=1, . . . , 24 of Examples 1 to 24 and of Comparative Example 25 according to the relationship Em(λ)=ln(Tm(λ)T25(λ)). The total optical density Em(λ) calculated in this way is in agreement with the sum of the optical densities of the two dyes weighted according to the established proportions by weight of the colouring additives. The colour values a*, b*, the optical transmission and also further data of Examples 1 to 24 and of Comparative Example 25 are shown in Table 3. TABLE 3Opticaltrans-ExampleMainSupplementarymissionNo.dyeDyea*b*[%]1) FH12) FH23) FH34) Fz15) Fz26) Fz31#9#11−1.2−11.9692.9017.2912.827.478.200.282#9#11−1.8−8.8722.3213.8310.265.606.150.213#9#14−1.6−11.3742.3213.8310.261.703.770.204#7#11−3.0−13.3790.6525.550.691.872.050.075#7#14−1.5−9.5810.4317.030.460.751.680.096#12#11−2.7−12.7724.5519.6515.365.606.150.217#12#14−1.2−11.9763.6415.7212.291.603.560.198#11#10−1.8−12.2720.9912.5616.9911.2112.300.429#10#14−1.1−9.6790.638.0410.882.365.240.2810#1#15−2.0−11.6790.6022.730.190.500.803.1511#19#2−1.1−11.6782.7012.380.061.375.128.4612#3#15−1.2−10.2761.9918.440.151.252.017.8713#19#4−1.1−14.2771.4810.790.002.067.6812.6814#5#19−1.5−9.8782.076.610.001.967.3212.0815#6#19−1.7−11.9802.1019.470.120.592.203.6216#8#11−2.3−10.4760.9214.381.937.478.200.2817#8#14−1.3−10.2790.6910.781.452.074.610.2418#19#17−0.9−13.0790.9312.850.041.375.128.4619#11#18−0.9−10.0761.8113.748.426.547.170.2420#18#14−1.0−9.7791.4811.246.891.603.560.1921#7#11−2.0−4.4820.5822.990.623.363.690.1322#1#15−1.8−5.0820.6625.260.210.500.803.1523#5#19−2.2−5.4812.768.810.002.7510.2416.9124#10#14−2.5−5.6810.9512.0616.323.016.700.3525——−0.615.8387—————— where FH1=11nm∫500nm420nmEH(λ)dλ;1)FH2=11nm∫600nm520nmEH(λ)dλ;2)FH3=11nm∫700nm620nmEH(λ)dλ;3)FZ1=11nm∫500nm420nmEZ(λ)dλ;4)FZ2=11nm∫600nm520nmEZ(λ)dλ;5)FZ3=11nm∫700nm620nmEZ(λ)dλ6) and EH(λ) and EZ(λ) are the optical densities of the respective main dye and of the supplementary dye. The integrals of the optical densities over the wavelength ranges from 420 to 500 nm, from 520 to 600 nm and from 620 to 700 nm serve as a measure of the strength of absorption of the respective dye for blue, green-yellow and red light. FIGS.11to13show graphs of the optical densities of the dyes used in the films of Examples 1 to 24 in absolute units as a function of the wavelength. | 55,367 |
11858242 | DETAILED DESCRIPTION OF THE DISCLOSURE In some embodiments, recyclable, all-polyethylene laminate film structure suitable for use in a flexible packaging are disclosed herein. The disclosed film structures are “all-polyethylene” in that they include only films consisting essentially of ethylene-based polymers. As used herein, “ethylene-based polymer(s)” means polymers comprising greater than 50% by weight of units which have been derived from ethylene monomer. This includes polyethylene homopolymers and interpolymers. “Polymer” means a macromolecular compound prepared by reacting (i.e., polymerizing) monomers of the same or different type, and includes homopolymers and interpolymers. “Interpolymer” means a polymer prepared by the polymerization of at least two different monomer types. This generic term includes copolymers (usually employed to refer to polymers prepared from two different monomer types), and polymers prepared from more than two different monomer types (e.g., terpolymers (three different monomer types) and quaterpolymers (four different monomer types)). Ethylene-based polymers suitable for use in the recyclable, all-polyethylene laminate structures disclosed herein include ethylene homopolymers, long chain branched ethylene polymers, ethylene-alpha-olefin interpolymers where the alpha-olefin moiety can be C2to C10. In particular, ethylene-based polymers suitable for use in the recyclable, all-polyethylene laminate structures disclosed herein include Low Density Polyethylene (“LDPE”); Linear Low Density Polyethylene (“LLDPE”); Ultra Low Density Polyethylene (“ULDPE”); Very Low Density Polyethylene (“VLDPE”); single site catalyzed Linear Low Density Polyethylene, including both linear and substantially linear low density resins (“m-LLDPE”); Medium Density Polyethylene (“MDPE”); and High Density Polyethylene (“HDPE”). The term “LDPE” may also be referred to as “high pressure ethylene polymer” or “highly branched polyethylene” and is defined to mean that the polymer is partly or entirely homopolymerized or copolymerized in autoclave or tubular reactors at pressures above 14,500 psi (100 MPa) with the use of free-radical initiators, such as peroxides (see for example U.S. Pat. No. 4,599,392, which is hereby incorporated by reference). LDPE resins typically have a density in the range of 0.916 to 0.940 g/cm3. The term “LLDPE”, includes both resin made using the traditional Ziegler-Natta catalyst systems as well as single-site catalysts such as metallocenes (sometimes referred to as “m-LLDPE”) and includes linear, substantially linear or heterogeneous polyethylene copolymers or homopolymers. LLDPEs contain less long chain branching than LDPEs and includes the substantially linear ethylene polymers which are further defined in U.S. Pat. Nos. 5,272,236, 5,278,272, 5,582,923 and 5,733,155; the homogeneously branched linear ethylene polymer compositions such as those in U.S. Pat. No. 3,645,992; the heterogeneously branched ethylene polymers such as those prepared according to the process disclosed in U.S. Pat. No. 4,076,698; and/or blends thereof (such as those disclosed in U.S. Pat. No. 3,914,342 or U.S. Pat. No. 5,854,045). The LLDPEs can be made via gas-phase, solution-phase or slurry polymerization or any combination thereof, using any type of reactor or reactor configuration known in the art, with gas and slurry phase reactors being most preferred. The term “MDPE” refers to polyethylenes having densities from 0.926 to 0.940 g/cm3. “MDPE” is typically made using chromium or Ziegler-Natta catalysts or using metallocene, constrained geometry, or single site catalysts, and typically have a molecular weight distribution (“MWD”) greater than 2.5. The term “HDPE” refers to polyethylenes having densities greater than about 0.940 g/cm3, which are generally prepared with Ziegler-Natta catalysts, chrome catalysts or even metallocene catalysts. The film structures disclosed herein can be subjected to a secondary machine direction or bi-axial stretching process to provide machine direction oriented or bi-axially oriented structures. Unless otherwise indicated herein, the following analytical methods are used in the describing aspects of the disclosure: Melt index: Melt indices I2and I10are measured in accordance to ASTM D-1238 at 190° C. and at 2.16 kg and 10 kg load, respectively. Their values are reported in g/10 min. Density: Samples for density measurement are prepared according to ASTM D4703. Measurements are made, according to ASTM D792, Method B, within one hour of sample pressing. In some embodiments, the laminate film structures comprise a film layer consisting essentially of an ethylene-based polymer and a barrier adhesive layer disposed on a surface of the film layer. In some embodiments, the recyclable, all-polyethylene laminate film structure has an oxygen transmission rate not greater than 100 O2/m2/day, measured according to ASTM Method D3985. In some embodiments, the barrier adhesive layer comprises a solvent-based adhesive, a water-based adhesive, and/or or a solventless adhesive. In some embodiments, the all-polyethylene laminate film structures comprise a sealant film layer consisting essentially of an ethylene-based polymer, an intermediate film layer consisting essentially of an ethylene-based polymer, a structural film layer consisting essentially of an ethylene-based polymer, and a barrier adhesive layer.FIG.1provides a schematic illustration of a disclosed recyclable, all-polyethylene laminate structure. InFIG.1, the recyclable, all-polyethylene laminate film structure100includes a first film layer102bonded to a second film layer104by way of a barrier adhesive layer106. The first film layer102and the second film layer104are each coextruded film layers comprising multiple films therein. In various embodiments, the first film layer102and the second film layer104can be coextruded, multi-layer structures, as indicated inFIG.1, or can be mono-layer films. In the coextruded, multi-layer structures illustrated inFIG.1, the first film layer102can include a structural film layer120. The structural film layer120can consist essentially of any polyethylene polymer material. In some embodiments, the structural film layer120can include an ethylene/octene copolymer material and a LDPE material. In some embodiments, suitable LDPE materials have a density not greater than 0.94 g/cm3and a peak melting point not greater than 126° C. Suitable ethylene/octene copolymer materials for use according to this disclosure include those sold by The Dow Chemical Company under the ELITE™ name, e.g., ELITE™ 5400G. Suitable LDPE materials for use according to this disclosure include those sold by The Dow Chemical Company under the AGILITY™ name, e.g., AGILITY™ 1021. Structure film layer120may further include a slip additive, an anti-block additive, and any other additive suitable for use in a laminate film. The first film layer102can further include one or more intermediate film layers110,112,114,116,118. The one or more intermediate film layers110,112,114,116,118can consist essentially of any polyethylene polymer material. In some embodiments, the one or more intermediate film layers110,112,114,116,118can include a HDPE material. In some embodiments, suitable HDPE materials have a density not less than 0.94 g/cm3and a peak melting point in the range of from 120 to 135° C. Suitable HDPE materials for use according to this disclosure include those sold by The Dow Chemical Company under the ELITE™ name, e.g., ELITE™ 5960G. In some embodiments, the one or more intermediate film layers110,112,114,116,118can include an ethylene/octene copolymer material and a LDPE material. The first film layer102can still further include a sealant layer108. In some embodiments, the sealant layer108can consist essentially of any polyethylene polymer material. In some embodiments, the sealant layer108can be a polyolefin plastomer material. Suitable polyolefin plastomer materials for use according to this disclosure include those sold by The Dow Chemical Company under the AFFINITY™ name, e.g., AFFINITY™ 1146G. As illustrated inFIG.1, the sealant layer108and structural layer120form the outer layers of the first film layer102, and the intermediate layers110,112,114,116,118are disposed between the sealant film layer108and the structural film layer120. The barrier adhesive layer106is disposed on a lower surface of the structural film layer120inFIG.1. The second film layer104is bonded to the first film layer102by way of the barrier adhesive layer106. The barrier adhesive layer106contacts the structural film layer122of the second film layer104. While suitable barrier adhesive layer106components are discussed in greater detail below, the barrier adhesive layer106can be solvent-based, water-based, or solventless. In some embodiments, the second film layer104is also a coextruded multi-layer film, wherein the individual films layers mirror those of the first film layer102(e.g.,122is a structural film layer,124,126,128,130,132are intermediate film layers, and134is a sealant film layer). Each film layer102,104can be a multi-layer film, as illustrated inFIG.1, or a single layer film. In some embodiments, each film layer102,104is a single-layer film. In some embodiments, one of films layers102,104is a single-layer film while the other film layer is a multi-layer film. In some embodiments, the barrier adhesive layer106includes an adhesive comprising an isocyanate component and an isocyanate-reactive component. In some embodiments, the isocyanate component comprises a single species of polyisocyanate. In some embodiments, the polyisocyanate is an aliphatic polyisocyanate. In some embodiments, the polyisocyanate is selected from polymeric hexamethylene diisocyanate (HDI trimer isocyanurate), methylene diphenyl diisocyanate, dicyclohexylmethane 4,4′-diisocyanate, and toluene diisocyanate. In some embodiments, the isocyanate-reactive component comprising a hydroxyl-terminated polyester incorporated as substantially-miscible solids in a carrier solvent, the polyester formed from a single species of a linear aliphatic diol having terminal hydroxyl groups and from 2 to 10 carbon atoms, and a linear dicarboxylic acid, the polyester having a number average molecular weight from 300 to 5,000 and being solid at 25° C., and having a melting point of 80° C. or below. In some embodiments, the carrier solvent is selected from ethyl acetate, methyl ethyl ketone, dioxolane, acetone, and combinations thereof. In some embodiments, the hydroxyl-terminated polyester is formed from a C3to C6diol and a dicarboxylic acid selected from adipic acid, azelaic acid, sebacic acid, and combinations thereof. In some embodiments, the isocyanate-reactive component further includes an acrylate viscosity modifier. In some embodiments, the weight ratio of the isocyanate component to the isocyanate-reactive component in the barrier adhesive layer is from 1:1 to 2:1. Articles comprising the disclosed recyclable, all-polyethylene laminate film structure are also disclosed. In some embodiments, the articles include flexible packaging and stand-up pouches. EXAMPLES OF THE DISCLOSURE The present disclosure will now be described in further detail by discussing Illustrative Examples (“IE”) and Comparative Examples (“CE”) (collectively “the Examples”). However, the scope of the present disclosure is not, of course, limited to the IEs. The Examples are fabricated using a LABO COMBI™ 400 laminator. The settings on the laminator include a treatment setting of 1 KW, with tensions at 3.6 lbs for the primary, 4.2 lbs for the secondary, and 7.4 lbs for the rewind roller. A barrier adhesive is coated on a multi-layer polyethylene film via gravure cylinder. For the gravure cylinder, a 130 quad with 15 BCM is used. The adhesive is applied at a coating weight of about 3 g/m2. The barrier adhesive comprises a crystallizable polyester resin comprising a hydroxyl-terminated polyester incorporated as substantially-miscible solids in a carrier solvent, the polyester formed from a single species of a linear aliphatic diol having terminal hydroxyl groups and from 2 to 10 carbon atoms, and a linear dicarboxylic acid, the polyester having a number average molecular weight from 300 to 5,000 and being solid at 25° C., and having a melting point of 80° C. or below. The barrier adhesive further comprises an aliphatic isocyanate crosslinker. The coated film is then passed through a three-zoned oven with temperatures set at 90° C. first zone, 100° C. second zone, and 110° C. third zone. The polyethylene film coated with barrier adhesive is then nipped to another multi-layer polyethylene film of the same composition under a heated steel roll at a temperature of 90° C. and a nip pressure set to 40 psi. The laminated structure is then passed to a chill roll of a temperature of 17° C. The laminate structure is then placed in a temperature control room to cure at 23° C. and 50% relative humidity for 7 days. Illustrative Example 1 is a laminate structure including two multi-layered film structures each having 7 film layers. In particular, each structure includes a sealant layer comprising 95 wt % AFFINITY™ 1146G with the remaining weight including slip additive, a filler layer adjacent to and in contact with the sealant layer and comprising 85 wt % ELITE™ 5400G, and 15 wt % AGILITY™ 1021, a first filler layer adjacent to and in contact with the sealant layer and comprising 100 wt % ELITE™ 5960G, a second filler layer adjacent to and in contact with the first filler layer and comprising 100 wt % ELITE™ 5960G, a third filler layer adjacent to and in contact with the second filler layer and comprising 100 wt % ELITE™ 5960G, a fourth filler layer adjacent to and in contact with the third filler layer and comprising 100 wt % ELITE™ 5960G, and a structural layer adjacent to and in contact with the fourth filler layer and comprising 82 wt % ELITE™ 5400G, 15 wt % AGILITY™ 1021 with the remaining weight including slip additive. A solvent-based polyurethane barrier adhesive prepared in accordance with the disclosure above is applied to the structural layer of one of the two multi-layered film structures. The film structures are then bonded together such that the sealant layers of each film structure seal the laminate. Illustrative Example 2 is a pouch formed using the laminate structure of Illustrative Example 1. Comparative Example 1 is a plain polyethylene film, having no barrier adhesive. The oxygen transmission rates of the laminated structures are tested according to the methods outlined in ASTM Method D3985 (Standard Test Method for Oxygen Gas Transmission Rate through a Plastic Film and Sheeting Using a Coulometric Sensor). The permeability of the laminated structures are tested according to methods outlined in ASTM Method D3985. Oxygen barrier properties are measured for the laminate structures and the permeability is compared. The performance results of the laminate structures are detailed in Table 1. TABLE 1PermeabilityOTRThickness(cc O2·Example(cc O2/m2/d)(μm)microns/m2/d)Illustrative Example 18516413,940Illustrative Example 26916411,316Comparative Example 19138173,953 In addition to the embodiments described above and those set forth in the Examples, many embodiments of specific combinations are within the scope of the disclosure, some of which are described below: Embodiment 1. A recyclable, all-polyethylene laminate film structure suitable for use in a flexible packaging, comprising: a film layer consisting essentially of an ethylene-based polymer; and a barrier adhesive layer disposed on a surface of the film layer, wherein the recyclable, all-polyethylene laminate film structure has an oxygen transmission rate not greater than 100 O2/m2/day, measured according to ASTM Method D3985. Embodiment 2. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the barrier adhesive layer comprises a solvent-based adhesive. Embodiment 3. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the barrier adhesive layer comprises a water-based adhesive. Embodiment 4. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the barrier adhesive layer comprises a solventless adhesive. Embodiment 5. A recyclable, all-polyethylene laminate film structure suitable for use in a flexible packaging, comprising: (A) a sealant film layer consisting essentially of an ethylene-based polymer; (B) an intermediate film layer consisting essentially of an ethylene-based polymer; (C) a structural film layer consisting essentially of an ethylene-based polymer; and (D) a barrier adhesive layer, wherein the recyclable, all-polyethylene laminate film structure has an oxygen transmission rate not greater than 100 O2/m2/day, measured according to ASTM Method D3985. Embodiment 6. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the sealant film layer (A), intermediate film layer (B), and structural film layer (C) form a coextruded film wherein the intermediate film layer (B) is disposed between the sealant film layer (A) and the structural film layer (C), and wherein the barrier adhesive layer (D) is disposed on a surface of the structural film layer (C) opposite the intermediate film layer (B). Embodiment 7. The recyclable, all-polyethylene laminate film structure according to Embodiment 6, wherein the barrier adhesive layer (D) is in contact with another film layer (E) opposite the structural film layer (A). Embodiment 8. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, the structure comprising more than one intermediate film layer (B). Embodiment 9. A recyclable, all-polyethylene laminate film structure suitable for use in a flexible packaging, comprising: (A) a sealant film layer consisting essentially of an ethylene/octene interpolymer and a low density polyethylene; (B) an intermediate film layer consisting essentially of a high density polyethylene; (C) a structural film layer consistently essentially of an ethylene/octene interpolymer and a low density polyethylene; and (D) a barrier adhesive layer, wherein the recyclable, all-polyethylene laminate film structure has an oxygen transmission rate not greater than 100 O2/m2/day, measured according to ASTM Method D3985. Embodiment 10. The recyclable, all-polyethylene laminate film structure suitable for use in a flexible packaging, wherein the low density polyethylene has a density not greater than 0.94 g/cm3and a peak melting point not greater than 126° C. Embodiment 11. The recyclable, all-polyethylene laminate film structure suitable for use in a flexible packaging, wherein the high density polyethylene has a density not less than 0.94 g/cm3and a peak melting point in the range of from 120 to 135° C. Embodiment 12. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the sealant film layer (A), intermediate film layer (B), and structural film layer (C) form a coextruded film wherein the intermediate film layer (B) is disposed between the sealant film layer (A) and the structural film layer (C), and wherein the barrier adhesive layer (D) is disposed on a surface of the structural film layer (C) opposite the intermediate film layer (B). Embodiment 13. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the barrier adhesive layer (D) is in contact with another film layer (E) opposite the structural film layer (A). Embodiment 14. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, the structure comprising more than one intermediate film layer (B). Embodiment 15. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the barrier adhesive layer (D) comprises an adhesive comprising: an isocyanate component comprising a single species of polyisocyanate; and an isocyanate-reactive component comprising a hydroxyl-terminated polyester incorporated as substantially-miscible solids in a carrier solvent, the polyester formed from a single species of a linear aliphatic diol having terminal hydroxyl groups and from 2 to 10 carbon atoms, and a linear dicarboxylic acid, the polyester having a number average molecular weight from 300 to 5,000 and being solid at 25° C., and having a melting point of 80° C. or below. Embodiment 16. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the hydroxyl-terminated polyester is formed from a C3 to C6 diol and a dicarboxylic acid selected from adipic acid, azelaic acid, sebacic acid, and combinations thereof. Embodiment 17. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the polyisocyanate is selected from polymeric hexamethylene diisocyanate (HDI trimer isocyanurate), methylene diphenyl diisocyanate, dicyclohexylmethane 4,4′-diisocyanate, and toluene diisocyanate. Embodiment 18. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the carrier solvent is selected from ethyl acetate, methyl ethyl ketone, dioxolane, acetone, and combinations thereof. Embodiment 19. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the isocyanate-reactive component further comprises an acrylate viscosity modifier. Embodiment 20. The recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment, wherein the ratio of the isocyanate component to the isocyanate-reactive component in the barrier adhesive layer is from 1:1 to 2:1. Embodiment 21. An article comprising the recyclable, all-polyethylene laminate film structure according to any preceding or succeeding Embodiment. Embodiment 22. The article of Embodiment 21, wherein the article is a flexible package. Embodiment 23. The article of Embodiment 21, wherein the article is a stand-up pouch. | 22,490 |
11858243 | DETAILED DESCRIPTION Unless specified otherwise herein, percentages are weight percentages (wt %) and temperatures are in ° C. The term “composition,” as used herein, includes material(s) which comprise the composition, as well as reaction products and decomposition products formed from the materials of the composition. The term “comprising,” and derivatives thereof, is not intended to exclude the presence of any additional component, step or procedure, whether or not the same is disclosed herein. In order to avoid any doubt, all compositions claimed herein through use of the term “comprising” may include any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless stated to the contrary. In contrast, the term, “consisting essentially of” excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability. The term “consisting of” excludes any component, step or procedure not specifically delineated or listed. The term “polymer,” as used herein, refers to a polymeric compound prepared by polymerizing monomers, whether of the same or a different type. The generic term polymer thus embraces the term homopolymer (employed to refer to polymers prepared from only one type of monomer, with the understanding that trace amounts of impurities can be incorporated into the polymer structure), and the term interpolymer as defined hereinafter. Trace amounts of impurities may be incorporated into and/or within the polymer. The term “interpolymer,” as used herein, refers to a polymer prepared by the polymerization of at least two different types of monomers. The generic term interpolymer thus includes copolymers (employed to refer to polymers prepared from two different types of monomers), and polymers prepared from more than two different types of monomers. The term “polymer”, as used herein, refers to a polymeric compound prepared by polymerizing monomers, whether of the same or a different type. The generic term polymer thus embraces the term “homopolymer”, usually employed to refer to polymers prepared from only one type of monomer as well as “copolymer” which refers to polymers prepared from two or more different monomers. “Polyethylene” or “ethylene-based polymer” shall mean polymers comprising greater than 50% by weight of units which have been derived from ethylene monomer. This includes polyethylene homopolymers or copolymers (meaning units derived from two or more comonomers). Common forms of polyethylene known in the art include Low Density Polyethylene (LDPE); Linear Low Density Polyethylene (LLDPE); Ultra Low Density Polyethylene (ULDPE); Very Low Density Polyethylene (VLDPE); single-site catalyzed Linear Low Density Polyethylene, including both linear and substantially linear low density resins (m-LLDPE); Medium Density Polyethylene (MDPE); and High Density Polyethylene (HDPE). These polyethylene materials are generally known in the art; however the following descriptions may be helpful in understanding the differences between some of these different polyethylene resins. The term “LDPE” may also be referred to as “high pressure ethylene polymer” or “highly branched polyethylene” and is defined to mean that the polymer is partly or entirely homopolymerized or copolymerized in autoclave or tubular reactors at pressures above 14,500 psi (100 MPa) with the use of free-radical initiators, such as peroxides (see for example U.S. Pat. No. 4,599,392, which is hereby incorporated by reference). LDPE resins typically have a density in the range of 0.916 to 0.935 g/cm3. The term “LLDPE”, includes both resin made using the traditional Ziegler-Natta catalyst systems as well as single-site catalysts, including, but not limited to, bis-metallocene catalysts (sometimes referred to as “m-LLDPE”) and constrained geometry catalysts, and includes linear, substantially linear or heterogeneous polyethylene copolymers or homopolymers. LLDPEs contain less long chain branching than LDPEs and includes the substantially linear ethylene polymers which are further defined in U.S. Pat. Nos. 5,272,236, 5,278,272, 5,582,923 and 5,733,155; the homogeneously branched linear ethylene polymer compositions such as those in U.S. Pat. No. 3,645,992; the heterogeneously branched ethylene polymers such as those prepared according to the process disclosed in U.S. Pat. No. 4,076,698; and/or blends thereof (such as those disclosed in U.S. Pat. No. 3,914,342; or U.S. Pat. No. 5,854,045). The LLDPEs can be made via gas-phase, solution-phase or slurry polymerization or any combination thereof, using any type of reactor or reactor configuration known in the art, with gas and slurry phase reactors being most preferred. The term “MDPE” refers to polyethylenes having densities from 0.926 to 0.935 g/cm3. “MDPE” is typically made using chromium or Ziegler-Natta catalysts or using single-site catalysts including, but not limited to, bis-metallocene catalysts and constrained geometry catalysts, and typically have a molecular weight distribution (“MWD”) greater than 2.5. The term “HDPE” refers to polyethylenes having densities greater than about 0.935 g/cm3, which are generally prepared with Ziegler-Natta catalysts, chrome catalysts or single-site catalysts including, but not limited to, bis-metallocene catalysts and constrained geometry catalysts. The term “ULDPE” refers to polyethylenes having densities of 0.880 to 0.912 g/cm3, which are generally prepared with Ziegler-Natta catalysts, chrome catalysts, or single-site catalysts including, but not limited to, bis-metallocene catalysts and constrained geometry catalysts. “Multimodal” means resin compositions which can be characterized by having at least two distinct peaks in a GPC chromatogram showing the molecular weight distribution. Multimodal includes resins having two peaks as well as resins having more than two peaks. Multimodal resins generally have a MWD (as defined herein) of greater than 6.0. Related thereto, multimodal resins also generally have I10/I2values greater than 10. In contrast, the term “unimodal” refers to resin compositions which can be characterized by having one peak in a GPC chromatogram showing the molecular weight distribution. Unimodal resins generally have a MWD of 6.0 or less and I10/I2values of 12 or less. Certain polymers are characterized as being prepared in the presence of a “single-site catalyst” or as being “single-site catalyzed.” Three major families of high efficiency single-site catalysts (SSC) have been commercially used for the preparation of polyethylene copolymers. These are bis-cyclopentadienyl single-site metallocene catalyst (also known as a Kaminsky catalyst), a half sandwich, constrained geometry mono-cyclopentadienyl single-site catalyst (known as a Constrained Geometry Catalyst, CGC, under the trademark of INSITE™ technology by The Dow Chemical Company), and post-metallocene catalysts. It should be understood that polymers characterized as being prepared in the presence of a single-site catalyst or as single-site catalyzed were prepared in the presence of one or more of such catalysts. Unless otherwise indicated herein, the following analytical methods are used in the describing aspects of the present invention: “Density” is determined in accordance with ASTM D792. “Melt index”: Melt indices I2(or I2) and I10(or I10) are measured in accordance with ASTM D-1238 at 190° C. and at 2.16 kg and 10 kg load, respectively. Their values are reported in g/10 min. “Melt flow rate” is used for polypropylene based resins and determined according to ASTM D1238 (230° C. at 2.16 kg). “Peak melting point” is determined by a Differential Scanning calorimeter (DSC) where the film is conditioned at 230° C. for 3 minutes prior to cooling at a rate of 10° C. per minute to a temperature of −40° C. After the film is kept at −40° C. for 3 minutes, the film is heated to 200° C. at a rate of 10° C. per minute. “VICAT softening point” is measured according to ASTM D 1525 “Percent crystallinity by weight” is calculated according to Equation 1: Crystallinity (wt. %)=ΔH/ΔHo×100%, (Eq. 1) where the heat of fusion (ΔH) is divided by the heat of fusion for the perfect polymer crystal (ΔH0) and then multiplied by 100%. For ethylene crystallinity, the heat of fusion for a perfect crystal is taken to be 290 J/g. For example, an ethylene-octene copolymer which upon melting of its polyethylene crystallinity is measured to have a heat of fusion of 29 J/g; the corresponding crystallinity is 10 wt %. For propylene crystallinity, the heat of fusion for a perfect crystal is taken to be 165 J/g. For example, a propylene-ethylene copolymer which upon melting of its propylene crystallinity is measured to have a heat of fusion of 20 J/g; the corresponding crystallinity is 12.1 wt %. “Heat of fusion” is obtained using a DSC thermogram obtained by model Q1000 DSC from TA Instruments, Inc. (New Castle, Del.). Polymer samples are pressed into a thin film at an initial temperature of 190° C. (designated as the “initial temperature”). About 5 to 8 mg of sample is weighed out and placed in the DSC pan. The lid is crimped on the pan to ensure a closed atmosphere. The DSC pan is placed in the DSC cell and then heated at a rate of about 100° C./minute to a temperature (To) of about 60° C. above the melt temperature of the sample. The sample is kept at this temperature for about 3 minutes. Then the sample is cooled at a rate of 10° C./minute to −40° C., and kept isothermally at that temperature for 3 minutes. The sample is then heated at a rate of 10° C./minute until complete melting. Enthalpy curves resulting from this experiment are analyzed for peak melt temperature, onset and peak crystallization temperatures, heat of fusion and heat of crystallization, and any other DSC analyses of interest. The term molecular weight distribution or “MWD” is defined as the ratio of weight average molecular weight to number average molecular weight (Mw/Mn). Mwand Mnare determined according to methods known in the art using conventional gel permeation chromatography (GPC). 2% secant modulus is measured according to ASTM D882. Elmendorf tear strength is measured according to ASTM D1922. Additional properties and test methods are described further herein. In one aspect, the present invention provides a uniaxially oriented film that comprises (a) a first layer comprising (i) a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst, wherein the first composition has a density of 0.935 g/cm3to 0.965 g/cm3, a melt index (I2) of 0.5 to 6 g/10 minutes, and a MWD of 6.0 or less, and (ii) a Ziegler-Natta catalyzed ultra low density polyethylene having a density of 0.880 g/cm3to 0.912 g/cm3, a melt index (I2) of 0.5 to 6 g/10 minutes, and a MWD of 6.0 or less; (b) a second layer comprising at least one polyolefin; and (c) at least one inner layer between the first layer and the second layer comprising a high density polyethylene, wherein the film is oriented in the machine direction at a draw ratio of between 4:1 and 10:1, and wherein the film exhibits a machine direction 2% secant modulus of 85,000 psi or more when measured as per ASTM D882. In some embodiments, the film can be oriented in the machine direction at a draw ratio of 5:1 to 9:1. In some embodiments, the first composition further comprises an ethylene-based polymer prepared in the presence of a Ziegler-Natta catalyst. In another aspect, the present invention provides a uniaxially oriented film that comprises (a) a first layer comprising (i) a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst, wherein the first composition has a density of 0.935 g/cm3to 0.965 g/cm3, a melt index (I2) of 0.5 to 6 g/10 minutes, and a MWD of 6.0 or less, and (ii) a Ziegler-Natta catalyzed ultra low density polyethylene having a density of 0.880 g/cm3to 0.912 g/cm3, a melt index (I2) of 0.5 to 6 g/10 minutes, and a MWD of 6.0 or less; (b) a second layer comprising at least one polyolefin; and (c) at least one inner layer between the first layer and the second layer comprising a Ziegler-Natta catalyzed ultra low density polyethylene having a density of 0.880 g/cm3to 0.912 g/cm3and a melt index (I2) of 0.5 to 6 g/10 minutes, wherein the film is oriented in the machine direction at a draw ratio of between 4:1 and 10:1, and wherein the film exhibits a machine direction 2% secant modulus of 85,000 psi or more when measured as per ASTM D882. In some embodiments, the film can be oriented in the machine direction at a draw ratio of 5:1 to 9:1. In some embodiments, the first composition further comprises an ethylene-based polymer prepared in the presence of a Ziegler-Natta catalyst. The at least one inner layer comprises 100% by weight of the Ziegler-Natta catalyzed ultra low density polyethylene in some embodiments. In other embodiments, the at least one inner layer further comprises a linear low density polyethylene having a density of 0.912 g/cm3to 0.935 g/cm3and a melt index (I2) of 0.5 to 4 g/10 minutes in some embodiments. In some embodiments, the at least one inner layer further comprises a second composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst, wherein the second composition has a density of 0.935 g/cm3to 0.965 g/cm3and a melt index (I2) of 0.5 to 6 g/10 minutes. In some such embodiments, the at least one inner layer comprises greater than 50% by weight of the Ziegler-Natta catalyzed ultra low density polyethylene and less than 50% by weight of the second composition. In some embodiments, the second composition further comprises an ethylene-based polymer prepared in the presence of a Ziegler-Natta catalyst. In some embodiments, the first layer in the uniaxially oriented films comprises greater than 50% by weight of the first composition and less than 50% by weight of the Ziegler-Natta catalyzed ultra low density polyethylene. The ultra low density polyethylene in the first layer, in some embodiments, has a peak melting point of 100° C. or more. In some embodiments, the ultra low density polyethylene in the first layer has a VICAT softening point of 100° C. or less. The second layer, in various embodiments, can comprise at least one polyolefin. As set forth in more detail below, the at least one polyolefin in the second layer can comprise a variety of polyolefins or combinations of polyolefins in various embodiments. With regard to the at least one inner layer, in some embodiments, the high density polyethylene is a Ziegler-Natta catalyzed high density polyethylene. In other embodiments, the high density polyethylene in the at least one inner layer is prepared in the presence of a single-site catalyst. In some embodiments, the high density polyethylene in the at least one inner layer is unimodal. In some embodiments, the at least one inner layer further comprises a linear low density polyethylene having a density of 0.912 g/cm3to 0.935 g/cm3and a melt index (I2) of 0.5 to 6 g/10 minutes. In some aspects, the first and/or second layers of the uniaxially oriented films can be outer layers. In some embodiments, uniaxially oriented films of the present invention have a thickness of 100 microns or less. In some embodiments, uniaxially oriented films of the present invention have a thickness of 10 microns or more. Uniaxially oriented films of the present invention can comprise more than 3 layers in some embodiments. For example, in some embodiments, uniaxially oriented films of the present invention can comprise up to nine layers. Uniaxially oriented films of the present invention, in some embodiments, can exhibit one or more physical properties that may be desirable. In some embodiments, uniaxially oriented films of the present invention exhibit a normalized Elmendorf tear strength in the machine direction of 150 to 450 grams/mil when measured as per ASTM D1922. Films of the present invention, in some embodiments, exhibit a machine direction 2% secant modulus of 150,000 psi or more when measured as per ASTM D882. In some embodiments, the 2% secant modulus can be 200,000 psi or more. Uniaxially oriented films of the present invention, in some embodiments, can be substantially flat. Embodiments of the present invention also provide articles formed from any of the uniaxially oriented films described herein. Examples of such articles can include flexible packages, pouches, stand-up pouches, and pre-made packages or pouches. Some embodiments of the present invention comprise laminates formed from any uniaxially oriented films described herein. In some embodiments, two or more uniaxially oriented films as described herein are sealed to each other to form the laminate. In other embodiments, a laminate can be formed from a single blown film. In such embodiments, the inner surface of the blown film can collapse and seal on itself to form a laminate having a thickness approximately twice the thickness of the blown film prior to forming the laminate. In some embodiments, machine direction oriented laminates of the present invention can have a thickness of 20 to 100 microns, of 40 to 100 microns, or of 20 to 50 microns. First Layer In describing a first layer of a uniaxially oriented film of the present invention, it should be understood that the term “first” is used to identify the layer within the context of the other layers in the film. Nonetheless, in some embodiments, the first layer is an outer layer of the film. In some embodiments, a first layer of the uniaxially oriented film comprises (i) a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst, wherein the first composition has a density of greater than 0.935 g/cm3to 0.965 g/cm3, a melt index (I2) of 0.5 to 6 g/10 minutes, and a MWD of 6.0 or less, and (ii) a Ziegler-Natta catalyzed ULDPE having a density of 0.880 g/cm3to 0.912 g/cm3, a melt index (I2) of 0.5 to 6 g/10 minutes, and a MWD of 6.0 or less. In some embodiments, the ethylene-based polymer comprises a single-site catalyzed high density polyethylene. In some embodiments, in addition to the single-site catalyzed ethylene-based polymer, the composition further comprises an ethylene-based polymer prepared in the presence of a Ziegler-Natta catalyst. The first composition has a density of than 0.935 g/cm3to 0.965 g/cm3. All individual values and subranges from 0.935 g/cm3to 0.965 g/cm3are included herein and disclosed herein; for example, the density of the first composition can be from a lower limit of 0.935, 0.940, 0.945 or 0.950 g/cm3to an upper limit of 0.945, 0.950, 0.955, 0.960, or 0.965 g/cm3. In some embodiments, the first composition has a density from 0.935 to 0.965 g/cm3, preferably 0.945 to 0.962 g/cc, more preferably 0.950 to 0.960 g/cc. In some embodiments, the first composition has a melt index (I2) of up to 4.0 g/10 minutes. All individual values and subranges up to 6.0 g/10 minutes are included herein and disclosed herein. For example, the first composition can have a melt index to an upper limit of 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, or 6.0 g/10 minutes. In a particular aspect of the invention, the first composition has an I2with a lower limit of 0.5 g/10 minutes. All individual values and subranges from 0.5 g/10 to 6.0 g/10 minutes are included herein and disclosed herein. In some embodiments, the first composition is unimodal. In some embodiments, the first composition has a MWD of 6.0 or less, preferably 5.5 or less. Examples of first compositions comprising an ethylene-based polymer prepared in the presence of a single-site catalyst that can be used in the first layer include those commercially available from The Dow Chemical Company under the name ELITE™ including, for example, ELITE™ 5960 and ELITE™ 5940. As noted above, in embodiments where the first layer comprises a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst as described above, the first layer can further comprise a Ziegler-Natta catalyzed ULDPE. The Ziegler-Natta catalyzed ULDPE has a density of 0.880 g/cm3to 0.912 g/cm3. All individual values and subranges from 0.880 g/cm3to 0.912 g/cm3are included herein and disclosed herein; for example, the density of the Ziegler-Natta catalyzed ULDPE can be from a lower limit of 0.880, 0.885, 0.890 or 0.895 g/cm3to an upper limit of 0.900, 0.905, 0.910, or 0.912 g/cm3. In some embodiments, the Ziegler-Natta catalyzed ULDPE has a density from 0.890 to 0.912 g/cm3, preferably 0.890 to 0.908 g/cc, more preferably 0.9 to 0.905 g/cc. In some embodiments, the Ziegler-Natta catalyzed ULDPE has a melt index (I2) of up to 6.0 g/10 minutes. All individual values and subranges up to 6.0 g/10 minutes are included herein and disclosed herein. For example, the Ziegler-Natta catalyzed ULDPE can have a melt index to an upper limit of 1.0, 1.5, 2.0, 2.5, 3.0 3.5, 4.0, 4.5, 5.0, 5.5, or 6.0 g/10 minutes. In a particular aspect of the invention, the Ziegler-Natta catalyzed ULDPE has an I2with a lower limit of 0.5 g/10 minutes. All individual values and subranges from 0.5 g/10 to 6.0 g/10 minutes are included herein and disclosed herein. In some embodiments, the Ziegler-Natta catalyzed ULDPE is unimodal. In some embodiments, the Ziegler-Natta catalyzed ULDPE has a MWD of 6.0 or less, preferably 5.5 or less. Examples of Ziegler-Natta catalyzed ULDPEs that can be used in the first layer include those commercially available from The Dow Chemical Company under the names ATTANE™ and FLEXOMER™ (a VLDPE) including, for example, ATTANE™ 4203, ATTANE™ 4201, ATTANE™ NG 4701, ATTANE™ SL 4101, FLEXOMER™ ETS-9064, FLEXOMER™ ETS-9066, and FLEXOMER™ DFDA 1137. In some embodiments wherein the first layer comprises a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst as described above and a Ziegler-Natta catalyzed ULDPE, the first layer can comprise greater than 50% by weight of the first composition and less than 50% by weight of the Ziegler-Natta catalyzed ULDPE, preferably greater than 60% by weight of the first composition and less than 40% by weight of the Ziegler-Natta catalyzed ULDPE, or greater than 65% by weight of the first composition and less than 35% by weight of the Ziegler-Natta catalyzed ULDPE. In embodiments of the present invention incorporating a Ziegler-Natta catalyzed ULDPE in the first layer, the Ziegler-Natta catalyzed ULDPE preferably has a difference between its VICAT softening point and its peak melting point of at least 30° C., preferably at least 40° C. This provides a very broad orientation window for orientation which is believed to provide significant stress relaxation and annealing after orienting for improved toughness, tear strength, and/or optics. In some embodiments, the Ziegler-Natta catalyzed ULDPE preferably has a peak melting point of 110° C. or more and/or a VICAT softening point of 90° C. or less. Second Layer In describing a second layer of a uniaxially oriented film of the present invention, it should be understood that the term “second” is used to identify the layer within the context of the other layers in the film. In some embodiments, the second layer is an outer layer of the film. In other embodiments, the second layer is an interior layer, with at least one inner layer being between the first layer and the second layer. For example, in some embodiments, such as a blown film, the film can be blown with the second layer being an inner surface layer, but then allowed to collapse on itself such that an A/B/C structured blown film becomes an A/B/C/C/B/A structured film with A being the first layer, C being the second layer, and B being the inner layer. In some embodiments, a second layer of the uniaxially oriented film comprises a polyolefin. A variety of polyolefins and combinations of polyolefins can be incorporated into the second layer in various embodiments. In some embodiments, the second layer can have the same composition as the first layer. Thus, in some such embodiments, when the first layer comprises (i) a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst as described above, and (ii) a Ziegler-Natta catalyzed ULDPE having a density of 0.880 g/cm3to 0.912 g/cm3and a melt index (I2) of 0.5 to 6 g/10 minutes, the second layer comprises two polyolefins: (i) a second composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst, wherein the second composition has a density of 0.935 g/cm3to 0.965 g/cm3and a melt index (I2) of 0.5 to 6 g/10 minutes, and (ii) a Ziegler-Natta catalyzed ULDPE having a density of 0.880 g/cm3to 0.912 g/cm3and a melt index (I2) of 0.5 to 6 g/10 minutes. The second composition can include any of the first compositions that are described above in connection with the first layer. Likewise, the Ziegler-Natta catalyzed ULDPE can include any of the Ziegler-Natta catalyzed ULDPEs that are described above in connection with the first layer. The relative amounts of the second composition and the Ziegler-Natta catalyzed ULDPE can likewise be the same as the relative amounts described above in connection with the first layer. In some embodiments, the at least one polyolefin in the second layer comprises a Ziegler-Natta catalyzed ULDPE having a density of 0.880 g/cm3to 0.912 g/cm3and a melt index (I2) of 0.5 to 6.0 g/10 minutes, and a metallocene catalyzed LLDPE having a density of 0.912 g/cm3to 0.935 g/cm3and a melt index (I2) of 0.5 to 6.0 g/10 minutes. The Ziegler-Natta catalyzed ULDPE can include any of the Ziegler-Natta catalyzed ULDPEs that are described above in connection with the first layer. Likewise, the metallocene catalyzed LLDPE can include any of the metallocene catalyzed LLDPEs that are described above in connection with the first layer. In some embodiments, wherein the second layer comprises a Ziegler-Natta catalyzed ULDPE and a metallocene catalyzed LLDPE, the second layer can comprise greater than 45% by weight of the Ziegler-Natta catalyzed ULDPE and less than 55% by weight of the metallocene catalyzed LLDPE, preferably greater than 60% by weight of the Ziegler-Natta catalyzed ULDPE and less than 40% by weight of the metallocene catalyzed LLDPE, or greater than 65% by weight of the Ziegler-Natta catalyzed ULDPE and less than 35% by weight of the metallocene catalyzed LLDPE. The at least one polyolefin in the second layer, in some embodiments, comprises a Ziegler-Natta catalyzed ULDPE having a density of 0.880 g/cm3to 0.912 g/cm3and a melt index (I2) of 0.5 to 6.0 g/10 minutes, and a polyolefin plastomer. In some such embodiments, the polyolefin plastomer has a density of 0.865 to 0.908 g/cm3and a melt index (I2) of 0.5-6 g/10 minutes, and the polyolefin plastomer comprises a polyethylene plastomer, a polypropylene plastomer, or combinations thereof. The Ziegler-Natta catalyzed ULDPE can include any of the Ziegler-Natta catalyzed ULDPEs that are described above in connection with the first layer. Likewise, the polyolefin plastomer can include any of the polyolefin plastomers that are described above in connection with the first layer. In some embodiments, wherein the second layer comprises a Ziegler-Natta catalyzed ULDPE and a polyolefin plastomer, the second layer can comprise greater than 50% by weight of the polyolefin plastomer and less than 50% by weight of the Ziegler-Natta catalyzed ULDPE, preferably greater than 55% by weight of the polyolefin plastomer and less than 45% by weight of the Ziegler-Natta catalyzed ULDPE, or greater than 35% by weight of the polyolefin plastomer and less than 65% by weight of the Ziegler-Natta catalyzed ULDPE. The at least one polyolefin in the second layer, in some embodiments, comprises a metallocene catalyzed LLDPE having a density of 0.912 g/cm3to 0.935 g/cm3and a melt index (I2) of 0.5 to 6 g/10 minutes, and a polyolefin plastomer. In some such embodiments, the polyolefin plastomer has a density of 0.865 to 0.908 g/cm3and a melt index (I2) of 0.5-6 g/10 minutes, and the polyolefin plastomer comprises a polyethylene plastomer, a polypropylene plastomer, or combinations thereof. The metallocene catalyzed LLDPE can include any of the metallocene catalyzed LLDPEs that are described above in connection with the first layer. Likewise, the polyolefin plastomer can include any of the polyolefin plastomers that are described above in connection with the first layer. In some embodiments, wherein the second layer comprises a metallocene catalyzed LLDPE and a polyolefin plastomer, the second layer can comprise greater than 45% by weight of the metallocene catalyzed LLDPE and less than 55% by weight of the polyolefin plastomer, preferably greater than 40% by weight of the metallocene catalyzed LLDPE and less than 60% by weight of the polyolefin plastomer, or greater than 35% by weight of the metallocene catalyzed LLDPE and less than 65% by weight of the polyolefin plastomer. In some embodiments, the at least one polyolefin in the second layer comprises 100% by weight of a Ziegler-Natta catalyzed ULDPE having a density of 0.880 g/cm3to 0.912 g/cm3and a melt index (I2) of 0.5 to 6.0 g/10 minutes. The Ziegler-Natta catalyzed ULDPE can include any of the Ziegler-Natta catalyzed ULDPEs that are described above in connection with the first layer. The at least one polyolefin in the second layer, in some embodiments, comprises 100% by weight of a metallocene catalyzed LLDPE having a density of 0.912 g/cm3to 0.935 g/cm3and a melt index (I2) of 0.5 to 6.0 g/10 minutes. The metallocene catalyzed LLDPE can include any of the metallocene catalyzed LLDPEs that are described above in connection with the first layer. In some embodiments, the at least one polyolefin in the second layer comprises 100% by weight of a polyolefin plastomer having a density of 0865 g/cm3to 0.908 g/cm3and a melt index (I2) of 0.5 to 6 g/10 minutes. In some such embodiments, the polyolefin plastomer comprises a polyethylene plastomer, a polypropylene plastomer, or combinations thereof. The polyolefin plastomer can include any of the polyolefin plastomers that are described above in connection with the first layer. Inner Layer The uniaxially oriented films of the present invention each comprise at least one inner layer. The term “inner” is used to indicate that the inner layer is between the first layer and the second layer. The term “at least one inner layer” is used to indicate that uniaxially oriented films of the present invention can include a single inner layer or multiple inner layers. In some embodiments comprising two or more inner layers, each of the inner layers can have the same composition. In other embodiments comprising two or more inner layers, each of the inner layers can have different compositions, or only some of the inner layers can have the same composition. With regard to the at least one inner layer, in some embodiments, wherein the first layer comprises a (i) a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst as described above, and (ii) a Ziegler-Natta catalyzed ULDPE, and wherein the second layer comprises at least one polyolefin, the at least one inner layer can comprise a HDPE. In some embodiments, the HDPE can be a unimodal HDPE. In some embodiments, the HDPE can have a MWD of 6.0 or less. The HDPE can be a Ziegler-Natta catalyzed HDPE in some embodiments and a single-site catalyzed HDPE in other embodiments. In some embodiments, the at least one inner lay can comprise the first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst, wherein the first composition has a density of greater than 0.935 g/cm3to 0.965 g/cm3and a melt index (I2) of 0.5 to 6 g/10 minutes, as described above in connection with the first layer. For example, the single-site catalyzed HDPE can include any of those described above in connection with the first layer. When the HDPE comprises a unimodal, Ziegler-Natta catalyzed HDPE, the HDPE has a density of 0.935 g/cm3to 0.965 g/cm3. All individual values and subranges from 0.935 g/cm3to 0.965 g/cm3are included herein and disclosed herein; for example, the density of the Ziegler-Natta catalyzed HDPE can be from a lower limit of 0.935, 0.940, 0.945 or 0.950 g/cm3to an upper limit of 0.945, 0.950, 0.955, 0.960, or 0.965 g/cm3. In some embodiments, the Ziegler-Natta catalyzed HDPE has a density from 0.935 to 0.965 g/cm3, preferably 0.945 to 0.962 g/cc, more preferably 0.950 to 0.960 g/cc. In some embodiments, the Ziegler-Natta catalyzed HDPE has a melt index (I2) of up to 6.0 g/10 minutes. All individual values and subranges up to 6.0 g/10 minutes are included herein and disclosed herein. For example, the Ziegler-Natta catalyzed HDPE can have a melt index to an upper limit of 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, or 6.0 or g/10 minutes. In a particular aspect of the invention, the Ziegler-Natta catalyzed HDPE has an I2with a lower limit of 0.2 g/10 minutes. All individual values and subranges from 0.2 g/10 to 6.0 g/10 minutes are included herein and disclosed herein. In some embodiments, the Ziegler-Natta catalyzed HDPE is unimodal. In some embodiments, the Ziegler-Natta catalyzed HDPE has a MWD of 6.0 or less, preferably 5.5 or less. Examples of Ziegler-Natta catalyzed HDPEs that can be used in the inner layer include those commercially available from The Dow Chemical Company under the names DGDA 6200 and DGDA 6400. In some embodiments wherein the at least one inner layer comprises a HDPE (either single-site catalyzed or Ziegler-Natta catalyzed), the at least one inner layer can further comprise a LLDPE having a density of 0.912 g/cm3to 0.935 g/cm3and a melt index (I2) of 0.5 to 6.0 g/10 minutes. The LLDPE can be any of those disclosed in connection with the first layer above. Turning to other embodiments wherein the first layer comprises a (i) a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst as described above and (ii) a Ziegler-Natta catalyzed ULDPE, and wherein the second layer comprises at least one polyolefin, the at least one inner layer can comprise a Ziegler-Natta catalyzed ULDPE having a density of 0.880 g/cm3to 0.912 g/cm3and a melt index (I2) of 0.5 to 6.0 g/10 minutes. The Ziegler-Natta catalyzed ULDPE can be any of those disclosed above in connection with the first layer. In some embodiments, the ULDPE can be blended with a LLDPE or with a single-site catalyzed HDPE. Such single-site catalyzed HDPEs can include any of those disclosed above in connection with the first layer including any of the first compositions. The LLDPE can be a metallocene catalyzed LLDPE or a Ziegler-Natta catalyzed LLDPE. A metallocene catalyzed LLDPE can be any of those disclosed in connection with the first layer above. The Ziegler-Natta catalyzed LLDPE has a density of 0.912 g/cm3to 0.935 g/cm3. All individual values and subranges from 0.912 g/cm3to 0.935 g/cm3are included herein and disclosed herein; for example, the density of the Ziegler-Natta catalyzed LLDPE can be from a lower limit of 0.912, 0.915, 0.920, or 0.925 g/cm3to an upper limit of 0.920, 0.925, 0.930, or 0.935 g/cm3. In some embodiments, the Ziegler-Natta catalyzed LLDPE has a density from 0.915 to 0.935 g/cm3, preferably 0.916 to 0.926 g/cc, more preferably 0.917 to 0.924 g/cc. In some embodiments, the Ziegler-Natta catalyzed LLDPE has a melt index (I2) of up to 4.0 g/10 minutes. All individual values and subranges up to 4.0 g/10 minutes are included herein and disclosed herein. For example, the Ziegler-Natta catalyzed LLDPE can have a melt index to an upper limit of 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, or 6.0 g/10 minutes. In a particular aspect of the invention, the Ziegler-Natta catalyzed LLDPE has an I2with a lower limit of 0.2 g/10 minutes. All individual values and subranges from 0.2 g/10 to 6.0 g/10 minutes are included herein and disclosed herein. Examples of Ziegler-Natta catalyzed LLDPEs that can be used include those commercially available from The Dow Chemical Company under the name DOWLEX™ including, for example, DOWLEX™ 2045 and DOWLEX™ 2038.68. When the Ziegler-Natta catalyzed ULDPE is blended with a single-site catalyzed HDPE or a LLDPE, the at least one inner layer can comprise greater than 50% by weight of the Ziegler-Natta catalyzed ULDPE and less than 50% by weight of the single-site catalyzed HDPE or the LLDPE, preferably greater than 60% by weight of the Ziegler-Natta catalyzed ULDPE and less than 40% by weight of the single-site catalyzed HDPE or the LLDPE, or greater than 65% by weight of the Ziegler-Natta catalyzed ULDPE and less than 35% by weight of the LLDPE. It should be understood that any of the foregoing layers can further comprise one or more additives as known to those of skill in the art such as, for example, antioxidants, ultraviolet light stabilizers, thermal stabilizers, slip agents, antiblock, pigments or colorants, processing aids, crosslinking catalysts, flame retardants, fillers and foaming agents. Films A variety of multilayer films can be formed in accordance with the teachings of the present invention. Certain combinations of resins may provide films having certain desirable properties. The multilayer films can have particularly desirable properties when oriented only in the machine direction to provide uniaxially oriented films of the present invention. A multilayer film can be formed according to any method known in the art. The combinations of resins described herein may be particularly well-suited for formation of multilayer films using blown film processes. When a blown film process is used, the blown film can be formed conventionally (e.g., slit and opened prior to winding), or the blown film can be allowed to collapse so that the interior layer (the second layer as described herein) can laminate to itself to form a multilayer film that is twice as thick. In other words, a blown film process can be configured to form an A/B/C multilayer film, with A corresponding to a first layer, C corresponding to a second layer, and B corresponding to an inner layer between A and C (if the first and second layer are the same composition, the film might also be characterized as an A/B/A film). In a typical process, the multilayer film would have an A/B/C structure. However, if the film were allowed to collapse on itself, the multilayer film would have an A/B/C/C/B/A structure. In either scenario, the multilayer film can later be oriented in the machine direction to provide a uniaxially oriented film of the present invention. The collapsing method may be desirable in certain situations such as when thicker films are desired. The collapsing method, in some embodiments, can also be advantageous as it facilitates the manufacture of symmetric films oriented in the machine direction without curling. The collapsing method, in some embodiments, can also allow for faster cooling as some cooling of the thinner film occurs prior to collapsing into the thicker film. Another advantage of the collapsing method is that it can provide enhanced barrier properties as a barrier layer (e.g., an oxygen barrier layer or water vapor barrier layer) can be included in the blown film, and then duplicated when the blown film collapses (e.g., a single barrier layer in the blown film becomes two barrier layers upon collapse). The number of layers in uniaxially oriented films can depend on a number of factors including, for example, the desired properties of the film, the end use application for the film, the desired polymers to be used in each layer, the desired thickness of the film, whether the film is formed by collapsing a blown film, and others. Uniaxially oriented films of the present invention comprise at least three layers. Typical films made with or without collapsing can have up to 9 layers, though collapsing a multilayer blown film can result in more layers (e.g., a 9 layer blown film collapses to form 18 layers). Structures could be, for example, A/B/A (if the outer layers have the same composition), A/B/C, A/B/C/A, A/B/C/D, A/B/C/D/E, A/B/C/D/E/F, A/B/C/D/E/F/G, A/B/C/D/D/C/B/A, A/B/C/D/E/F/G/H, A/B/C/D/E/F/G/H/I, and others. The structures described herein can be used to make films with thicknesses of up to 200 or 250 microns in a non-collapsed configuration of 3, 5, 7, or 9 layers. A primary limiting factor as to the thickness of the film is the ability to cool such thick films and to make stable bubbles while maintaining a reasonable gauge variation (e.g., +/−10%). By collapsing the film and allowing an interior layer to laminate to itself, much thicker films can be made (e.g., a 250 micron film becomes 500 microns). Thus, some embodiments relate to blown films that are collapsed to form a thicker film. If such structures are allowed to collapse such that the interior layer collapses on itself, the structures could be, for example, A/B/C/C/B/A, A/B/C/D/D/C/B/A, A/B/C/D/E/E/D/C/B/A, A/B/C/D/E/F/G/G/F/E/D/C/B/A, and others. In embodiments where collapsing is desired, the composition of the second layer (as described above, not the second layer in the film structure itself), can be selected so as to facilitate its lamination to itself during the blown film process. Forming the blown film using a collapsing method can provide several advantages. As indicated above, a blown film can be made that doubles in thickness upon collapsing (e.g., a 50 micron blown film collapses to make a 100 micron film; a 100 micron blown film collapses to make a 200 micron film). Thus, the collapsing method allows one to initially make (i.e., prior to collapsing) relatively thinner and symmetrically blown films with better cooling efficiency, lower film crystallinity and better optics compared to a non-collapsed film having a thickness comparable to the film after collapsing. The collapsing method also advantageously provides, in some embodiments, substantially flat films after collapsing. The ability to make very thick films (e.g., up to 400 or 500 microns in some embodiments) can provides advantage when the film is then oriented in the machine direction. For example, a 400 or 500 micron film can be oriented in the machine direction at a stretch ratio of 4:1 or 5:1 to provide a 100 micron film for heavy duty bag applications. Or, such a film could oriented in the machine direction at a stretch ratio of up to 10:1 to provide a very stiff fill of 40-50 microns which might be used in tape or label applications. While forming thicker films by allowing a blown film to collapse on itself, other embodiments relate to films formed by later laminating two or more existing films to one another. For example, two or more films having the same structure can be prepared using a cast film process and then laminated to simulate the symmetric collapsed structures described above. The two films can each have a contact layer with a relatively low melting point such that the films can pass over a hot roll that heats the films and thermally laminates them together. The two films also could be laminated together with an adhesive. When the two films having the same structure are laminated together, the laminated film can simulate what occurs when a blown film is collapsed. Once formed, multilayer films are then oriented in the machine direction only so as to provide uniaxially oriented films of the present invention. The film web can be oriented in the machine direction only using techniques known to those of skill in the art, such as a tenter frame process. The film can be oriented at a draw ratio of 4:1 to 10:1 in embodiments of the present invention. In some embodiments, the film can be oriented at a draw ratio of 5:1 to 9:1. The draw ratio will impact the thickness of the uniaxially oriented film, in addition to the original thickness and whether the film is collapsed. For example, a multilayer film having an initial thickness of 200 microns, can be collapsed to a thickness of 400 microns, and then oriented in the machine direction to thicknesses of 40 microns (with a draw ratio of 10:1), of 50 microns (with a draw ratio of 8:1), of 100 microns (with a draw ratio of 4:1), or others. As another example, a multilayer film having an initial thickness of 125 microns, can be collapsed to a thickness of 250 microns, and then oriented in the machine direction to thicknesses of 25 microns (with a draw ratio of 10:1), of 50 microns (with a draw ratio of 5:1), or others. As another example, a multilayer film having an initial thickness of 100 microns, can be collapsed to a thickness of 200 microns, and then oriented in the machine direction to thicknesses of 20 microns (with a draw ratio of 10:1), of 40 microns (with a draw ratio of 5:1), or others. Thus, uniaxially oriented films of the present invention can permit a significant amount of orientation in the machine direct while still maintaining a significant range of potential film thicknesses. This amount of orientation combined with the composition of the different layers in the film as described herein can provide uniaxially oriented films having one or more desirable properties. In some embodiments, uniaxially oriented films of the present invention can exhibit a machine direction 2% secant modulus of 75,000 psi or more when measured as per ASTM D882. Uniaxially oriented films, in some embodiments of the present invention, can exhibit a machine direction 2% secant modulus of 100,000 psi or more when measured as per ASTM D882. Uniaxially oriented films of the present invention can exhibit a machine direction 2% secant modulus of 150,000 psi or more when measured as per ASTM D882 in some embodiments. Uniaxially oriented films, in some embodiments, of the present invention can exhibit a machine direction 2% secant modulus of 200,000 psi or more when measured as per ASTM D882. Uniaxially oriented films of the present invention can also exhibit desirable tear strength values. In some embodiments, uniaxially oriented films of the present invention exhibit a normalized Elmendorf tear strength in the machine direction of 150 to 450 grams/mil when measured as per ASTM D1922. In some embodiments, films of the present invention can exhibit a limited drop in tear strength in the machine direction even after orientation only in the machine direction at draw ratios of greater than 5:1, greater than 6:1, and even up to 9:1. Uniaxially oriented films of the present invention, in some embodiments, also exhibit high 2% secant modulus in the machine direction (e.g., >150,000 psi at a 6:1 draw ratio; >200,000 psi at a 8:1 draw ratio, and >250,000 psi at a 9:1 draw ratio) while maintaining relatively high normalized Elmendorf tear strength values (e.g., >200 g/mil). In some embodiments, uniaxially oriented films of the present invention are substantially flat. In some embodiments, uniaxially oriented films of the present invention have a gauge variation that is within 5% of the average gauge of the film. Various embodiments of the present invention contemplate different combinations of resins in different layers of the uniaxially oriented films to provide certain properties. For example, in embodiments where high stiffness but low tear resistance is desired, the film might incorporate relatively high levels of HDPE. For a non-collapsed film, a uniaxially oriented film having an A/B/A structure may comprise A layers (the first and second layer) having 70% by weight of the layer of a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst having a density of 0.935 to 0.965 g/cm3and 30% by weight of the layer of a Ziegler-Natta catalyzed ULDPE, and a B layer (an inner layer) comprising 100% of a second composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst (e.g., a single-site catalyzed HDPE). The first composition, the second composition, and the Ziegler-Natta catalyzed ULDPE can be any of those disclosed above in connection with the descriptions of the corresponding layers. In this structure, the high density compositions are believed to provide high stiffness with low tear strength, while the inclusion of ULDPE is believed to provide surface tackiness to help the film stick to the rolls during orientation and to prevent neck-in in the cross direction during high machine direction orientation. For a collapsed film where high stiffness but low tear resistance is desired, a uniaxially oriented film having an A/B/C/C/B/A structure may comprise the same A layer (the first layer), the same B layer (an inner layer between the first layer and second layer), and a C layer (a second layer) comprising 100% by weight of a Ziegler-Natta catalyzed ULDPE. The Ziegler-Natta catalyzed ULDPE can be any of those disclosed above in connection with the descriptions of the corresponding layers. In this structure, the ULDPE in the C layer can be a relatively thin layer to provide adhesion during collapsing of the film without significantly increasing tear resistance. As another example, some embodiments relate to uniaxially oriented films that combine high stiffness with high tear resistance. For a non-collapsed film, a uniaxially oriented film having an A/B/A structure may comprise A layers (the first and second layer) having 70% by weight of the layer of a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst having a density of 0.935 to 0.965 g/cm3and 30% by weight of the layer of a Ziegler-Natta catalyzed ULDPE, and a B layer (an inner layer) comprising either 100% of a Ziegler-Natta catalyzed ULDPE or blends of such a ULDPE with a LLDPE. The first composition, the Ziegler-Natta catalyzed ULDPEs, and any LLDPE can be any of those disclosed above in connection with the descriptions of the corresponding layers. In this structure, the high density first composition in the A layers (the first and second layers) is believed to provide high stiffness with low tear strength, while the inclusion of ULDPE in the A layers (the first and second layers) is believed to provide surface tackiness to help the film stick to the rolls during orientation and to prevent neck-in in the cross direction during high machine direction orientation. The ULDPE or combination of ULDPE and LLDPE in the B layer (the inner layer) is believed to provide high tear resistance. For a collapsed film having a combination of high stiffness and high tear resistance, a uniaxially oriented film having an A/B/C/C/B/A structure may comprise the same A layer (the first layer). The B layer (an inner layer between the first layer and second layer) can comprise 70% by weight of the layer of a Ziegler-Natta catalyzed ULDPE, and a C layer (a second layer) comprising 100% by weight of a Ziegler-Natta catalyzed ULDPE. The Ziegler-Natta catalyzed ULDPEs can be any of those disclosed above in connection with the descriptions of the corresponding layers. In this structure, the HDPE/ULDPE combination in the B layer is believed to provide high tear resistance with toughness, and the ULDPE in the C layer also provides high tear resistance and toughness while also providing adhesion during collapsing of the film. As another example, some embodiments relate to uniaxially oriented films that combine high stiffness with high tear resistance. For a non-collapsed film, a uniaxially oriented film having an A/B/A structure may comprise A layers (the first and second layer) having 70% by weight of the layer of a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst having a density of 0.935 to 0.965 g/cm3and 30% by weight of the layer of a Ziegler-Natta catalyzed ULDPE, and a B layer (an inner layer) comprising either 100% of a Ziegler-Natta catalyzed ULDPE or blends of such a ULDPE with a LLDPE. The metallocene catalyzed HDPE, the Ziegler-Natta catalyzed ULDPEs, and any LLDPE can be any of those disclosed above in connection with the descriptions of the corresponding layers. In this structure, the high density composition in the A layers (the first and second layers) is believed to provide high stiffness with low tear strength, while the inclusion of ULDPE in the A layers (the first and second layers) is believed to provide surface tackiness to help the film stick to the rolls during orientation and to prevent neck-in in the cross direction during high machine direction orientation. The ULDPE or combination of ULDPE and LLDPE in the B layer (the inner layer) is believed to provide high tear resistance. For a collapsed film having a combination of high stiffness and high tear resistance, a uniaxially oriented film having an A/B/C/C/B/A structure may comprise the same A layer (the first layer). The B layer (an inner layer between the first layer and second layer) can comprise 70% by weight of the layer of a Ziegler-Natta catalyzed ULDPE and 30% by weight of a single-site catalyzed HDPE, and a C layer (a second layer) comprising 100% by weight of a Ziegler-Natta catalyzed ULDPE. The Ziegler-Natta catalyzed ULDPE can be any of those disclosed above in connection with the descriptions of the corresponding layers. In this structure, the HDPE/ULDPE combination in the B layer is believed to provide high tear resistance with toughness, and the ULDPE in the C layer also provides high tear resistance and toughness while also providing adhesion during collapsing of the film. As another example, some embodiments relate to uniaxially oriented films that provide good stiffness, high tear resistance, and high sealability. For a non-collapsed film, a uniaxially oriented film having an A/B/C structure may comprise an A layer (the first layer) having 70% by weight of the layer of a first composition comprising an ethylene-based polymer prepared in the presence of a single-site catalyst having a density of 0.935 to 0.965 g/cm3and 30% by weight of the layer of a Ziegler-Natta catalyzed ULDPE, a B layer (an inner layer) comprising either 100% of a Ziegler-Natta catalyzed ULDPE or blends of such a ULDPE with a LLDPE, and a C layer (the second layer) having 60% by weight of the layer of a polyolefin plastomer and 40% by weight of the layer of a metallocene catalyzed LLDPE. The first composition, the Ziegler-Natta catalyzed ULDPEs, the LLDPEs, and the polyolefin plastomer can be any of those disclosed above in connection with the descriptions of the corresponding layers. In this structure, the high density composition in the A layer (the first and second layers) is believed to provide high stiffness with low tear strength, while the inclusion of ULDPE in the A layer (the first and second layers) is believed to provide surface tackiness to help the film stick to the rolls during orientation and to prevent neck-in in the cross direction during high machine direction orientation. The ULDPE or combination of ULDPE and LLDPE in the B layer (the inner layer) is believed to provide high tear resistance. The combination of polyolefin plastomer and metallocene catalyzed LLDPE in the C layer is believed to provide high sealability. Articles Embodiments of the present invention also provide articles formed from any of the uniaxially oriented films described herein. Examples of such articles can include flexible packages, pouches, stand-up pouches, and pre-made packages or pouches. Such articles can be formed using techniques known to those of skill in the art in view of the teachings herein. For example, thin gauge (e.g., 25-35 micron), single films having very good optics, stiffness, and sealability, according to some embodiments of the present invention, can be useful in pouches made with form/fill/seal processing equipment. Such pouches can useful for powder and grain pouches holding ˜250 grams to 1 kilogram. The orientation of the films of the present invention in the machine direction is believed to provide a combination of stiffness, toughness, and optics that is advantageous over conventional blown films. Uniaxially oriented films having high stiffness and clarity, according to some embodiments of the present invention, can be laminated to one another to provide a laminate formed entirely from polyethylene. As another example, a uniaxially oriented film having high stiffness and clarity, according to some embodiments of the present invention, can be laminated to a stiff, HDPE-rich blown film, and the laminate can be used to form a stand-up pouch formed entirely from polyethylene. As another example, uniaxially oriented films having high stiffness, high optics, and good tear strength, in some embodiments can be used as a film for candy wrap applications. Some embodiments of the invention will now be described in detail in the following Examples. EXAMPLES Several blown film structures are developed for off-line orientation in the machine direction. Example 1 Table 1 shows the film structure for Example 1. Example 1 has an A/B/A film structure with a stiff core layer provided by an enhanced polyethylene having a high density (“EPE-HD”), and softer and tackier skin layers obtained by blending a Ziegler-Natta catalyzed ULDPE (“Z-N ULDPE”) with the HDPE. TABLE 1(Example 1)% of FilmLayerCompositionLayer DensityThicknessA (First Layer)70% EPE-HD;0.94425%30% Z-N ULDPEB (Inner Layer)EPE-HD0.96150%A (Second Layer)70% EPE-HD;0.94425%30% Z-N ULDPE The EPE-HD is ELITE™ 5960G, which is an enhanced polyethylene resin having a density of 0.9580-0.9650 g/cm3and a melt index (I2) of 0.7-1.0 g/10 minutes, and is commercially available from The Dow Chemical Company. The Z-N ULDPE is ATTANE™ 4203 having a density of 09030-0.9070 g/cm3and a melt index (I2) of 0.7-0.9 g/10 minutes, which is commercially available from The Dow Chemical Company. The coextruded A/B/A film structure of Example 1 is produced at 115 microns on a 3-layer blown film line run by using the layers set forth above. One of the A layers is the outside layer of the bubble while the other A layer is the inner layer of the bubble. The B layer is encapsulated between the two A layers. The blow up ratio used is 2.5:1. The standard frost line height is 30 centimeters. The layer distribution used is 25/50/25. The film of Example 1 has an overall density of 0.953 g/cm3, and an initial thickness of ˜114 microns. Films according to Example 1 are stretched at 235° F. and at draw ratios of 4.8:1 and 6.2:1 to obtain 27.7 and 21.1 micron thick films as shown in Table 2: TABLE 2(Example 1)Thickness4.8:1 Draw6.2:1 DrawLayerComposition(μ)Ratio (μ)Ratio (μ)A (First70% EPE-HD;28.386.925.27Layer)30% Z-N ULDPEB (InnerEPE-HD56.7713.8410.54Layer)A (Second70% EPE-HD;28.386.925.27Layer)30% Z-N ULDPETotal Thickness113.5427.6921.08 Both films are substantially flat and are quite stiff with the 21 micron film having lower haze and higher gloss. Measurements are taken to evaluate the Example 1 films orientation performance. The 21 micron Example 1 film had an initial roll width of 1400 mm, a roll width after orientation in the machine direction of 1180 mm, and a final roll width after edge trimming of 1040 mm. These values represent a width retraction after orientation in the machine direction of 15.71%, and a total width reduction of 25.71% after additional trimming of slightly thicker film edges after orientation. Example 2 Table 3 shows the film structure for Example 2. Example 2 also has an A/B/A film structure and includes the same EPE-HD and Z-N ULDPE as Example 1. In Example 2, the EPE-HD, which provided the stiff core in Example 1, is replaced with the Z-N ULDPE. TABLE 3(Example 2)% of FilmLayerCompositionLayer DensityThicknessA (First Layer)70% EPE-HD;0.94425%30% Z-N ULDPEB (Inner Layer)Z-N ULDPE0.90550%A (Second Layer)70% EPE-HD;0.94425%30% Z-N ULDPE The coextruded A/B/A film structure of Example 2 is produced at 115 microns on a 3-layer blown film line run by using the layers set forth above. One of the A layers is the outside layer of the bubble while the other A layer is the inner layer of the bubble. The B layer is encapsulated between the two A layers. The blow up ratio used is 2.5:1. The standard frost line height is 30 centimeters. The layer distribution used is 25/50/25. The film of Example 2 has an overall density of 0.925 g/cm3, and an initial thickness of ˜118 microns. A film similar to Example 2 is also prepared except that one of the A layers in Example 2 is replaced with a C layer comprising an enhanced polyethylene resin. The enhanced polyethylene resin is ELITE™ 5401G having a density of 0.918 g/cm3and a melt index (I2) of 1.0 g/10 minutes, which is commercially available from The Dow Chemical Company. When this film is oriented in the machine direction at a draw ratio of 8:1, the film exhibits uncontrollable curling. Films according to Example 2 are stretched at 235° F. and at draw ratios of 6.2:1, 8.3:1, and 9.1:1 to obtain the film thicknesses shown in Table 4: TABLE 4(Example 2)Thick-6.2:18.3:19.1:1nessDrawDrawDrawLayerComposition(μ)Ratio (μ)Ratio (μ)Ratio (μ)A (First70% EPE-HD;29.535.464.063.94Layer)30% Z-NULDPEB (InnerZ-N ULDPE59.0610.928.137.89Layer)A70% EPE-HD;29.535.464.063.94(Second30% Z-NLayer)ULDPETotal Thickness118.1121.8416.2615.77 Measurements are taken to evaluate the Example 2 films orientation performance. The 16.26 micron Example 2 film has an initial roll width of 1400 mm, a roll width after orientation in the machine direction of 1200 mm, and a final roll width after edge trimming of 1050 mm. These values represent a width retraction after orientation in the machine direction of 14.29%, and a total width reduction of 25.00% after additional film edge trimming to remove the slightly thicker edges. The Example 2 films are measured for Elmendorf tear according to ASTM D1922.FIG.1plots the Elmendorf tear values for the machine direction (“MD”) and the cross direction (“CD”), as well as the MD/CD ratio of the Elmendorf tear values, versus draw ratio for the machine direction orientation.FIG.2plots the normalized Elmendorf tear values (Elmendorf tear value/film thickness, grams/mil) versus draw ratio for the machine direction orientation. The Elmendorf tear values are desirable for certain applications. The films exhibit unexpectedly good Elmendorf tear retention after machine direction orientation draw ratios of 8:1 and higher. One might expect Elmendorf tear values in the machine direction to drop significantly below Elmendorf tear values in the cross direction upon increasing the draw ratio in the machine direction. As shown inFIGS.1and2, for the Example 2 films, the MD and CD Elmendorf tear values equalize at a draw ratio of about 6:1, and the MD Elmendorf tear values become higher as the draw ratio increases. The Example 2 films are also measured for 2% secant modulus in the machine direction (“MD”) and the cross direction (“CD”) in accordance with ASTM D882. The results are shown inFIG.3. As shown inFIG.3, the 2% MD secant modulus increases by a factor of four from the non-oriented thick film value of ˜50,000 psi to over 200,000 psi at an 8:1 draw ratio in the MD. The 2% CD secant modulus also almost doubles, indicating a MD/CD 2% sec modulus ratio of 2:1. FIGS.4and5show the interrelationship between normalized Elmendorf tear (grams/mil) and 2% secant modulus for the MD and CD, respectively. In the MD, the 2% secant modulus values increase at increasing draw ratios while the Elmendorf tear values decrease before seeming to plateau at draw ratios above 6:1. In the CD, the 2% secant modulus values also increase with increasing draw ratios, though at a lesser rate than the MD, while the Elmendorf tear values decrease with increasing draw ratios. Similarly,FIG.6compares normalized Elmendorf tear values (grams/mil) to the 2% secant modulus values. As shown inFIG.6, at a draw ratio of 6:1 in the MD, the film reaches a 2% secant modulus of ˜180,000 psi. As the film is stretched to draw ratios of 8:1 and 9:1, the normalized Elmendorf tear in the MD is maintained while the film gauge decreases from ˜22 microns to ˜15 microns, while the 2% secant modulus in the MD increases to ˜250,000 psi. Of particular note, the ˜15 micron film, oriented in the machine direction at a draw ratio of 9:1, advantageously exhibits a 2% secant modulus in the MD of ˜250,000 psi and a normalized Elmendorf tear of ˜223 g/mil. Example 3 Example 3 is an example of a uniaxially oriented film formed by collapsing an A/B/C structure film to form a six layer film having an A/B/C/C/B/A structure. The film includes the same EPE-HD and Z-N ULDPE as Example 1. The A layers comprise an enhanced polyethylene resin (“EPE”). The EPE is ELITE™ 5401G having a density of 0.917 g/cm3and a melt index (I2) of 1.0 g/10 minutes, which is commercially available from The Dow Chemical Company. Table 5 provides the formulation for Example 3: TABLE 5(Example 3)% of FilmLayerCompositionLayer DensityThicknessA (First Layer)100% EPE0.91720.0%B (Inner Layer)70% EPE-HD;0.944212.5%30% Z-N ULDPEC (Second Layer)100% Z-N ULDPE0.90517.5%C100% Z-N ULDPE0.90517.5%B70% EPE-HD;0.944212.5%30% Z-N ULDPEA100% EPE0.91720.0% An A/B/C coextruded film structure using the layers set forth in Table 5 is produced at 115 microns on a 3-layer blown film line. The A layer is the outside layer of the bubble while the C layer is the inner layer of the bubble. The B layer is encapsulated between the A layer and the C layer. The blow up ratio used is 2.5:1. The standard frost line height is 30 centimeters. The layer distribution used is 25/50/25. The film of Example 3 has an overall density of 0.9196 g/cm3. The C layer is a Ziegler-Natta catalyzed ULDPE resin with a VICAT softening point of 84° C. and peak melting point of 123° C., which promotes collapsing of the bubble to form the A/B/C/C/B/A film structure. The blown film has a thickness of ˜100 microns, but is allowed to collapse to heat laminate the ULDPEs in its C layer to form a ˜200 micron film. Films according to Example 3 are stretched at 225° F. and at a draw ratio of 7.1:1 to obtain the film thicknesses shown in Table 6: TABLE 6(Example 3)7.1:1 Draw RatioLayerCompositionThickness (μ)(μ)A (First Layer)100% EPE406.1B (Inner Layer)70% EPE-HD;253.830% Z-N ULDPEC (Second Layer)100% Z-N ULDPE355.3C100% Z-N ULDPE355.3B70% EPE-HD;253.830% Z-N ULDPEA100% EPE406.1Total Thickness20030.5 The Example 3 film stretches easily at 225° F., and is substantially flat. The film also shows excellent optical properties. Measurements are taken to evaluate the Example 3 film's orientation performance. The Example 3 film had an initial roll width of 1600 mm, a roll width after 7:1 orientation in the machine direction of 1430 mm, and a final roll width after edge trimming of 1260 mm. These values represent a width retraction after orientation in the machine direction of 10.63%, and a total width reduction of 21.25% after edge trimming. | 67,326 |
11858244 | DETAILED DESCRIPTION OF THE EMBODIMENTS In order to make objectives, technical solutions and advantages of the embodiments of the present disclosure clearer, the technical solutions in the embodiments of the present disclosure will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present disclosure. It should be noted that the sizes and shapes of all patterns in the accompanying drawings do not reflect real scales, and are merely to illustrate the contents of the present disclosure. Furthermore, same or similar numerals throughout indicate same or similar elements or elements with same or similar functions. Obviously, the described embodiments are a part of the embodiments of the present disclosure, not all the embodiments. Based on the described embodiments of the present disclosure, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present disclosure. Unless otherwise defined, technical terms or scientific terms used herein shall have ordinary meanings as understood by those of ordinary skill in the art to which the present disclosure belongs. The words “first”, “second” and similar words used in the specification and claims of the present disclosure do not denote any order, quantity or importance, but are merely used to distinguish different components. The word “including” or “includes” or the like means that the element or item preceding the word covers the element or object listed after the word and its equivalent, without excluding other elements or objects. “Inner”, “outer”, “upper”, “lower” and the like are only used to denote relative position relations. When an absolute position of a described object changes, the relative position relationship may also change accordingly. For a flexible foldable and curly display product, laminate layers of a flexible display product are generally laminated by adopting a single-roller laminating solution shown inFIG.1and a vacuum chamber laminating solution shown inFIG.2. In a process of laminating realized by adopting above two laminating solutions, the laminate layers are relatively uniformly stressed, so that the laminate layers in an unfolded state are in an initial state, that is, there are no inward tension/compressive stresses inside the laminate layers. However, in a folded state, the laminate layers may be subjected to greater inward tension/compressive stresses. For a long time, repeated mechanical folding on materials of the laminate layers may result in failure of product performances. For the above-mentioned problems existing in the related art, embodiments of the present disclosure provide a laminating device configured to laminate layers of a flexible display module. As shown inFIG.3toFIG.5, the laminating device includes:a first laminating base platform1, provided with a tension stress and configured to bear a first laminate layer2of the flexible display module;a second laminating base platform3, opposite to the first laminating base platform1, wherein the second laminating base platform3is provided with a tension stress, and a surface, facing the first laminating base platform1, of the second laminating base platform3is configured to bear a second laminate layer4of the flexible display module; anda stress applying component5, configured to control the first laminating base platform1and the second laminating base platform3to laminate in a lamination direction X, and control at least one of the first laminating base platform1and the second laminating base platform3to be deformed in a direction perpendicular to the lamination direction during lamination, such that the first laminate layer2, that has been laminated, in an unfolded state is provided with a pre-applied stress, wherein a direction of the pre-applied stress is opposite to a direction of a stress borne by the first laminate layer2in a folded state. By adopting the above-mentioned laminating device provided in the embodiments of the present disclosure, the purpose of applying a pre-applied stress to the first laminate layer2in the unfolded state is achieved. Moreover, since the direction of the pre-applied stress is opposite to the direction of the stress borne by the first laminate layer2in the folded state, after the first laminate layer2is folded, the pre-applied stress is capable of partially or completely neutralizing a stress borne by folding, that is, the stress borne by the first laminate layer2in the folded state is reduced, furthermore, the risk of fatigue failure caused by folding the first laminate layer2is reduced, and the service life is prolonged. When the first laminate layer2represents a different laminate layer, the pre-applied stress situations of the different laminate layers may be respectively adjusted by repeatedly using the laminating device, thereby improving the overall mechanical failure resistance of a foldable display product. Optionally, in the above-mentioned laminating device provided in the embodiments of the present disclosure, the elastic modulus of the second laminate layer4is greater than the elastic modulus of the first laminate layer2, which facilitates applying a stress to the first laminate layer2by the second laminate layer4in a process of restoring to the unfolded state after lamination, such that the first laminate layer2is provided with the pre-applied stress in the unfolded state. Optionally, in the above-mentioned laminating device provided in the embodiments of the present disclosure, the first laminating base platform1and the second laminating base platform3are made of a non-woven fabric. The non-woven fabric has good breathability and flexibility and is capable of fixing the first laminate layer2or the second laminate layer4in a vacuum adsorption way. Optionally, in the above-mentioned laminating device provided in the embodiments of the present disclosure, as shown inFIG.4, the stress applying component5may include: a first roller501, a second roller502, a first cylinder503, a second cylinder504, a first servo motor505, a second servo motor506, a first driving track507and a second driving track508; wherein the first roller501is in contact with the surface, away from the first laminate layer2, of the first laminating base platform1, and the first roller501is fixed to the first cylinder503; the first servo motor505is configured to drive the first cylinder503to move on the first driving track507in the lamination direction, and provide power, in the direction perpendicular to the lamination direction, for the first cylinder503; and when moving back and forth in the direction perpendicular to the lamination direction, the first cylinder503may drive the first roller501and the first laminating base platform1bearing the first laminate layer2to synchronously move in the direction perpendicular to the lamination direction, such that the first laminating base platform1is deformed in the direction perpendicular to the lamination direction. The second roller502is in contact with the surface, away from the second laminate layer4, of the second laminating base platform3, and the second roller502is fixed to the second cylinder504; the second servo motor506is configured to drive the second cylinder504to synchronously move with the first cylinder503on the second driving track508in the lamination direction, and provide power, in the direction perpendicular to the lamination direction, for the second cylinder504; and when moving back and forth in the direction perpendicular to the lamination direction, the second cylinder504may drive the second roller502and the second laminating base platform3bearing the second laminate layer4to synchronously move in the direction perpendicular to the lamination direction, such that the second laminating base platform3is deformed in the direction perpendicular to the lamination direction. Optionally, in the above-mentioned laminating device provided in the embodiments of the present disclosure, the first cylinder503controls a stroke of the first roller501in the direction perpendicular to the lamination direction to be equal to ½ of a distance from the first laminating base platform1to the second laminating base platform3, and the second cylinder504controls a stroke of the second roller502in the direction perpendicular to the lamination direction to be equal to ½ of a distance from the first laminating base platform1to the second laminating base platform3, that is, the relative movement distances of the first roller501and the second roller502in the direction perpendicular to the lamination direction are the same, as shown inFIG.6. In this case, the first laminating base platform1and the second laminating base platform3have the same deformation, such that a tension stress applied to the first laminate layer2by the first laminating base platform1is the same as a tension stress applied to the second laminate layer4by the second laminating base platform3. Since the elastic modulus of the second laminate layer4is greater than the elastic modulus of the first laminate layer2, after the tension stresses applied by the first laminating base platform1and the second laminating base platform3are withdrawn, the second laminate layer4may apply a compressive stress to the first laminate layer2, such that the second laminate layer4itself is restored to an unstressed state. Meanwhile, the tension stress applied to the first laminate layer2by the first laminating base platform1may be neutralized by the compressive stress from the second laminate layer4, and thus, the first laminate layer2is also restored to an unstressed state. In other words, in the above-mentioned overall process, the first laminate layer2and the second laminate layer4are both in the unstressed state after the lamination is completed. The process is suitable for laminating flat parts in the foldable display product, and the flat parts are unstressed in both an unfolded state and a folded state. Generally, there may be folding parts in addition to the flat parts in the foldable display product. Specifically, in a folded state, the folding parts may bear a compressive stress or a tension stress. In addition, the foldable display product may be provided with one or more folding parts. In a folded state, there may be folding parts bearing the compressive stress and folding parts bearing the tension stress among the plurality of folding parts. Therefore, the folding parts bearing different stresses need to be laminated respectively. Specifically, for the folding parts bearing the compressive stress when in the folded state, as shown inFIG.7, the first cylinder503can control a stroke of the first roller501in the direction perpendicular to the lamination direction to be equal to a distance from the first laminating base platform1to the second laminating base platform3, and the second cylinder504can control a stroke of the second roller502in the direction perpendicular to the lamination direction to be zero. That is, the first roller501drives the first laminating base platform1to move in the direction perpendicular to the lamination direction to be in contact with the second laminating base platform3, while the second laminating base platform3does not move in the direction perpendicular to the lamination direction. In this case, the first laminating base platform1is deformed, and therefore, the first laminating base platform1may apply a tension stress to the first laminate layer2; while the second laminating base platform3is not deformed, and therefore, the second laminating base platform3does not apply a stress to the second laminate layer4. In addition, since the elastic modulus of the second laminate layer4is greater than the elastic modulus of the first laminate layer2, after the tension stress applied to the first laminate layer2by the first laminating base platform1is withdrawn, the first laminate layer2may still be kept with the tension stress inside and is hardly restored to an unstressed state. By the process, a pre-tension stress may be applied to a folding part in an unfolded state, and when the pre-tension stress is kept until a folding operation starts, a compressive stress borne by folding may be neutralized, thereby improving the bending resistance of the product, and reducing the risk of fatigue failure. In addition, for the folding parts bearing the tension stress in the folded state, as shown inFIG.8, the first cylinder503can control a stroke of the first roller501in the direction perpendicular to the lamination direction to be zero, and the second cylinder504can control the second roller502in the direction perpendicular to the lamination direction to be equal to a distance from the first laminating base platform1to the second laminating base platform3. That is, the second roller502drives the second laminating base platform3to move in the direction perpendicular to the lamination direction to be in contact with the first laminating base platform1, while the first laminating base platform1does not move in the direction perpendicular to the lamination direction. In this case, the second laminating base platform3is deformed, and therefore, the second laminating base platform3may apply a tension stress to the second laminate layer4; while the first laminating base platform1is not be deformed, and therefore, the first laminating base platform1does not apply a stress to the first laminate layer2. In addition, since the elastic modulus of the second laminate layer4is greater than the elastic modulus of the first laminate layer2, after the tension stress applied to the second laminate layer4by the second laminating base platform3is withdrawn, the second laminate layer4is easily restored to an unstressed state, a compressive stress may be applied to the first laminate layer2in the process that the second laminate layer4is restored to the unstressed state, and therefore, after the lamination is completed, the first laminate layer2is provided with a pre-compressive stress, while the second laminate layer4is provided with no stress inside. In the case that a folding part in an unfolded state is provided with a pre-compressive stress, when the pre-compressive stress is kept until a folding operation starts, a tension stress borne by folding may be neutralized, thereby improving the bending resistance of the product, and reducing the risk of fatigue failure. Optionally, in order to realize vacuum adsorption of the laminating base platforms to the laminate layers, as shown inFIG.4, the above-mentioned laminating device provided in the embodiments of the present disclosure may further include: a first vacuum chamber6and a second vacuum chamber7which are oppositely disposed; wherein the first laminating base platform1and the first driving track507are fixed inside the first vacuum chamber6, the side, facing the second vacuum chamber7, of the first vacuum chamber6is provided with a first opening to expose the surface, bearing the first laminate layer2, of the first laminating base platform1, and at this point, the first roller501, the first cylinder503and the first servo motor505are also located in the first vacuum chamber6; and the second laminating base platform3and the second driving track508are fixed inside the second vacuum chamber7, the side, facing the first vacuum chamber6, of the second vacuum chamber7is provided with a second opening to expose the surface, bearing the second laminate layer4, of the second laminating base platform3, and at this point, the second roller502, the second cylinder504and the second servo motor506are also located in the second vacuum chamber7. Optionally, in order to make the first laminating base platform1and the second laminating base platform3themselves have tension stresses, the above-mentioned laminating device provided in the embodiments of the present disclosure, as shown inFIG.3andFIG.4, may further include: a first sealing strip8and a second sealing strip9; wherein the first sealing strip8is fixedly connected with a peripheral region of the first laminating base platform1and with the first vacuum chamber6around the first opening, such that the first laminating base platform1is stretched to be fixed on the first vacuum chamber6at the first opening by the first sealing strip8; and the second sealing strip9is fixedly connected with a peripheral region of the second laminating base platform3and with the second vacuum chamber7around the second opening, such that the second laminating base platform3is stretched to be fixed on the second vacuum chamber7at the second opening by the second sealing strip9. Based on the same inventive concept, embodiments of the present disclosure further provide a laminating method implemented by the above-mentioned laminating device. The principle of the laminating method to solve problems is similar to that of the above-mentioned laminating device, and therefore, for the implementation of the laminating method provided in the embodiments of the present disclosure, please referring to the implementation of the above-mentioned laminating device, and the descriptions thereof are omitted herein. Specifically, embodiments of the present disclosure provide a laminating method implemented by the above-mentioned laminating device, including the following steps. A first laminate layer of a flexible display module is placed on a first laminating base platform with a tension stress, and a second laminate layer of the flexible display module is placed on a second laminating base platform with a tension stress. A stress applying component controls the first laminating base platform and the second laminating base platform to laminate in a lamination direction, and controls at least one of the first laminating base platform and the second laminating base platform to be deformed in a direction perpendicular to the lamination direction during lamination, such that the first laminate layer, that has been laminated, in an unfolded state is provided with a pre-applied stress, wherein a direction of the pre-applied stress is opposite to a direction of a stress borne by the first laminate layer in a folded state. Optionally, in the above-mentioned laminating method provided in the embodiments of the present disclosure, the step that the first laminate layer of the flexible display module is placed on the first laminating base platform with the tension stress, and the second laminate layer of the flexible display module is placed on the second laminating base platform with the tension stress may be specifically implemented in the following way. The first laminate layer of the flexible display module is vacuum-adsorbed on the first laminating base platform with the tension stress, and the second laminate layer of the flexible display module is vacuum-adsorbed on the second laminating base platform with the tension stress, wherein the elastic modulus of the second laminate layer is greater than the elastic modulus of the first laminate layer. Optionally, in the above-mentioned laminating method provided in the embodiments of the present disclosure, the step that the stress applying component controls the first laminating base platform and the second laminating base platform to laminate in the lamination direction, and controls at least one of the first laminating base platform and the second laminating base platform to be deformed in the direction perpendicular to the lamination direction during lamination may specifically include the following three possible implementation ways. A first possible implementation way: a first servo motor and a second servo motor respectively drive a first cylinder and a second cylinder to synchronously move in the lamination direction, and the first cylinder and the second cylinder are controlled to move towards each other in the direction perpendicular to the lamination direction, and both moving distances of the first cylinder and the second cylinder in the direction perpendicular to the lamination direction are ½ of a distance from the first laminating base platform to the second laminating base platform, such that the pre-applied stress of the first laminate layer, that has been laminated, in the unfolded state is zero, as shown inFIG.6. A second possible implementation way: a first servo motor and a second servo motor respectively drive a first cylinder and a second cylinder to synchronously move in the lamination direction, the first cylinder is controlled to move in the direction perpendicular to the lamination direction until the first laminate layer is in contact with the second laminate layer, and the second cylinder is controlled not to move in the direction perpendicular to the lamination direction, such that the first laminate layer, that has been laminated, in the unfolded state is provided with a pre-tension stress, as shown inFIG.7. A third possible implementation way: a first servo motor and a second servo motor respectively drive a first cylinder and a second cylinder to synchronously move in the lamination direction, the first cylinder is controlled not to move in the direction perpendicular to the lamination direction, and the second cylinder is controlled to move in the direction perpendicular to the lamination direction until the first laminate layer is in contact with the second laminate layer, such that the first laminate layer, that has been laminated, in the unfolded state is provided with a pre-compressive stress, as shown inFIG.8. Specifically,FIG.9shows a situation that pre-stresses are correspondingly applied to different parts in the first laminate layer2after the first laminate layer2and the second laminate layer4are laminated by adopting the above-mentioned laminating method. Accordingly, embodiments of the present disclosure provide a flexible display module, including a plurality of laminate layers, wherein the laminate layers are laminated by the above-mentioned laminating device. The principle of the flexible display module to solve problems is similar to that of the above-mentioned laminating device, and therefore, for the implementation of the flexible display module provided in the embodiments of the present disclosure, please refer to the implementation of the above-mentioned laminating device provided in the embodiments of the present disclosure, and the descriptions thereof are omitted herein. Generally, as shown inFIG.10toFIG.12, the flexible display module includes: a flexible display substrate401, a supporting plate402, a protective cover plate403, a first optical adhesive layer201used for adhering the flexible display substrate401to the protective cover plate403, and a second optical adhesive layer202used for adhering the flexible display substrate401to the supporting plate402. Specifically,FIG.10andFIG.11show situations of stresses borne by different areas of the flexible display module in the related art in a folded (that is, infolded and outfolded) state, andFIG.12specifically shows situations of pre-applied stresses of different areas of the first optical adhesive layer201and the second optical adhesive layer202in an unfolded state in the case that the first laminate layer2is the first optical adhesive layer201or the second optical adhesive layer202, and the second laminate layer4is the flexible display substrate401in the present disclosure. It can be seen fromFIG.10andFIG.11, the first optical adhesive layer201bears a compressive stress in an infolded area and bears a tension stress in outfolded areas at two sides of the infolded area, and the second optical adhesive layer202bears a tension stress in an infolded area and bears a compressive stress in outfolded areas at two sides of the infolded area. InFIG.12, a pre-applied stress opposite to a stress borne in a folded state is applied to the first optical adhesive layer201and the second optical adhesive layer202in an unfolded state, so that the phenomenon that peeling of an upper laminate layer from a lower laminate layer is caused by long-term action of a folding stress on the optical adhesive layer201or the second optical adhesive layer202can be effectively avoided. A main performance of the foldable display product is displaying, while it is inevitable to generate cracks on traces of an inorganic layer inside the flexible display substrate401under the long-term action of the folding stress, which may further lead to problems such as corrosive short connection to affect a display function. Therefore, preferably, in the above-mentioned flexible display module provided in the embodiments of the present disclosure, the first laminate layer2is the flexible display substrate401, and the second laminate layer4is the supporting plate402or the protective cover plate403, so that the stress on the flexible display substrate is better adjusted to prolong the normal service life of the flexible display substrate. Optionally, the pre-applied stress of the flexible display substrate401may be adjusted when it is laminated with the supporting plate402or the protective cover plate403. If the pre-applied stress required by the flexible display substrate401is so large that the pre-applied stress cannot be met by adopting a single laminating process, the pre-applied stress can be preliminarily adjusted in a process of laminating with the supporting plate402and then adjusted in a process of laminating with the protective cover plate403. Optionally, in the above-mentioned flexible display module provided in the embodiments of the present disclosure, a pre-applied stress of each laminate layer in an unfolded state may be set to be half of a stress borne by the laminate layer in a completely folded state, such that a stress borne by the laminate layer in a semi-folded state is zero, a stress borne by the laminate layer in the unfolded state is half of the stress borne by the laminate layer in the completely folded state in the related art, a stress borne by the laminate layer in the completely folded state is reduced by half, and thus, the risk that each laminate layer bears an overlarge stress when in the folded or unfolded state is reduced. Of course, the pre-applied stress may also have other numerical values, and specifically, it is preferable to ensure that the pre-applied stress is not greater than the stress borne by the laminate layer in the completely folded state. Specifically,FIG.13shows that an internal stress of each laminate layer in a semi-folded (that is, semi-infolded or semi-outfolded) state is zero.FIG.14shows that the foldable display product in the related art bears no internal stress when in an initial state (that is, an unfolded state), but bears a great stress when in a bent state (that is, a completely folded state).FIG.15shows that a stress borne by the foldable display product provided in the present disclosure when in an initial state is half of a stress borne in a completely folded state in the related art, a stress borne by the foldable display product in a completely folded state is reduced by half, and a stress borne by the foldable display product in a semi-folded state is zero. Optionally, the above-mentioned flexible display module provided in the embodiments of the present disclosure is suitable for various foldable and curly products. Optionally, as shown inFIG.16, the above-mentioned flexible display module may include: two folding parts, namely a first folding part B1and second folding parts B2with opposite bending directions and opposite pre-applied stress directions; or, as shown inFIG.17andFIG.18, the above-mentioned flexible display module may further include a folding part B. Specifically,FIG.16further shows that the second folding parts B2are located at two ends of the first folding part B1, and the flexible display module further includes first flat parts F1connecting the first folding part B1with the second folding parts B2, and second flat parts F2connected with the ends, away from the first flat parts F1, of the second folding parts B2. Optionally, the first folding part B1, the second folding parts B2, the first flat parts F1and the second flat parts F2are in a water drop shape when in a completely folded state. Moreover, as shown inFIG.10, the flexible display module may include: a flexible display substrate401, a supporting plate402, a protective cover plate403, a first optical adhesive layer201used for adhering the flexible display substrate401to the protective cover plate403, and a second optical adhesive layer202used for adhering the flexible display substrate401to the supporting plate402. Specifically, in the water drop shape, as shown inFIG.10, in the related art, the first optical adhesive layer201and the supporting plate402in an area where the first folding part B1is located bear a compressive stress, the second optical adhesive layer202and the protective cover plate403bear a tension stress, and the flexible display substrate401is unstressed; the first optical adhesive layer201and the supporting plate402in areas where the second folding parts B2are located bear a tension stress, the second optical adhesive layer202and the protective cover plate403bear a compressive stress, and the flexible display substrate401is unstressed; and the flexible display substrate401, the first optical adhesive layer201, the supporting plate402, the second optical adhesive layer202and the protective cover plate403in areas where the first flat parts F1and the second flat parts F2are located are unstressed. During lamination in the present disclosure, pre-tension stresses of the first optical adhesive layer201and the supporting plate402in the area where the first folding part B1is located are equal to ½ of compressive stresses borne by them in the water drop shape, and pre-compressive stresses of the second optical adhesive layer202and the protective cover plate403are equal to ½ of tension stresses borne by them in the water drop shape. Pre-compressive stresses of the first optical adhesive layer201and the supporting plate402in the areas where the second folding parts B2are located are equal to ½ of tension stresses borne by them in the water drop shape, and pre-tension stresses of the second optical adhesive layer202and the protective cover plate403are equal to ½ of compressive stresses borne by them in the water drop shape. In this way, when the flexible display module provided in the present disclosure is in the water drop shape, stresses borne by each film layer corresponding to the first folding part B1and the second folding parts B2are both reduced by half.FIG.17further shows flat parts F at two ends of the folding part B, and in a completely folded state, a distance between the two flat parts F is gradually reduced in a direction away from the folding part B to form a baseball bat shape.FIG.18further shows flat parts F located at two ends of the folding part B, and in a completely folded state, a distance between the two flat parts F is kept unchanged in a direction away from the folding part B to form a U-shape. Based on the same inventive concept, an embodiment of the present disclosure further provides a display device, including the above-mentioned flexible display module provided in the embodiments of the present disclosure. The display device may be any product or component with a display function, such as a mobile phone, a tablet computer, a television, a display, a notebook computer, a digital photo frame, a navigator, a smart watch, a fitness wristband and a personal digital assistant. Other essential components of the display device should be known to those of ordinary skill in the art, and they will not be repeated herein and should not be taken as a limitation to the present disclosure. In addition, the principle of the display device to solve problems is similar to that of the above-mentioned flexible display module, and therefore, for the implementation of the display device, please referring to the implementation of the above-mentioned flexible display module, the descriptions thereof are omitted herein. Obviously, those skilled in the art can make various modifications and variations to the present disclosure without departing from the spirit and scope of the present disclosure. In this way, if these modifications and variations of the present disclosure fall within the scope of the claims of the present disclosure and their equivalent technologies, the present disclosure is also intended to include these modifications and variations. | 32,688 |
11858245 | DETAILED DESCRIPTION OF THE INVENTION “Article” as used herein means a consumer-usable structure comprising one or more and/or two or more and/or three or more and/or four or more fibrous webs according to the present invention. In one example the article is a dry article. In addition, the article may be a sanitary tissue product. The article may comprise two or more and/or three or more different fibrous webs selected from the group consisting of: wet-laid fibrous webs, air-laid fibrous webs, co-formed fibrous web, meltblown fibrous web, and spunbond fibrous web. In one example, the article is void of a hydroentangled fibrous web and/or is not a hydroentangled fibrous web. In another example, the article is void of a carded fibrous web and/or is not a carded fibrous web. In addition to the fibrous webs, the articles of the present invention may comprise other solid matter, such as sponges, foams, particle, such as absorbent gel materials, and mixtures thereof. In one example, two or more fibrous webs (fibrous web plies) of the present invention may be associated together to form the article. In one example, the article of the present invention comprises one or more co-formed fibrous webs (co-formed fibrous web plies). In addition to the co-formed fibrous web, the article may further comprise one or more wet-laid fibrous webs (wet-laid fibrous web plies). Also in addition to the co-formed fibrous web (co-formed fibrous web ply) with or without one or more wet-laid fibrous webs (wet-laid fibrous web plies), the article may further comprise one or more meltblown fibrous webs (meltblown fibrous web plies). In another example, the article of the present invention may comprise one or more multi-fibrous element fibrous webs (e.g., a fibrous structure comprising a mixture of filaments and fibers), such as a co-formed fibrous web, and one or more mono-fibrous element fibrous webs (e.g., a fibrous structure comprising only fibers or only filaments, not a mixture of fibers and filaments), such as a paper web, for example a fibrous web and/or a meltblown fibrous web. In one example, at least a portion of the article exhibits a basis weight of about 150 gsm or less and/or about 100 gsm or less and/or from about 30 gsm to about 95 gsm. “Sanitary tissue product” as used herein means a soft, low density (i.e. <about 0.15 g/cm3) web useful as a wiping implement for post-urinary and post-bowel movement cleaning (toilet tissue), for otorhinolaryngological discharges (facial tissue), and multi-functional absorbent and cleaning uses (absorbent towels). Non-limiting examples of suitable sanitary tissue products of the present invention include paper towels, bath tissue, facial tissue, napkins, baby wipes, adult wipes, wet wipes, cleaning wipes, polishing wipes, cosmetic wipes, car care wipes, wipes that comprise an active agent for performing a particular function, cleaning substrates for use with implements, such as a Swiffer® cleaning wipe/pad. The sanitary tissue product may be convolutedly wound upon itself about a core or without a core to form a sanitary tissue product roll. The sanitary tissue products of the present invention may exhibit a basis weight between about 10 g/m2to about 500 g/m2and/or from about 15 g/m2to about 400 g/m2and/or from about 20 g/m2to about 300 g/m2and/or from about 20 g/m2to about 200 g/m2and/or from about 20 g/m2to about 150 g/m2and/or from about 20 g/m2to about 120 g/m2and/or from about 20 g/m2to about 110 g/m2and/or from about 20 g/m2to about 100 g/m2and/or from about 30 to 90 g/m2. In addition, the sanitary tissue product of the present invention may exhibit a basis weight between about 40 g/m2to about 500 g/m2and/or from about 50 g/m2to about 400 g/m2and/or from about 55 g/m2to about 300 g/m2and/or from about 60 to 200 g/m2. In one example, the sanitary tissue product exhibits a basis weight of less than 100 g/m2and/or less than 80 g/m2and/or less than 75 g/m2and/or less than 70 g/m2and/or less than 65 g/m2and/or less than 60 g/m2and/or less than 55 g/m2and/or less than 50 g/m2and/or less than 47 g/m2and/or less than 45 g/m2and/or less than 40 g/m2and/or less than 35 g/m2and/or to greater than 20 g/m2and/or greater than 25 g/m2and/or greater than 30 g/m2as measured according to the Basis Weight Test Method described herein. The sanitary tissue products of the present invention may exhibit a density (measured at 95 g/in2) of less than about 0.60 g/cm3and/or less than about 0.30 g/cm3and/or less than about 0.20 g/cm3and/or less than about 0.10 g/cm3and/or less than about 0.07 g/cm3and/or less than about 0.05 g/cm3and/or from about 0.01 g/cm3to about 0.20 g/cm3and/or from about 0.02 g/cm3to about 0.10 g/cm3. The sanitary tissue products of the present invention may comprises additives such as softening agents, temporary wet strength agents, permanent wet strength agents, bulk softening agents, silicones, wetting agents, latexes, especially surface-pattern-applied latexes, dry strength agents such as carboxymethylcellulose and starch, and other types of additives suitable for inclusion in and/or on sanitary tissue products. “Fibrous web” as used herein means a unitary structure comprising one or more fibrous structures that are associated with one another, such as by compression bonding (for example by passing through a nip formed by two rollers), thermal bonding (for example by passing through a nip formed by two rollers where at least one of the rollers is heated to a temperature of at least about 120° C. (250° F.), microselfing, needle punching, and gear rolling, to form the unitary structure, for example a unitary structure that exhibits sufficient integrity to be processed with web handling equipment and/or exhibits a basis weight of at least 6 gsm and/or at least 8 gsm and/or at least 10 gsm and/or at least 15 gsm and/or at least 20 gsm and/or at least 30 gsm and/or at least 40 gsm. The unitary structure may also be referred to as a ply, a fibrous web ply. “Fibrous structure” as used herein means a structure that comprises a plurality of fibrous elements, for example a plurality of filaments and/or a plurality of fibers, for example pulp fibers, for example wood pulp fibers, and/or cellulose fibrous elements and/or cellulose fibers, such as pulp fibers, for example wood pulp fibers. In addition to the fibrous elements, the fibrous structures may comprise particles, such as absorbent gel material particles. In one example, a fibrous structure according to the present invention means an orderly arrangement of fibrous elements within a structure in order to perform a function. In another example, a fibrous structure according to the present invention is a nonwoven. In one example, the fibrous structures of the present invention may comprise wet-laid fibrous structures, for example embossed conventional wet pressed fibrous structures, through-air-dried (TAD) fibrous structures both creped and/or uncreped, belt-creped fibrous structures, fabric-creped fibrous structures, and combinations thereof, air-laid fibrous structures, such as thermally-bonded air-laid (TBAL) fibrous structures, melt-bonded air-laid (MBAL), latex-bonded air-laid (LBAL) fibrous structures and combinations thereof, co-formed fibrous structures, meltblown fibrous structures, and spunbond fibrous structures, carded fibrous structures, and combinations thereof. In one example, the fibrous structure is a non-hydroentangled fibrous structure. In another example, the fibrous structure is a non-carded fibrous structure. In another example of the present invention, a fibrous structure comprises a plurality of inter-entangled fibrous elements, for example inter-entangled filaments. Non-limiting examples of fibrous structures and/or fibrous webs (fibrous web plies) of the present invention include paper. The fibrous structures of the present invention may be homogeneous or may be layered. If layered, the fibrous structures may comprise at least two and/or at least three and/or at least four and/or at least five layers. Any one of the fibrous structures may itself be a fibrous web (fibrous web ply) if the fibrous structure exhibits sufficient integrity to be processed with web handling equipment and/or exhibits a basis weight of at least 6 gsm and/or at least 8 gsm and/or at least 10 gsm and/or at least 15 gsm and/or at least 20 gsm and/or at least 30 gsm and/or at least 40 gsm. An example of such a fibrous structure, for example a paper web, for example a fibrous structure exhibiting a basis weight of at least 10 gsm and/or at least 15 gsm and/or at least 20 gsm can be a fibrous web (fibrous web ply) itself. Non-limiting examples of processes for making the fibrous structures of the present invention include known wet-laid papermaking processes, for example conventional wet-pressed (CWP) papermaking processes and through-air-dried (TAD), both creped TAD and uncreped TAD, papermaking processes, and air-laid papermaking processes. Such processes typically include steps of preparing a fiber composition in the form of a fiber suspension in a medium, either wet, more specifically aqueous medium, or dry, more specifically gaseous, i.e. with air as medium. The aqueous medium used for wet-laid processes is oftentimes referred to as a fiber slurry. The fiber slurry is then used to deposit a plurality of the fibers onto a forming wire, fabric, or belt such that an embryonic web material is formed, after which drying and/or bonding the fibers together results in a fibrous structure and/or fibrous web (fibrous web ply). Further processing of the fibrous structure and/or fibrous web (fibrous web ply) may be carried out such that a fibrous structure and/or fibrous web (fibrous web ply) is formed. For example, in typical papermaking processes, the fibrous structure and/or fibrous web (fibrous web ply) is wound on the reel at the end of papermaking, often referred to as a parent roll, and may subsequently be converted into a fibrous web (fibrous web ply) of the present invention and/or ultimately incorporated into an article, such as a single- or multi-ply sanitary tissue product. “Multi-fibrous element fibrous structure” as used herein means a fibrous structure that comprises filaments and fibers, for example a co-formed fibrous structure is a multi-fibrous element fibrous structure. “Mono-fibrous element fibrous structure” as used herein means a fibrous structure that comprises only fibers or filaments, for example a paper web, such as a paper web, for example a fibrous structure, or meltblown fibrous structure, such as a scrim, respectively, not a mixture of fibers and filaments. “Co-formed fibrous structure” as used herein means that the fibrous structure comprises a mixture of filaments, for example meltblown filaments, such as thermoplastic filaments, for example polypropylene filaments, and fibers, such as pulp fibers, for example wood pulp fibers. The filaments and fibers are commingled together to form the co-formed fibrous structure. The co-formed fibrous structure may be associated with one or more meltblown fibrous structures and/or spunbond fibrous structures, which form a scrim (in one example the scrim may be present at a basis weight of greater than 0.5 gsm to about 5 gsm and/or from about 1 gsm to about 4 gsm and/or from about 1 gsm to about 3 gsm and/or from about 1.5 gsm to about 2.5 gsm), such as on one or more surfaces of the co-formed fibrous structure. The co-formed fibrous structure of the present invention may be made via a co-forming process. A non-limiting example of making a co-formed fibrous structure and/or co-formed fibrous web (co-formed fibrous web ply) comprising a co-formed fibrous structure associated with or without a meltblown fibrous structure, for example a scrim layer of filaments, on one or both surfaces, when present, of the co-formed fibrous structure and process for making is shown inFIGS.2A and2B. “Fibrous element” as used herein means an elongate particulate having a length greatly exceeding its average diameter, i.e. a length to average diameter ratio of at least about 10. A fibrous element may be a filament or a fiber. In one example, the fibrous element is a single fibrous element rather than a yarn comprising a plurality of fibrous elements. The fibrous elements of the present invention may be spun from polymer melt compositions via suitable spinning operations, such as meltblowing and/or spunbonding and/or they may be obtained from natural sources such as vegetative sources, for example trees. The fibrous elements of the present invention may be monocomponent and/or multicomponent. For example, the fibrous elements may comprise bicomponent fibers and/or filaments. The bicomponent fibers and/or filaments may be in any form, such as side-by-side, core and sheath, islands-in-the-sea and the like. “Filament” as used herein means an elongate particulate as described above that exhibits a length of greater than or equal to 5.08 cm (2 in.) and/or greater than or equal to 7.62 cm (3 in.) and/or greater than or equal to 10.16 cm (4 in.) and/or greater than or equal to 15.24 cm (6 in.). Filaments are typically considered continuous or substantially continuous in nature. Filaments are relatively longer than fibers. Non-limiting examples of filaments include meltblown and/or spunbond filaments. Non-limiting examples of polymers that can be spun into filaments include natural polymers, such as starch, starch derivatives, cellulose, such as rayon and/or lyocell, and cellulose derivatives, hemicellulose, hemicellulose derivatives, and synthetic polymers including, but not limited to polyvinyl alcohol filaments and/or polyvinyl alcohol derivative filaments, and thermoplastic polymer filaments, such as polyesters, nylons, polyolefins such as polypropylene filaments, polyethylene filaments, and biodegradable or compostable thermoplastic fibers such as polylactic acid filaments, polyhydroxyalkanoate filaments, polyesteramide filaments, and polycaprolactone filaments. The filaments may be monocomponent or multicomponent, such as bicomponent filaments. The filaments may be made via spinning, for example via meltblowing and/or spunbonding, from a polymer, for example a thermoplastic polymer, such as polyolefin, for example polypropylene and/or polyethylene, and/or polyester. Filaments are typically considered continuous or substantially continuous in nature. “Meltblowing” is a process for producing filaments directly from polymers or resins using high-velocity air or another appropriate force to attenuate the filaments before collecting the filaments on a collection device, such as a belt, for example a patterned belt or molding member. In a meltblowing process the attenuation force is applied in the form of high speed air as the material (polymer) exits a die or spinnerette. “Spunbonding” is a process for producing filaments directly from polymers by allowing the polymer to exit a die or spinnerette and drop a predetermined distance under the forces of flow and gravity and then applying a force via high velocity air or another appropriate source to draw and/or attenuate the polymer into a filament. “Fiber” as used herein means an elongate particulate as described above that exhibits a length of less than 5.08 cm (2 in.) and/or less than 3.81 cm (1.5 in.) and/or less than 2.54 cm (1 in.). Fibers are typically considered discontinuous in nature. Non-limiting examples of fibers include pulp fibers, such as wood pulp fibers, and synthetic staple fibers such as polypropylene, polyethylene, polyester, copolymers thereof, rayon, lyocell, glass fibers and polyvinyl alcohol fibers. Staple fibers may be produced by spinning a filament tow and then cutting the tow into segments of less than 5.08 cm (2 in.) thus producing fibers; namely, staple fibers. “Pulp fibers” as used herein means fibers that have been derived from vegetative sources, such as plants and/or trees. In one example of the present invention, “pulp fiber” refers to papermaking fibers. In one example of the present invention, a fiber may be a naturally occurring fiber, which means it is obtained from a naturally occurring source, such as a vegetative source, for example a tree and/or plant, such as trichomes. Such fibers are typically used in papermaking and are oftentimes referred to as papermaking fibers. Papermaking fibers useful in the present invention include cellulosic fibers commonly known as wood pulp fibers. Applicable wood pulps include chemical pulps, such as Kraft, sulfite, and sulfate pulps, as well as mechanical pulps including, for example, groundwood, thermomechanical pulp and chemically modified thermomechanical pulp. Chemical pulps, however, may be preferred since they impart a superior tactile sense of softness to fibrous structures made therefrom. Pulps derived from both deciduous trees (hereinafter, also referred to as “hardwood”) and coniferous trees (hereinafter, also referred to as “softwood”) may be utilized. The hardwood and softwood fibers can be blended, or alternatively, can be deposited in layers to provide a stratified web. Also applicable to the present invention are fibers derived from recycled paper, which may contain any or all of the above categories of fibers as well as other non-fibrous polymers such as fillers, softening agents, wet and dry strength agents, and adhesives used to facilitate the original papermaking. In one example, the wood pulp fibers are selected from the group consisting of hardwood pulp fibers, softwood pulp fibers, and mixtures thereof. The hardwood pulp fibers may be selected from the group consisting of: tropical hardwood pulp fibers, northern hardwood pulp fibers, and mixtures thereof. The tropical hardwood pulp fibers may be selected from the group consisting of: eucalyptus fibers, acacia fibers, and mixtures thereof. The northern hardwood pulp fibers may be selected from the group consisting of: cedar fibers, maple fibers, and mixtures thereof. In addition to the various wood pulp fibers, other cellulosic fibers such as cotton linters, rayon, lyocell, trichomes, seed hairs, rice straw, wheat straw, bamboo, and bagasse fibers can be used in this invention. Other sources of cellulose in the form of fibers or capable of being spun into fibers include grasses and grain sources. “Trichome” or “trichome fiber” as used herein means an epidermal attachment of a varying shape, structure and/or function of a non-seed portion of a plant. In one example, a trichome is an outgrowth of the epidermis of a non-seed portion of a plant. The outgrowth may extend from an epidermal cell. In one embodiment, the outgrowth is a trichome fiber. The outgrowth may be a hairlike or bristlelike outgrowth from the epidermis of a plant. Trichome fibers are different from seed hair fibers in that they are not attached to seed portions of a plant. For example, trichome fibers, unlike seed hair fibers, are not attached to a seed or a seed pod epidermis. Cotton, kapok, milkweed, and coconut coir are non-limiting examples of seed hair fibers. Further, trichome fibers are different from nonwood bast and/or core fibers in that they are not attached to the bast, also known as phloem, or the core, also known as xylem portions of a nonwood dicotyledonous plant stem. Non-limiting examples of plants which have been used to yield nonwood bast fibers and/or nonwood core fibers include kenaf, jute, flax, ramie and hemp. Further trichome fibers are different from monocotyledonous plant derived fibers such as those derived from cereal straws (wheat, rye, barley, oat, etc), stalks (corn, cotton, sorghum,Hesperaloe funifera, etc.), canes (bamboo, bagasse, etc.), grasses (esparto, lemon, sabai, switchgrass, etc), since such monocotyledonous plant derived fibers are not attached to an epidermis of a plant. Further, trichome fibers are different from leaf fibers in that they do not originate from within the leaf structure. Sisal and abaca are sometimes liberated as leaf fibers. Finally, trichome fibers are different from wood pulp fibers since wood pulp fibers are not outgrowths from the epidermis of a plant; namely, a tree. Wood pulp fibers rather originate from the secondary xylem portion of the tree stem. “Basis Weight” as used herein is the weight per unit area of a sample reported in lbs/3000 ft2or g/m2(gsm) and is measured according to the Basis Weight Test Method described herein. “Machine Direction” or “MD” as used herein means the direction parallel to the flow of the fibrous structure through the fibrous structure making machine and/or sanitary tissue product manufacturing equipment. “Cross Machine Direction” or “CD” as used herein means the direction parallel to the width of the fibrous structure making machine and/or sanitary tissue product manufacturing equipment and perpendicular to the machine direction. “Embossed” as used herein with respect to an article, sanitary tissue product, and/or fibrous web (fibrous web ply), means that an article, sanitary tissue product, and/or fibrous web (fibrous web ply) has been subjected to a process which converts a smooth surfaced article, sanitary tissue product, and/or fibrous web (fibrous web ply) to a out-of-plane, textured surface by replicating a pattern on one or more emboss rolls, which form a nip through which the article, sanitary tissue product and/or fibrous web (fibrous web ply) passes. Embossed does not include creping, microcreping, printing or other processes that may also impart a texture and/or decorative pattern to an article, sanitary tissue product and/or fibrous web (fibrous web ply). “Differential density”, as used herein, means a fibrous structure and/or fibrous web (fibrous web ply) that comprises one or more regions of relatively low fibrous element, for example fiber, density, which are referred to as pillow regions, and one or more regions of relatively high fibrous element, for example fiber, density, which are referred to as knuckle regions. “Densified”, as used herein means a portion of a fibrous structure and/or fibrous web (fibrous web ply) that is characterized by regions of relatively high fibrous element, e.g., fiber, density (knuckle regions). “Non-densified”, as used herein, means a portion of a fibrous structure and/or fibrous web (fibrous web ply) that exhibits a lesser fibrous element, e.g., fiber, density (one or more regions of relatively lower fibrous element, e.g., fiber, density) (pillow regions) than another portion (for example a knuckle region) of the fibrous structure and/or fibrous web (fibrous web ply). “Wet textured” as used herein means that a three-dimensional (3D) patterned fibrous structure and/or 3D patterned fibrous web (3D patterned fibrous web ply) comprises texture (for example a three-dimensional topography) imparted to the fibrous structure and/or fibrous structure's surface and/or fibrous web's surface (fibrous web ply's surface) during a fibrous structure making process. In one example, in a paper web, for example a fibrous structure making process, wet texture may be imparted to a fibrous structure upon fibers and/or filaments being collected on a collection device that has a three-dimensional (3D) surface which imparts a 3D surface to the fibrous structure being formed thereon and/or being transferred to a fabric and/or belt, such as a through-air-drying fabric and/or a patterned drying belt, comprising a 3D surface that imparts a 3D surface to a fibrous structure being formed thereon. In one example, the collection device with a 3D surface comprises a patterned, such as a patterned formed by a polymer or resin being deposited onto a base substrate, such as a fabric, in a patterned configuration. The wet texture imparted to a paper web, for example a fibrous structure is formed in the fibrous structure prior to and/or during drying of the fibrous structure. Non-limiting examples of collection devices and/or fabric and/or belts suitable for imparting wet texture to a fibrous structure include those fabrics and/or belts used in fabric creping and/or belt creping processes, for example as disclosed in U.S. Pat. Nos. 7,820,008 and 7,789,995, coarse through-air-drying fabrics as used in uncreped through-air-drying processes, and photo-curable resin patterned through-air-drying belts, for example as disclosed in U.S. Pat. No. 4,637,859. For purposes of the present invention, the collection devices used for imparting wet texture to the fibrous structures would be patterned to result in the fibrous structures comprising a surface pattern comprising a plurality of parallel line elements wherein at least one, two, three, or more, for example all of the parallel line elements exhibit a non-constant width along the length of the parallel line elements. This is different from non-wet texture that is imparted to a fibrous structure after the fibrous structure has been dried, for example after the moisture level of the fibrous structure is less than 15% and/or less than 10% and/or less than 5%. An example of non-wet texture includes embossments imparted to a fibrous structure and/or fibrous web (fibrous web ply) by embossing rolls during converting of the fibrous structure and/or fibrous web (fibrous web ply). In one example, the fibrous structure and/or fibrous web (fibrous web ply), for example a paper web, for example a fibrous structure and/or wet-laid fibrous web (wet-laid fibrous web ply), is a wet textured fibrous structure and/or wet textured fibrous web (wet textured fibrous web ply). “3D pattern” with respect to a fibrous structure and/or fibrous web's surface (fibrous web ply's surface) in accordance with the present invention means herein a pattern that is present on at least one surface of the fibrous structure and/or fibrous web (fibrous web ply). The 3D pattern texturizes the surface of the fibrous structure and/or fibrous web (fibrous web ply), for example by providing the surface with protrusions and/or depressions. The 3D pattern on the surface of the fibrous structure and/or fibrous web (fibrous web ply) is made by making the fibrous structure on a patterned molding member that imparts the 3D pattern to the fibrous structure made thereon. For example, the 3D pattern may comprise a series of line elements, such as a series of line elements that are substantially oriented in the cross-machine direction of the fibrous structure and/or sanitary tissue product. In one example, a series of line elements may be arranged in a 3D pattern selected from the group consisting of: periodic patterns, aperiodic patterns, straight line patterns, curved line patterns, wavy line patterns, snaking patterns, square line patterns, triangular line patterns, S-wave patterns, sinusoidal line patterns, and mixtures thereof. In another example, a series of line elements may be arranged in a regular periodic pattern or an irregular periodic pattern (aperiodic) or a non-periodic pattern. “Distinct from” and/or “different from” as used herein means two things that exhibit different properties and/or levels of materials, for example different by 0.5 and/or 1 and/or 2 and/or 3 and/or 5 and/or 10 units and/or different by 1% and/or 3% and/or 5% and/or 10% and/or 20%, different materials, and/or different average fiber diameters. “Textured pattern” as used herein means a pattern, for example a surface pattern, such as a three-dimensional (3D) surface pattern present on a surface of the fibrous structure and/or on a surface of a component making up the fibrous structure. “Fibrous Structure Basis Weight” as used herein is the weight per unit area of a sample reported in lbs/3000 ft2or g/m2. “Ply” as used herein means an individual, integral fibrous structure. “Plies” as used herein means two or more individual, integral fibrous structures disposed in a substantially contiguous, face-to-face relationship with one another, forming a multi-ply sanitary tissue product. It is also contemplated that an individual, integral fibrous structure can effectively form a multi-ply sanitary tissue product, for example, by being folded on itself. “Common Intensive Property” as used herein means an intensive property possessed by more than one region within a fibrous structure. Such intensive properties of the fibrous structure include, without limitation, density, basis weight, thickness, and combinations thereof. For example, if density is a common intensive property of two or more different regions, a value of the density in one region can differ from a value of the density in one or more other regions. Regions (such as, for example, a first region and a second region and/or a continuous network region and at least one of a plurality of discrete zones) are identifiable areas visually discernible and/or visually distinguishable from one another by distinct intensive properties. “X,” “Y,” and “Z” designate a conventional system of Cartesian coordinates, wherein mutually perpendicular coordinates “X” and “Y” define a reference X-Y plane, and “Z” defines an orthogonal to the X-Y plane. “Z-direction” designates any direction perpendicular to the X-Y plane. Analogously, the term “Z-dimension” means a dimension, distance, or parameter measured parallel to the Z-direction. When an element, such as, for example, a molding member curves or otherwise deplanes, the X-Y plane follows the configuration of the element. “Substantially continuous” or “continuous” region refers to an area within which one can connect any two points by an uninterrupted line running entirely within that area throughout the line's length. That is, the substantially continuous region has a substantial “continuity” in all directions parallel to the first plane and is terminated only at edges of that region. The term “substantially,” in conjunction with continuous, is intended to indicate that while an absolute continuity is preferred, minor deviations from the absolute continuity may be tolerable as long as those deviations do not appreciably affect the performance of the fibrous structure (or a molding member) as designed and intended. “Substantially semi-continuous” or “semi-continuous” region refers an area which has “continuity” in all, but at least one, directions parallel to the first plane, and in which area one cannot connect any two points by an uninterrupted line running entirely within that area throughout the line's length. The semi-continuous framework may have continuity only in one direction parallel to the first plane. By analogy with the continuous region, described above, while an absolute continuity in all, but at least one, directions is preferred, minor deviations from such a continuity may be tolerable as long as those deviations do not appreciably affect the performance of the fibrous structure. “Discontinuous” or “discrete” regions or zones refer to discrete, and separated from one another areas or zones that are discontinuous in all directions parallel to the first plane. “Molding member” is a structural element that can be used as a support for the mixture of filaments and solid additives that can be deposited thereon during a process of making a fibrous structure, and as a forming unit to form (or “mold”) a desired microscopical geometry of a fibrous structure. The molding member may comprise any element that has the ability to impart a three-dimensional pattern to the fibrous structure being produced thereon, and includes, without limitation, a stationary plate, a belt, a cylinder/roll, a woven fabric, and a band. “Osmotic material” as used herein is a material that absorbs liquids by transfer of the liquids across the periphery of the material forming a gelatinous substance, which imbibes the liquids and tightly holds the liquids. In one example, osmotic materials retain greater than 5 times their weight of deionized water when subjected to centrifugal forces of less than or equal to 3000 G's for 10 to 15 minutes. In comparison, typically capillary absorbents retain about 1 times their weight under similar conditions. Non-limiting examples of osmotic materials include crosslinked polyacrylic acids and/or crosslinked carboxymethyl cellulose. “Osmotic material-free” as used herein with respect to a fibrous structure and/or article means that the fibrous structure and/or article contains less than an amount of osmotic material that results in the fibrous structure and/or article exhibiting a VFS of greater than 11 g/g as measured according to the Vertical Full Sheet (VFS) Test Method described herein. In one example, an osmotic material-free fibrous structure comprises 0% by dry weight of the fibrous structure and/or article of osmotic material. As used herein, the articles “a” and “an” when used herein, for example, “an anionic surfactant” or “a fiber” is understood to mean one or more of the material that is claimed or described. All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise indicated. Unless otherwise noted, all component or composition levels are in reference to the active level of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources. Article An article of the present invention comprises one or more and/or two or more and/or three or more and/or four or more fibrous webs (fibrous web plies), which comprise one or more fibrous structures, according to the present invention. It has unexpectedly been found that the arrangement of the fibrous structures and/or fibrous webs (fibrous web plies) within the articles of the present invention and/or type of fibrous structures and/or type of fibrous elements, for example filaments and/or fibers, within the articles of the present invention result in the article of the present invention exhibiting novel properties, such as bulk and/or absorbent properties without negatively impacting the softness and/or flexibility and/or stiffness of the articles. In one example, the articles of the present invention may comprise different combinations of fibrous webs (fibrous web plies) and/or fibrous structures and/or fibrous elements. For example, the articles of the present invention may comprise different combinations (associations) of wet-laid fibrous structures, for example 100% by weight of fibers, such as pulp fibers, for example wood pulp fibers (e.g., cellulosic wood pulp fibers) and co-formed fibrous structures, for example a mixture of filaments and fibers, such as polypropylene filaments and pulp fibers, such as wood pulp fibers (e.g., cellulosic wood pulp fibers), which allows for the creation of both wet and dry bulk, while maintaining a soft and/or flexibility and/or non-stiff sheet. This unique combination of properties is afforded, in this case, by the use of the co-formed fibrous structure, in which continuous filaments are combined with fibers in a way that the resultant bulk density of the sheet is very low. This low bulk density is maintained even when wet due the lack of collapse of the article, as the continuous filaments are not subject to water induced collapse. In contrast, such bulk in wet-laid fibrous structures is created via hydrogen bonding of the fibers within the wet-laid fibrous structure, which collapse if dry forming, such as embossing and/or microselfing, is used to create a soft fibrous structure with dry bulk (resulting in low wet bulk), or will be stiff if wet forming, such as forming the wet-laid fibrous structure on a molding member and/or subjecting the wet-laid fibrous structure to wet microcontraction during forming, is used to create a dry bulk that is resilient when wet. In one example, the articles of the present invention comprise less than 50% and/or less than 40% and/or less than 30% and/or less than 25% and/or less than 20% and/or less than 15% and/or greater than 0% and/or greater than 5% by weight of filaments, for example thermoplastic filaments such as polyolefin filaments, for example polypropylene filaments. In another example, the articles of the present invention allow for the optimization of different fibrous structures and/or fibrous webs (fibrous web plies) for different characteristics and/or properties. One example of this is how a very low density, high bulk co-formed fibrous structure that is strong can be placed with a wet formed, high bulk wet-laid fibrous structure that is very absorbent. The resultant article is one which is both highly absorbent, very compressible, and able to spring back after compression. This results in a spongelike article which is resilient under compression yet highly absorbent like a paper towel. Another example, of this is how a very low density, high bulk co-formed fibrous structure can be placed with a wet formed, high bulk wet-laid fibrous structure. The resultant article exhibits high bulk values when dry, are compressible under load and rebound when the load is relieved. Additionally, the resultant article exhibits high bulk, compressibility, and recovery when wet, due to the wet formed nature of the wet-laid fibrous structure and the co-formed fibrous structure, which is impervious to wet collapse. In another example, the articles of the present invention exhibit very high sheet and/or roll bulk without negatively impacting softness. This high bulk can be achieved through multiple inner fibrous structures and/or fibrous webs (fibrous web plies), with the interior fibrous structures and/or fibrous webs (fibrous web plies) comprised of high loft, pin-holed wet-laid fibrous structures. Co-formed fibrous structures, which contain continuous, thermoplastic filaments and pulp fibers, enable the use of high loft wet-laid fibrous structures because the filaments are used for strength (especially when wet). Furthermore, the commingled nature of the filaments and fibers within the co-formed fibrous structures allows for very high bulk fibrous structures that are both absorbent and soft, as individual fibers are commingled within a network of continuous filaments. Articles like these are very difficult to make via other technologies such as solely wet-laid technology due to the fact that the fibers, such as pulp fibers, must impart strength and bulk and absorbency. These different demands in the past have caused product developers to optimize for some attributes at the expense of others. In still another example, the articles of the present invention exhibit very high absorbencies without compromising softness of the article. This is achieved through the heterogenous composition of the article; namely, the combination of at least two different fibrous structures, for example at least one co-formed fibrous structure and at least one wet-laid fibrous structure. To allow for high absorbencies, wet-laid fibrous structure making process choices such as fiber furnish mix, fiber refining levels, and molding member, for example belt design upon which the wet-laid fibrous structure is formed, can be chosen to create a lofty, high absorbent capacity wet-laid fibrous structure that is soft and low in strength. The filaments, for example polypropylene filaments, present in the co-formed fibrous structure is relied upon to deliver the strength of the article, while still being soft and/or flexible and/or non-stiff both wet and dry. Additionally, the interspersion of fibers, for example pulp fibers, with the filaments within the co-formed fibrous structure adds to the soft, velvet-like hand feel of the article. In yet another example, the articles of the present invention exhibit very high absorbencies without compromising strength of the article. This is achieved through the heterogenous composition of the article; namely, the combination of at least two different fibrous structures, for example at least one co-formed fibrous structure and at least one wet-laid fibrous structure. The wet-laid structure can be optimized for high absorbent capacities and/or rates without having to compromise to maintain strength. To allow for high absorbencies, wet-laid fibrous structure making process choices such as fiber furnish mix, fiber refining levels, and molding member, for example belt design upon which the wet-laid fibrous structure is formed, can be chosen to create a lofty, high absorbent capacity wet-laid fibrous structure that is soft and low in strength. The filaments, for example polypropylene filaments, present in the co-formed fibrous structure is relied upon to deliver the strength of the article, while still being soft and/or flexible and/or non-stiff both wet and dry. Additionally, the interspersion of fibers, for example pulp fibers, with the filaments within the co-formed fibrous structure adds to the soft, velvet-like hand feel of the article. In another example, the articles of the present invention exhibit high absorbent capacity while still maintaining hand protection. This can be achieved by tailoring the density, capillary pressure, and absorbent capacity of the different fibrous structures within the article. In one example, high density and capillary pressure wet-laid fibrous structures on one or both of the exterior surfaces of the article allow for rapid redistribution of water on a surface of the article, while lower density fibrous structure, such as co-formed fibrous structures, in the interior of the article creates storage capacity. In another example, thin, low density fibrous structures on one or more of the exterior surfaces of the article allow for rapid acquisition of water by the inner, more dense, high capillary pressure fibrous structures, such as wet-laid fibrous structures, whose high capillary pressure structures will redistribute the water in the article and not give it back to the exterior surfaces of the article. In still another example, the articles of the present invention exhibit high bulk/low density without impacting the overall opacity of the articles. This can be achieved by the combining of differential density wet-laid fibrous structures, which have been wet formed such that relatively low density regions and relatively high density regions are formed in the wet-laid fibrous structure, to the extent that the low density regions of the wet-laid fibrous structure have very low basis weight, to the point of making pinholes. This is normally undesirable in wet-laid fibrous structures and/or wet-laid fibrous structure making processes, as the pinholes are detrimental to strength as well as opacity. When this wet-laid fibrous structure is combined with a co-formed fibrous structure the opacity significantly increases, creating a low density and high opacity article. In yet another example, the articles of the present invention are very reopenable while still maintaining consumer acceptable absorbent properties. This is achieved through the combination of fibrous structures comprising filaments and/or a mixture of filaments and fibers, and wet-laid fibrous structures. In one example, low basis weight filament-containing fibrous structures, such as scrims of filaments, for example scrims of polypropylene filaments, are arranged on one or more of the exterior surfaces of the articles, which in turn further comprises one or more inner fibrous structures comprising wet-laid fibrous structures and co-formed fibrous structures. This combination of materials creates an article exhibits very high bulk absorbency and at the same time exhibits high wet resiliency, allowing it to be easily reopened during use, especially after being wetted. In still another example, the articles of the present invention exhibit both high absorbent capacity and high surface drying properties. This combination is achieved through the combination of fibrous structures that exhibit different capillary pressures. One example of such an article that exhibits this characteristic is an article that has one or more wet-laid fibrous structure on one or more exterior surfaces of the articles, along with a co-formed fibrous structure as one or more inner fibrous structures within the articles. This low density co-formed fibrous structure core of the articles creates large absorbent capacity, while the wet-laid fibrous structure on the outside of the articles allows for consumer acceptable surface drying. In even yet another example, the articles of the present invention exhibit both high wet bulk and high surface drying properties. This combination is achieved through the combination of fibrous structures that exhibit high capillary pressure with fibrous structures that exhibit high bulk when wet. One example of such an article that exhibits these characteristic is one that has one or more wet-laid fibrous structures on one or more exterior surfaces of an article, along with a co-formed fibrous structure in the center of the article. The co-formed fibrous structure core does not collapse when wetted, while the wet-laid fibrous structure on the outside of the article allows for consumer acceptable surface drying. Non-limiting examples of articles of the present invention are described below in more detail. In one example, as shown inFIG.3, an article20of the present invention comprises three fibrous webs (fibrous web plies): 1) a first fibrous web (fibrous web ply) example of which is shown inFIGS.2A and2Bcomprising a co-formed fibrous structure22(a multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24(mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure22, 2) a second fibrous web (fibrous web ply) example of which is shown inFIGS.2A and2Bcomprising a co-formed fibrous structure22(a multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure22, and 3) a third fibrous web (fibrous web ply) comprising a paper web, for example a fibrous structure26(a mono-fibrous element fibrous structure), for example a textured fibrous structure, for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure, positioned between and associated with at least one and/or both of the first and second fibrous webs, the co-formed fibrous webs28(co-formed fibrous web plies). The fibrous webs may be associated with each other in one operation or in multiple operations, such as by combining two of the fibrous webs first and then combining the remaining fibrous web with the already combined fibrous webs. In one example, the article20shown inFIG.3is made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIG.4, an article20of the present invention comprises four fibrous webs (fibrous web plies) similar to the article shown inFIG.3above: 1) a first fibrous web (fibrous web ply) example of which is shown inFIGS.2A and2Bcomprising a co-formed fibrous structure22(a multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure22, 2) a second fibrous web (fibrous web ply) example of which is shown inFIGS.2A and2Bcomprising a co-formed fibrous structure22(a multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24(mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure, and 3) third and fourth fibrous webs (fibrous web plies) comprising paper webs, for example wet-laid fibrous structures26, (mono-fibrous element fibrous structures), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure, positioned between and associated with at least one and/or both of the first and second fibrous webs. The fibrous webs may be associated with each other in one operation or in multiple operations, such as by combining two or three of the fibrous webs first and then combining the remaining fibrous webs with the already combined fibrous webs. In one example, the article20shown inFIG.4is made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIG.5, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) a fibrous web (fibrous web ply) example of which is shown inFIGS.2A and2Bcomprising a co-formed fibrous structure22(multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure22, and 2) a second fibrous web (fibrous web ply) example of which is shown inFIGS.6A and6Bcomprising a co-formed fibrous structure22(multi-fibrous element fibrous structure) associated with one meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) on one surface of the co-formed fibrous structure22and a paper web, for example a wet-laid fibrous structure26(a mono-fibrous element fibrous structure), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure on the opposite surface of the co-formed fibrous structure22. The paper web, for example the wet-laid fibrous structure26may be further associated with a meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) on the wet-laid fibrous structure's surface opposite the co-formed fibrous structure22. The fibrous webs may be associated with each other in one operation, such as by combining the two fibrous webs such that the paper web, for example the wet-laid fibrous structure26is positioned between the two co-formed fibrous structures22in the article20. In one example, the article20shown inFIG.5is made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIG.7, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) two fibrous webs (fibrous web plies) examples of which are shown inFIGS.6A and6Bcomprising a co-formed fibrous structure22(multi-fibrous element fibrous structure) associated with one meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) on one surface of the co-formed fibrous structure22and a paper web, for example a wet-laid fibrous structure26(a mono-fibrous element fibrous structure), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure on the opposite surface of the fibrous structure. The paper web, for example the wet-laid fibrous structure26may be further associated with a meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) on the wet-laid fibrous structure's surface opposite the co-formed fibrous structure22. The fibrous webs may be associated with each other in one operation, such as by combining the two fibrous webs such that the paper webs, for example the wet-laid fibrous structures26are positioned between the two co-formed fibrous structures22in the article20. In one example, the article20shown inFIG.7is made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIG.8, an article20of the present invention comprises a single fibrous web (fibrous web ply): 1) a fibrous web (fibrous web ply) example of which is shown inFIGS.9A and9Bcomprising a paper web, for example a wet-laid fibrous structure26, such as a textured fibrous structure, (mono-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the wet-laid fibrous structure26. In one example, as shown inFIG.10, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) two fibrous webs (fibrous web plies) examples of which are shown inFIGS.9A and9Bcomprising a paper web, for example a wet-laid fibrous structure26, such as a textured fibrous structure, (mono-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the paper web, for example the wet-laid fibrous structure26. In one example, the article20shown inFIG.10is made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIG.11, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) a first fibrous web (fibrous web ply) example of which is shown inFIGS.9A and9Bcomprising a paper web, for example a wet-laid fibrous structure26, such as a textured fibrous structure, (mono-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the wet-laid fibrous structure26, and 2) a second fibrous web (fibrous web ply) example of which is shown inFIGS.6A and6Bcomprising a co-formed fibrous structure22(multi-fibrous element fibrous structure) associated with one meltblown fibrous structure24, for example two scrim layers of filaments, (mono-fibrous element fibrous structure) on one surface of the co-formed fibrous structure22and a paper web, for example a wet-laid fibrous structure26(a mono-fibrous element fibrous structure), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure on the opposite surface of the fibrous structure. The paper web, for example the wet-laid fibrous structure26may be further associated with a meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) on the wet-laid fibrous structure's surface opposite the co-formed fibrous structure22. The fibrous webs may be associated with each other in one operation, such as by combining the two fibrous webs such that the paper webs, for example the wet-laid fibrous structures26are positioned as shown inFIG.11. In one example, the article20shown inFIG.11is made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIG.12, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) a first fibrous web (fibrous web ply) example of which is shown inFIGS.9A and9Bcomprising a paper web, for example a wet-laid fibrous structure26, such as a textured fibrous structure, (mono-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the wet-laid fibrous structure26, and 2) a second fibrous web (fibrous web ply) example of which is shown inFIGS.2A and2Bcomprising a co-formed fibrous structure22(multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure22. The fibrous webs may be associated with each other in one operation, such as by combining the two fibrous webs as shown inFIG.12. In one example, the article20shown inFIG.12is made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIG.13, an article20of the present invention comprises a single fibrous web (fibrous web ply): 1) a fibrous web (fibrous web ply) example of which is shown inFIGS.14A and14Bcomprising a co-formed fibrous structure22(multi-fibrous element fibrous structure) associated with one meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) on one surface of the co-formed fibrous structure22and a paper web, for example a wet-laid fibrous structure26(a mono-fibrous element fibrous structure), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure on the opposite surface of the co-formed fibrous structure22. The paper web, for example the wet-laid fibrous structure26may be further associated with another co-formed fibrous structure22which in turn may be associated with another meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) such that the paper web, for example the wet-laid fibrous structure26is positioned between the two co-formed fibrous structures22. In one example, as shown inFIG.15, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) two fibrous webs (fibrous web plies) examples of which are shown inFIGS.6A and6Bcomprising a two different co-formed fibrous structures22or a variably density (in the z-direction) co-formed fibrous structure28example of which is shown inFIGS.16A and16B(multi-fibrous element fibrous structure) associated with one meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) on one surface of the co-formed fibrous structure22and a paper web, for example a wet-laid fibrous structure26(a mono-fibrous element fibrous structure), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure on the opposite surface of the fibrous structure. The paper web, for example the wet-laid fibrous structure26may be further associated with a meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) on the wet-laid fibrous structure's surface opposite the co-formed fibrous structure22. The fibrous webs may be associated with each other in one operation, such as by combining the two fibrous webs such that the paper webs, for example the wet-laid fibrous structures26are positioned between the two co-formed fibrous structures22in the article20. In one example, the article20shown inFIG.15is made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIG.17, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) two fibrous webs (fibrous web plies) examples of which are shown inFIGS.6A and6Bcomprising a co-formed fibrous structure22(multi-fibrous element fibrous structure) associated with one meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) on one surface of the co-formed fibrous structure22and a paper web, for example a wet-laid fibrous structure26(a mono-fibrous element fibrous structure), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure on the opposite surface of the fibrous structure. The paper web, for example the wet-laid fibrous structure26may be further associated with a meltblown fibrous structure24, for example a scrim layer of filaments, (mono-fibrous element fibrous structure) on the wet-laid fibrous structure's surface opposite the co-formed fibrous structure22. The fibrous webs may be associated with each other in one operation, such as by combining the two fibrous webs such that the co-formed fibrous structures22are positioned between the two paper webs, for example the two wet-laid fibrous structures26in the article20. In one example, the article20shown inFIG.17is made by combining the pre-formed fibrous webs (fibrous web plies). The article20shown inFIG.17is similar to the article20shown inFIG.7, with a different arrangement of the fibrous webs within the article20. In one example, as shown inFIG.18, an article20of the present invention comprises three fibrous webs (fibrous web plies): 1) a first fibrous web (fibrous web ply) example of which is shown inFIGS.2A and2Bcomprising a co-formed fibrous structure22(a multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure22forming a co-formed fibrous web28, 2) second and third fibrous webs (fibrous web plies) comprising paper webs, for example wet-laid fibrous structures26(mono-fibrous element fibrous structures), for example a textured fibrous structure, for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure associated with the co-formed fibrous web28(co-formed fibrous web plies). The paper webs, for example the wet-laid fibrous structure26may also be associated with one or more meltblown fibrous structures24, for example one or more scrim layers of filaments, present on one or both of the wet-laid fibrous structure's surfaces.FIG.19shows a similar article20to that shown inFIG.18except that the paper web, for example the wet-laid fibrous structure26forms at least one or both of the exterior surfaces of the article20. In other words, the paper web, for example the wet-laid fibrous structure26is not associated with a meltblown fibrous structure24, for example not associated with a scrim layer of filaments, that forms an exterior surface of the article20. The fibrous webs may be associated with each other in one operation or in multiple operations, such as by combining two of the fibrous webs first and then combining the remaining fibrous web with the already combined fibrous webs. In one example, the article20shown inFIG.18is made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIG.20, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) two fibrous webs (fibrous web plies) examples of which are shown inFIGS.21A and21Bcomprising a co-formed fibrous structure22(a multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure22forming a co-formed fibrous web28, wherein the co-formed fibrous web28is associated with a paper web, for example a wet-laid fibrous structure26(mono-fibrous element fibrous structure), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure. The combined webs may be embossed in an emboss nip33formed by one or more patterned emboss rolls39, one or more of which may be heated. The paper web, for example the wet-laid fibrous structure26may be associated with one or more meltblown fibrous structures24, for example one or more scrim layers of filaments, present on one or both of the wet-laid fibrous structure's surfaces. The fibrous webs may be associated with each other in one operation, such as by combining the fibrous webs (fibrous web plies) such that the paper webs, for example the wet-laid fibrous structures26are positioned between the co-formed fibrous webs28. In one example, the article20shown inFIG.20is made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIGS.22A and22B, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) two fibrous webs (fibrous web plies) examples of which are shown inFIGS.23A and23Bcomprising a co-formed fibrous structure22(a multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure22forming a co-formed fibrous web28, wherein the co-formed fibrous web28is associated with a paper web, for example a wet-laid fibrous structure26(mono-fibrous element fibrous structure), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure. The paper webs, for example wet-laid fibrous structures26may be formed on a textured collection device31and passed through a nip33formed between two rolls41, for example a heated steel roll and a rubber roll. The paper web, for example the wet-laid fibrous structure26may be associated with one or more meltblown fibrous structures24, for example one or more scrim layers of filaments, present on one or both of the wet-laid fibrous structure's surfaces. The fibrous webs may be associated with each other in one operation, such as by combining the fibrous webs (fibrous web plies) such that the paper webs, for example the wet-laid fibrous structures26are positioned between the co-formed fibrous webs28. In one example, the article20shown inFIGS.22A and22Bis made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIGS.24A and24B, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) two fibrous webs (fibrous web plies) examples of which are shown inFIGS.25A and25Bcomprising a co-formed fibrous structure22(a multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure22forming a co-formed fibrous web28, wherein the co-formed fibrous web28is associated with a paper web, for example a wet-laid fibrous structure26(mono-fibrous element fibrous structure), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure. The paper webs, for example wet-laid fibrous structures26may be formed on a textured collection device31and passed through a nip33formed between two rolls41, for example a heated steel roll and a rubber roll. The paper web, for example the wet-laid fibrous structure26may be associated with one or more meltblown fibrous structures24, for example one or more scrim layers of filaments, present on one or both of the wet-laid fibrous structure's surfaces. The fibrous webs may be associated with each other in one operation, such as by combining the fibrous webs (fibrous web plies) such that the paper webs, for example the wet-laid fibrous structures26are positioned between the co-formed fibrous webs28. In one example, the article20shown inFIGS.24A and24Bis made by combining the pre-formed fibrous webs (fibrous web plies). In one example, as shown inFIGS.26A and26B, an article20of the present invention comprises two fibrous webs (fibrous web plies): 1) two fibrous webs (fibrous web plies) examples of which are shown inFIGS.27A and27Bcomprising a co-formed fibrous structure22(a multi-fibrous element fibrous structure) associated with two meltblown fibrous structures24, for example two scrim layers of filaments, (mono-fibrous element fibrous structures), which function as scrims on opposite surfaces of the co-formed fibrous structure22forming a co-formed fibrous web28, wherein the co-formed fibrous web28is associated with a paper web, for example a wet-laid fibrous structure26(mono-fibrous element fibrous structure), for example a textured wet-laid fibrous structure, such as a 3D patterned wet-laid fibrous structure. The combined webs may be embossed in an emboss nip33formed by one or more patterned emboss rolls39, one or more of which may be heated. The paper web, for example the wet-laid fibrous structure26may be associated with one or more meltblown fibrous structures24, for example one or more scrim layers of filaments, present on one or both of the wet-laid fibrous structure's surfaces. The fibrous webs may be associated with each other in one operation, such as by combining the fibrous webs (fibrous web plies) such that the paper webs, for example the wet-laid fibrous structures26are positioned between the co-formed fibrous webs28. In one example, the article20shown inFIGS.26A and26Bis made by combining the pre-formed fibrous webs (fibrous web plies). Any of the meltblown fibrous structures24may be optional, especially if they represent an exterior surface of the articles20. In one example, the article20ofFIG.11may be void of the meltblown fibrous structure24forming the exterior surface of the article20, which is associated with the paper web, for example the wet-laid fibrous structure26. In another example, the combined fibrous webs shown inFIG.23Amay be combined with a paper web, for example a wet-laid fibrous structure26to form an article20. The paper web, for example the wet-laid fibrous structure26may be void of a meltblown fibrous structure24or may comprise one or more, two or more, meltblown fibrous structures24on at least one exterior surface and/or on both exterior surfaces (opposite surfaces). The articles of the present invention and/or any fibrous webs of the present invention may be subjected to any post-processing operations such as embossing operations, printing operations, tuft-generating operations, thermal bonding operations, ultrasonic bonding operations, perforating operations, surface treatment operations such as application of lotions, silicones and/or other materials and mixtures thereof. Physical Properties of Articles of the Present Invention The articles of the present inventions due their fibrous structures and/or the arrangement of the fibrous structures in the articles exhibit novel physical properties, for example absorbent, strength, fluid retention, surface drying, thickness, bulk, compressibility, flexibility, and resiliency, and novel combinations of two or more of these properties. Table 1 below shows data from inventive samples and prior art samples. TABLE 1BWContinuous Filament% ContinuousCommingled FilamentPaper WebSpecifics(gsm)ContainingFilament& FiberContainingINVENTION A82Yes14.9%YesYesINVENTION B81.6Yes12.9%YesYesINVENTION C84.6Yes7.7%YesYesINVENTION D84.0Yes15.2%YesYesINVENTION E58.5Yes20.9%YesYesPrior Art Bounty53.8No0NoYesPrior Art Viva (DRC)59.8No0NoYesPrior Art Brawny51.5No0NoYes(Fabric TAD)Prior Art49.1No0NoYesSparkle (Conv)Prior Art with58.7Yes21.3%YesNoContinuous FilamentPrior Art with61.6Yes20.3%YesNoContinuous FilamentPrior Art with55.4Yes22.6%YesNoContinuous FilamentFilament andPVD % totalPVD % totalPVD % totalcommingledvolume 2.5-volume >225volume 301-Specificsoutward facing30 micronmicron600 micronINVENTION AYes6.3%33.5%12.0%INVENTION BNo6.8%45.7%26.0%INVENTION CNo7.0%43.7%27.8%INVENTION DYes8.5%24.1%10.0%INVENTION EYes0.5%38.0%9.1%Prior Art BountyNo12.3%42.6%22.7%Prior Art Viva (DRC)No12.3%5.7%2.1%Prior Art BrawnyNo12.6%34.0%10.9%(Fabric TAD)Prior ArtNo10.7%59.1%35.2%Sparkle (Conv)Prior Art withYes0.4%0.3%0.0%Continuous FilamentPrior Art withYes0.3%10.0%5.2%Continuous FilamentPrior Art withYes6.1%9.6%4.2%Continuous FilamentPlate StiffnessFlexuralBendingPlatecorrected forRigidityFlexuralModulusStiffnessBasis WeightOverhangRigidity[(mg*cm · g)/Specifics(N*mm)(N*mg/M)Avg. (cm)(mg*cm)mils3]INVENTION A14.70.18010.7412704.69INVENTION B16.30.20012.720706.12INVENTION C14.30.16912.721565.56INVENTION D13.70.16310.512197.36INVENTION E8.40.1448.84985.07Prior Art Bounty11.30.21011.293910.18Prior Art Viva (DRC)4.50.0755.51244.03Prior Art Brawny13.90.27010.675917.28(Fabric TAD)Prior Art15.60.31711.8101126.35Sparkle (Conv)Prior Art with6.00.1026.72204.74Continuous FilamentPrior Art with3.60.0595.31162.55Continuous FilamentPrior Art with7.10.1298.339522.19Continuous FilamentDry ThickWet ThickCompressionCompressionEmtec(mils* mils/Dry Thick(mils* mils/Wet ThickTS7 (dBlog (grCompressivelog (grCompressiveSpecificsV2rms)force/in2))Recoveryforce/in2))RecoveryINVENTION A10.651408102236461602INVENTION B15.63100781232511709INVENTION C17.33127198949782125INVENTION D10.3676460623991235INVENTION E11.36144294527401137Prior Art Bounty16.136274691792798Prior Art Viva (DRC)16.71246187429159Prior Art Brawny25.07418320658291(Fabric TAD)Prior Art25.0331420836147Sparkle (Conv)Prior Art with9.01————Continuous FilamentPrior Art with9.5556434795468Continuous FilamentPrior Art with11.06235192412233Continuous FilamentLow LoadMid LoadDry MDDry CDDry TensileDry TensileSpecificsWet ResiliencyWet ResiliencyTEATEAModulus MDModulus CDINVENTION A0.970.76160572080983INVENTION B1.140.991507117551766INVENTION C1.140.901064712551369INVENTION D1.150.921556125501621INVENTION E0.960.65124721945597Prior Art Bounty1.080.85945118913438Prior Art Viva (DRC)0.910.678044685856Prior Art0.870.68803721433656Sparkle (Conv)Prior Art0.540.20912427106551Bounty BasicPrior Art with——1431241469406Continuous FilamentPrior Art with0.920.77119103665.8363Continuous FilamentPrior Art with0.950.7516612834791216.4Continuous FilamentGeo MeanDry TensileWetWet BEADryDry BEAWet Burst/SpecificsModulus (g/cm* %)Burst (g)(g-in/in2)Burst (g)(g-in/in2)Dry BurstINVENTION A143076034.697833.40.78INVENTION B176073326.1113231.80.65INVENTION C131151017.989724.40.57INVENTION D203379337.4104731.90.76INVENTION E107763927.980227.90.80Prior Art Bounty25504378.2103218.90.42Prior Art Viva (DRC)7652757.0362618.20.44Prior Art Brawny27992955.8277414.20.38(Fabric TAD)Prior Art42141773.4164810.80.27Sparkle (Conv)Prior Art with77278639.793851.80.84Continuous FilamentPrior Art with49274528.4873627.31.01Continuous FilamentPrior Art with205784030.879834.21.05Continuous FilamentTOTAL DRYWet BEA/WetWetWetWetWet/DryTENSILESpecificsDry BEAMD (g/in)MD TEACD (g/in)CD TEACD TEA(g/in)INVENTION A1.0448613019684.41.4771190INVENTION B0.8219628.329137.90.5311586INVENTION C0.7334047.818217.50.3761227INVENTION D1.1759810728192.81.5111370INVENTION E1.004821292391261.743994Prior Art Bounty0.4341023.5627814.820.2932203Prior Art Viva (DRC)0.3933235.618616.60.379856Prior Art Brawny0.4126918.12529.80.2621614(Fabric TAD)Prior Art0.3227612.61443.50.1451685Sparkle (Conv)Prior Art with0.77417188.0257158.01.274660Continuous FilamentPrior Art with1.04425.6125.1238.493.80.911750Continuous FilamentPrior Art with0.90523188.02290.4137.021.072796Continuous FilamentAbsorptiveWet TotalGeo MeanHFSVFSRate CRTCRTCRTSpecificsTensile (g/in)Wet TEA(g/g)(g/g)(g/sec)(g/in2)(g/g)INVENTION A68210521.514.20.420.8917.99INVENTION B4873323.613.00.501.0219.36INVENTION C5222925.911.60.651.3124.03INVENTION D87910019.414.40.440.8817.26INVENTION E72112724.514.30.430.7921.07Prior Art Bounty6881923.09.10.580.6819.63Prior Art Viva (DRC)5172414.59.80.210.4712.09Prior Art Brawny5211318.08.30.250.4814.30(Fabric TAD)Prior Art420713.15.40.3380.309.45Sparkle (Conv)Prior Art with67417216.611.80.33—13.30Continuous FilamentPrior Art with66410816.711.60.270.5914.03Continuous FilamentPrior Art with79616113.69.50.210.4211.21Continuous FilamentSSTDry CaliperWet CaliperBulkWet BulkWet Web-Liquid Break-Specifics(g/sec0.5)(mils)(mils)(cc/g)(cc/g)Web CoFThrough (seconds)INVENTION A1.4658.341.218.112.80.822.66INVENTION B2.362.850.919.515.80.983.22INVENTION C2.8665.756.519.717.02.280.64INVENTION D1.5149.540.915.012.40.873.38INVENTION E1.6641.634.318.114.9—2.29Prior Art Bounty1.840.7233.019.215.61.920.74Prior Art Viva (DRC)0.5728.2121.412.09.12.022.16Prior Art Brawny—31.823.915.711.81.960.62(Fabric TAD)Prior Art0.4030.414.715.77.61.182.56Sparkle (Conv)Prior Art with0.6932.427.614.011.9—2.86Continuous FilamentPrior Art with0.7432.1825.913.310.71.151.44Continuous FilamentPrior Art with0.4823.5421.6610.89.90.682.18Continuous Filament In addition to or alternatively, the articles, for example articles comprising a co-formed fibrous structure and optionally other fibrous structures, of the present invention, when in roll form, may exhibit novel roll properties. In one example, an article of the present invention, for example an article comprising a co-formed fibrous structure, may exhibit a Roll Firmness at 7.00 N of less than 11.5 and/or less 11.0 and/or less than 9.5 and/or less than 9.0 and/or less than 8.5 and/or less than 8.0 and/or less than 7.5 mm as measured according to the Roll Firmness Test Method described herein. In one example, a co-formed fibrous structure and/or a co-formed fibrous web (co-formed fibrous web ply) in roll form may exhibit a roll firmness at 7.00 N of less than 11.5 and/or less 11.0 and/or less than 9.5 and/or less than 9.0 and/or less than 8.5 and/or less than 8.0 and/or less than 7.5 mm as measured according to the Roll Firmness Test Method described herein. Fibrous Webs (Fibrous Web Plies) Non-limiting examples of fibrous webs (fibrous web plies) according to the present invention comprise one or more and/or two or more and/or three or more and/or four or more and/or five or more and/or six or more and/or seven or more fibrous structures that are associated with one another, such as by compression bonding (for example by passing through a nip formed by two rollers), thermal bonding (for example by passing through a nip formed by two rollers where at least one of the rollers is heated to a temperature of at least about 120° C. (250° F.)), microselfing, needle punching, and gear rolling, to form a unitary structure. Wet-Laid Fibrous Structure (an Example of a Mono-Fibrous Element Fibrous Structure) The wet-laid fibrous structure comprises a plurality of fibrous elements, for example a plurality of fibers. In one example, the wet-laid fibrous structure comprises a plurality of naturally-occurring fibers, for example pulp fibers, such as wood pulp fibers (hardwood and/or softwood pulp fibers). In another example, the wet-laid fibrous structure comprises a plurality of non-naturally occurring fibers (synthetic fibers), for example staple fibers, such as rayon, lyocell, polyester fibers, polycaprolactone fibers, polylactic acid fibers, polyhydroxyalkanoate fibers, and mixtures thereof. The mono-fibrous element fibrous structure may comprise one or more filaments, such as polyolefin filaments, for example polypropylene and/or polyethylene filaments, starch filaments, starch derivative filaments, cellulose filaments, polyvinyl alcohol filaments. The wet-laid fibrous structure of the present invention may be single-ply or multi-ply web material. In other words, the wet-laid fibrous structures of the present invention may comprise one or more wet-laid fibrous structures, the same or different from each other so long as one of them comprises a plurality of pulp fibers. In one example, the wet-laid fibrous structure comprises a wet laid fibrous structure ply, such as a through-air-dried fibrous structure ply, for example an uncreped, through-air-dried fibrous structure ply and/or a creped, through-air-dried fibrous structure ply. In another example, the wet-laid fibrous structure and/or wet laid fibrous structure ply may exhibit substantially uniform density. In another example, the wet-laid fibrous structure and/or wet laid fibrous structure ply may comprise a surface pattern. In one example, the surface pattern comprises a one or more relatively high density regions and one or more relatively low density regions. In another example, the surface pattern comprises one or more relatively high elevation regions and one or more relatively low elevation regions. In yet another example, the surface pattern comprises one or more relatively high basis weight regions and one or more relatively low basis weight regions. In still another example, the surface pattern is a non-random, repeating pattern, which may comprise a plurality of discrete regions dispersed throughout a continuous network. At least a portion of the plurality of discrete regions may exhibit a value of a common intensive property (such as density, bulk, and/or basis weight) that is different from the value of the common intensive property exhibited by the continuous network. In one example, the wet laid fibrous structure ply comprises a conventional wet-pressed fibrous structure ply. The wet laid fibrous structure ply may comprise a fabric-creped fibrous structure ply. The wet laid fibrous structure ply may comprise a belt-creped fibrous structure ply. In still another example, the wet-laid fibrous structure may comprise an air laid fibrous structure ply. The wet-laid fibrous structures of the present invention may comprise a surface softening agent or be void of a surface softening agent, such as silicones, quaternary ammonium compounds, lotions, and mixtures thereof. In one example, the sanitary tissue product is a non-lotioned wet-laid fibrous structure. The wet-laid fibrous structures of the present invention may comprise trichome fibers or may be void of trichome fibers. Patterned Molding Members The wet-laid fibrous structures of the present invention may be formed on patterned molding members that result in the wet-laid fibrous structures of the present invention. In one example, the pattern molding member comprises a non-random repeating pattern. In another example, the pattern molding member comprises a resinous pattern. In one example, the wet-laid fibrous structure comprises a textured surface. In another example, the wet-laid fibrous structure comprises a surface comprising a three-dimensional (3D) pattern, for example a 3D pattern imparted to the wet-laid fibrous structure by a patterned molding member. Non-limiting examples of suitable patterned molding members include patterned felts, patterned forming wires, patterned rolls, patterned fabrics, and patterned belts utilized in conventional wet-pressed papermaking processes, air-laid papermaking processes, and/or wet-laid papermaking processes that produce 3D patterned sanitary tissue products and/or 3D patterned fibrous structure plies employed in sanitary tissue products. Other non-limiting examples of such patterned molding members include through-air-drying fabrics and through-air-drying belts utilized in through-air-drying papermaking processes that produce through-air-dried fibrous structures, for example 3D patterned through-air dried fibrous structures, and/or through-air-dried sanitary tissue products comprising the wet-laid fibrous structure. A “reinforcing element” may be a desirable (but not necessary) element in some examples of the molding member, serving primarily to provide or facilitate integrity, stability, and durability of the molding member comprising, for example, a resinous material. The reinforcing element can be fluid-permeable or partially fluid-permeable, may have a variety of embodiments and weave patterns, and may comprise a variety of materials, such as, for example, a plurality of interwoven yarns (including Jacquard-type and the like woven patterns), a felt, a plastic, other suitable synthetic material, or any combination thereof. Non-limiting examples of patterned molding members suitable for use in the present invention comprises a through-air-drying belts. The through-air-drying belts may comprise a plurality of continuous knuckles, discrete knuckles, semi-continuous knuckles and/or continuous pillows, discrete pillows, and semi-continuous pillows formed by resin arranged in a non-random, repeating pattern supported on a support fabric comprising filaments, such as a forming fabric. The resin is patterned such that deflection conduits that contain little to know resin present in the pattern and result in the fibrous structure being formed on the patterned molding member having one or more pillow regions (low density regions) compared to the knuckle regions that are imparted to the fibrous structure by the resin areas. Non-limiting Examples of Making Wet-laid Fibrous Structures In one non-limiting example, the wet-laid fibrous structure is made on a molding member of the present invention. The method may be a paper web, for example a fibrous structure making process that uses a cylindrical dryer such as a Yankee (a Yankee-process) (creped) or it may be a Yankeeless process (uncreped) as is used to make substantially uniform density and/or uncreped wet-laid fibrous structures (fibrous structures). In one example, a process for making a paper web, for example a fibrous structure according to the present invention comprises supplying an aqueous dispersion of fibers (a fibrous or fiber furnish or fiber slurry) to a headbox which can be of any convenient design. From the headbox the aqueous dispersion of fibers is delivered to a first foraminous member (forming wire) which is typically a Fourdrinier wire, to produce an embryonic fibrous structure. The embryonic fibrous structure is brought into contact with a patterned molding member, such as a 3D patterned through-air-drying belt. While in contact with the patterned molding member, the embryonic fibrous structure will be deflected, rearranged, and/or further dewatered. This can be accomplished by applying differential speeds and/or pressures. After the embryonic fibrous structure has been associated with the patterned molding member, fibers within the embryonic fibrous structure are deflected into pillows (“deflection conduits”) present in the patterned molding member. In one example of this process step, there is essentially no water removal from the embryonic fibrous structure through the deflection conduits after the embryonic fibrous structure has been associated with the patterned molding member but prior to the deflecting of the fibers into the deflection conduits. Further water removal from the embryonic fibrous structure can occur during and/or after the time the fibers are being deflected into the deflection conduits. Water removal from the embryonic fibrous structure may continue until the consistency of the embryonic fibrous structure associated with patterned molding member is increased to from about 25% to about 35%. Once this consistency of the embryonic fibrous structure is achieved, then the embryonic fibrous structure can be referred to as an intermediate fibrous structure. As noted, water removal occurs both during and after deflection; this water removal may result in a decrease in fiber mobility in the embryonic web material. This decrease in fiber mobility may tend to fix and/or freeze the fibers in place after they have been deflected and rearranged. Of course, the drying of the web material in a later step in the process of this invention serves to more firmly fix and/or freeze the fibers in position. Any convenient means conventionally known in the papermaking art can be used to dry the intermediate fibrous structure. Examples of such suitable drying process include subjecting the intermediate fibrous structure to conventional and/or flow-through dryers and/or Yankee dryers. In one example of a drying process, the intermediate fibrous structure may first pass through an optional predryer. This predryer can be a conventional flow-through dryer (hot air dryer) well known to those skilled in the art. Optionally, the predryer can be a so-called capillary dewatering apparatus. In such an apparatus, the intermediate fibrous structure passes over a sector of a cylinder having preferential-capillary-size pores through its cylindrical-shaped porous cover. Optionally, the predryer can be a combination capillary dewatering apparatus and flow-through dryer. The quantity of water removed in the predryer may be controlled so that a predried fibrous structure exiting the predryer has a consistency of from about 30% to about 98%. The predried fibrous structure may be applied to a surface of a Yankee dryer via a nip with pressure, the pattern formed by the top surface of patterned molding member is impressed into the predried web material to form a 3D patterned fibrous structure, for example a 3D patterned wet-laid fibrous structure of the present invention. The 3D patterned wet-laid fibrous structure is then adhered to the surface of the Yankee dryer where it can be dried to a consistency of at least about 95%. The 3D patterned wet-laid fibrous structure can then be foreshortened by creping the 3D patterned wet-laid fibrous structure with a creping blade to remove the 3D patterned wet-laid fibrous structure from the surface of the Yankee dryer resulting in the production of a 3D patterned creped wet-laid fibrous structure in accordance with the present invention. As used herein, foreshortening refers to the reduction in length of a dry (having a consistency of at least about 90% and/or at least about 95%) web material which occurs when energy is applied to the dry web material in such a way that the length of the dry web material is reduced and the fibers in the dry web material are rearranged with an accompanying disruption of fiber-fiber bonds. Foreshortening can be accomplished in any of several well-known ways. One common method of foreshortening is creping. Another method of foreshortening that is used to make the wet-laid fibrous structures of the present invention is wet microcontraction. Further, the wet-laid fibrous structure may be subjected to post processing steps such as calendaring, tuft generating operations, and/or embossing and/or converting. Co-Formed Fibrous Structures The co-formed fibrous structures of the present invention comprise a plurality of filaments and a plurality of solid additives. The filaments and the solid additives may be commingled together. In one example, the fibrous structure is a coform fibrous structure comprising filaments and solid additives. The filaments may be present in the fibrous structures of the present invention at a level of less than 90% and/or less than 80% and/or less than 65% and/or less than 50% and/or greater than 5% and/or greater than 10% and/or greater than 20% and/or from about 10% to about 50% and/or from about 25% to about 45% by weight of the fibrous structure on a dry basis. The solid additives may be present in the fibrous structures of the present invention at a level of greater than 10% and/or greater than 25% and/or greater than 50% and/or less than 100% and/or less than 95% and/or less than 90% and/or less than 85% and/or from about 30% to about 95% and/or from about 50% to about 85% by weight of the fibrous structure on a dry basis. The filaments and solid additives may be present in the fibrous structures of the present invention at a weight ratio of filaments to solid additive of greater than 10:90 and/or greater than 20:80 and/or less than 90:10 and/or less than 80:20 and/or from about 25:75 to about 50:50 and/or from about 30:70 to about 45:55. In one example, the filaments and solid additives are present in the fibrous structures of the present invention at a weight ratio of filaments to solid additives of greater than 0 but less than 1. In one example, the fibrous structures of the present invention exhibit a basis weight of from about 10 gsm to about 1000 gsm and/or from about 10 gsm to about 500 gsm and/or from about 15 gsm to about 400 gsm and/or from about 15 gsm to about 300 gsm as measured according to the Basis Weight Test Method described herein. In another example, the fibrous structures of the present invention exhibit a basis weight of from about 10 gsm to about 200 gsm and/or from about 20 gsm to about 150 gsm and/or from about 25 gsm to about 125 gsm and/or from about 30 gsm to about 100 gsm and/or from about 30 gsm to about 80 gsm as measured according to the Basis Weight Test Method described herein. In still another example, the fibrous structures of the present invention exhibit a basis weight of from about 80 gsm to about 1000 gsm and/or from about 125 gsm to about 800 gsm and/or from about 150 gsm to about 500 gsm and/or from about 150 gsm to about 300 gsm as measured according to the Basis Weight Test Method described herein. In one example, the fibrous structure of the present invention comprises a core component. A “core component” as used herein means a fibrous structure comprising a plurality of filaments and optionally a plurality of solid additives. In one example, the core component is a coform fibrous structure comprising a plurality of filaments and a plurality of solid additives, for example pulp fibers. In one example, the core component is the component that exhibits the greatest basis weight with the fibrous structure of the present invention. In one example, the total core components present in the fibrous structures of the present invention exhibit a basis weight that is greater than 50% and/or greater than 55% and/or greater than 60% and/or greater than 65% and/or greater than 70% and/or less than 100% and/or less than 95% and/or less than 90% of the total basis weight of the fibrous structure of the present invention as measured according to the Basis Weight Test Method described herein. In another example, the core component exhibits a basis weight of greater than 12 gsm and/or greater than 14 gsm and/or greater than 16 gsm and/or greater than 18 gsm and/or greater than 20 gsm and/or greater than 25 gsm as measured according to the Basis Weight Test Method described herein. “Consolidated region” as used herein means a region within a fibrous structure where the filaments and optionally the solid additives have been compressed, compacted, and/or packed together with pressure and optionally heat (greater than 150° F.) to strengthen the region compared to the same region in its unconsolidated state or a separate region which did not see the compression or compacting pressure. In one example, a region is consolidated by forming unconsolidated regions within a fibrous structure on a patterned molding member and passing the unconsolidated regions within the fibrous structure while on the patterned molding member through a pressure nip, such as a heated metal anvil roll (about 275° F.) and a rubber anvil roll with pressure to compress the unconsolidated regions into one or more consolidated regions. In one example, the filaments present in the consolidated region, for example on the side of the fibrous structure that is contacted by the heated roll comprises fused filaments that create a skin on the surface of the fibrous structure, which may be visible via SEM images. The fibrous structure of the present invention may, in addition a core component, further comprise a scrim component. “Scrim component” as used herein means a fibrous structure comprising a plurality of filaments. In one example, the total scrim components present in the fibrous structures of the present invention exhibit a basis weight that is less than 25% and/or less than 20% and/or less than 15% and/or less than 10% and/or less than 7% and/or less than 5% and/or greater than 0% and/or greater than 1% of the total basis weight of the fibrous structure of the present invention as measured according to the Basis Weight Test Method described herein. In another example, the scrim component exhibits a basis weight of 10 gsm or less and/or less than 10 gsm and/or less than 8 gsm and/or less than 6 gsm and/or greater than 5 gsm and/or less than 4 gsm and/or greater than 0 gsm and/or greater than 1 gsm as measured according to the Basis Weight Test Method described herein. In one example, at least one of the core components of the fibrous structure comprises a plurality of solid additives, for example pulp fibers, such as comprise wood pulp fibers and/or nonwood pulp fibers. In one example, at least one of the core components of the fibrous structure comprises a plurality of core filaments. In another example, at least one of the core components comprises a plurality of solid additives and a plurality of the core filaments. In one example, the solid additives and the core filaments are present in a layered orientation within the core component. In one example, the core filaments are present as a layer between two solid additive layers. In another example, the solid additives and the core filaments are present in a coform layer. At least one of the core filaments comprises a polymer, for example a thermoplastic polymer, such as a polyolefin. The polyolefin may be selected from the group consisting of: polypropylene, polyethylene, and mixtures thereof. In another example, the thermoplastic polymer of the core filament may comprise a polyester. In one example, at least one of the scrim components is adjacent to at least one of the core components within the fibrous structure. In another example, at least one of the core components is positioned between two scrim components within the fibrous structure. In one example, at least one of the scrim components of the fibrous structure of the present invention comprises a plurality of scrim filaments, for example scrim filaments, wherein the scrim filaments comprise a polymer, for example a thermoplastic and/or hydroxyl polymer as described above with reference to the core components. In one example, at least one of the scrim filaments exhibits an average fiber diameter of less than 50 and/or less than 25 and/or less than 10 and/or at least 1 and/or greater than 1 and/or greater than 3 μm as measured according to the Average Diameter Test Method described herein. The average fiber diameter of the core filaments is less than 250 and/or less than 200 and/or less than 150 and/or less than 100 and/or less than 50 and/or less than 30 and/or less than 25 and/or less than 10 and/or greater than 1 and/or greater than 3 μm as measured according to the Average Diameter Test Method described herein. In one example, the fibrous structures of the present invention may comprise any suitable amount of filaments and any suitable amount of solid additives. For example, the fibrous structures may comprise from about 10% to about 70% and/or from about 20% to about 60% and/or from about 30% to about 50% by dry weight of the fibrous structure of filaments and from about 90% to about 30% and/or from about 80% to about 40% and/or from about 70% to about 50% by dry weight of the fibrous structure of solid additives, such as wood pulp fibers. In one example, the filaments and solid additives of the present invention may be present in fibrous structures according to the present invention at weight ratios of filaments to solid additives of from at least about 1:1 and/or at least about 1:1.5 and/or at least about 1:2 and/or at least about 1:2.5 and/or at least about 1:3 and/or at least about 1:4 and/or at least about 1:5 and/or at least about 1:7 and/or at least about 1:10. In one example, the solid additives, for example wood pulp fibers, may be selected from the group consisting of softwood kraft pulp fibers, hardwood pulp fibers, and mixtures thereof. Non-limiting examples of hardwood pulp fibers include fibers derived from a fiber source selected from the group consisting of: Acacia, Eucalyptus, Maple, Oak, Aspen, Birch, Cottonwood, Alder, Ash, Cherry, Elm, Hickory, Poplar, Gum, Walnut, Locust, Sycamore, Beech, Catalpa, Sassafras, Gmelina, Albizia, Anthocephalus, and Magnolia. Non-limiting examples of softwood pulp fibers include fibers derived from a fiber source selected from the group consisting of: Pine, Spruce, Fir, Tamarack, Hemlock, Cypress, and Cedar. In one example, the hardwood pulp fibers comprise tropical hardwood pulp fibers. Non-limiting examples of suitable tropical hardwood pulp fibers include Eucalyptus pulp fibers, Acacia pulp fibers, and mixtures thereof. In one example, the wood pulp fibers comprise softwood pulp fibers derived from the kraft process and originating from southern climates, such as Southern Softwood Kraft (SSK) pulp fibers. In another example, the wood pulp fibers comprise softwood pulp fibers derived from the kraft process and originating from northern climates, such as Northern Softwood Kraft (NSK) pulp fibers. The wood pulp fibers present in the fibrous structure may be present at a weight ratio of softwood pulp fibers to hardwood pulp fibers of from 100:0 and/or from 90:10 and/or from 86:14 and/or from 80:20 and/or from 75:25 and/or from 70:30 and/or from 60:40 and/or about 50:50 and/or to 0:100 and/or to 10:90 and/or to 14:86 and/or to 20:80 and/or to 25:75 and/or to 30:70 and/or to 40:60. In one example, the weight ratio of softwood pulp fibers to hardwood pulp fibers is from 86:14 to 70:30. In one example, the fibrous structures of the present invention comprise one or more trichomes. Non-limiting examples of suitable sources for obtaining trichomes, especially trichome fibers, are plants in the Labiatae (Lamiaceae) family commonly referred to as the mint family Examples of suitable species in the Labiatae family includeStachys byzantina, also known asStachys lanatacommonly referred to as lamb's ear, woolly betony, or woundwort. The termStachys byzantinaas used herein also includes cultivarsStachys byzantina‘Primrose Heron’,Stachys byzantina‘Helene von Stein’ (sometimes referred to asStachys byzantina‘Big Ears’),Stachys byzantina‘Cotton Boll’,Stachys byzantina‘Variegated’ (sometimes referred to asStachys byzantina‘Striped Phantom’), andStachys byzantina‘Silver Carpet’. Non-limiting examples of suitable polypropylenes for making the filaments of the present invention are commercially available from Lyondell-Basell and Exxon-Mobil. Any hydrophobic or non-hydrophilic materials within the fibrous structure, such as polypropylene filaments, may be surface treated and/or melt treated with a hydrophilic modifier. Non-limiting examples of surface treating hydrophilic modifiers include surfactants, such as Triton X-100. Non-limiting examples of melt treating hydrophilic modifiers that are added to the melt, such as the polypropylene melt, prior to spinning filaments, include hydrophilic modifying melt additives such as VW351 and/or S-1416 commercially available from Polyvel, Inc. and Irgasurf commercially available from Ciba. The hydrophilic modifier may be associated with the hydrophobic or non-hydrophilic material at any suitable level known in the art. In one example, the hydrophilic modifier is associated with the hydrophobic or non-hydrophilic material at a level of less than about 20% and/or less than about 15% and/or less than about 10% and/or less than about 5% and/or less than about 3% to about 0% by dry weight of the hydrophobic or non-hydrophilic material. The fibrous structures of the present invention may include optional additives, each, when present, at individual levels of from about 0% and/or from about 0.01% and/or from about 0.1% and/or from about 1% and/or from about 2% to about 95% and/or to about 80% and/or to about 50% and/or to about 30% and/or to about 20% by dry weight of the fibrous structure. Non-limiting examples of optional additives include permanent wet strength agents, temporary wet strength agents, dry strength agents such as carboxymethylcellulose and/or starch, softening agents, lint reducing agents, opacity increasing agents, wetting agents, odor absorbing agents, perfumes, temperature indicating agents, color agents, dyes, osmotic materials, microbial growth detection agents, antibacterial agents, liquid compositions, surfactants, and mixtures thereof. The fibrous structure of the present invention may itself be a sanitary tissue product. It may be convolutedly wound about a core to form a roll. It may be combined with one or more other fibrous structures as a ply to form a multi-ply sanitary tissue product. In one example, a co-formed fibrous structure of the present invention may be convolutedly wound about a core to form a roll of co-formed sanitary tissue product. The rolls of sanitary tissue products may also be coreless. Method for Making a Co-Formed Fibrous Structure A non-limiting example of a method for making a fibrous structure according to the present invention comprises the steps of: 1) collecting a mixture of filaments and solid additives, such as fibers, for example pulp fibers, onto a collection device, for example a through-air-drying fabric or other fabric or a patterned molding member of the present invention. This step of collecting the filaments and solid additives on the collection device may comprise subjecting the co-formed fibrous structure while on the collection device to a consolidation step whereby the co-formed fibrous structure, while present on the collection device, is pressed between a nip, for example a nip formed by a flat or even surface rubber roll and a flat or even surface or patterned, heated (with oil) or unheated metal roll. In another example, the co-forming method may comprise the steps of a) collecting a plurality of filaments onto a collection device, for example a belt or fabric, such as a patterned molding member, to form a scrim component (a meltblown fibrous structure. The collection of the plurality of filaments onto the collection device to form the scrim component may be vacuum assisted by a vacuum box. Once the scrim component (meltblown fibrous structure) is formed on the collection device, the next step is to mix, such as commingle, a plurality of solid additives, such as fibers, for example pulp fibers, such as wood pulp fibers, with a plurality of filaments, such as in a coform box, and collecting the mixture on the scrim component carried on the collection device to form a core component. Optionally, an additional scrim component (meltblown fibrous structure) comprising filaments may be added to the core component to sandwich the core component between two scrim components. The meltblown die used to make the meltblown fibrous structures and/or filaments herein may be a multi-row capillary die and/or a knife-edge die. In one example, the meltblown die is a multi-row capillary die. NON-LIMITING EXAMPLES Example 1 A 1.0 gsm meltblown fibrous structure24comprising meltblown filaments23is laid down upon a collection device31, for example an Albany International Velostat 170pc740 belt (“forming fabric”), (available from Albany International, Rochester, N.H.) traveling at 240 ft/min. The meltblown filaments23of the meltblown fibrous structure24are comprised of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951 and are spun from a die25, for example a multi-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.), at a mass flow of 28 g/min and a ghm of 0.22 and is attenuated with 16.4 kg/min of 204° C. (400° F.) air. An example of this process is shown inFIG.2B. Then, fibers27, for example pulp fibers such as 440 grams per minute of Koch Industries 4725 semi-treated SSK, are fed into a hammer mill29and individualized into fibers27, for example cellulose pulp fibers, which are pneumatically conveyed into a coforming box, example of which is described in U.S. Patent Publication No. US 2016/0355950A1 filed Dec. 16, 2015, which is incorporated herein by reference. In the coforming box, the fibers27, for example pulp fibers, are commingled with meltblown filaments23. The meltblown filaments23are comprised of a blend of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951. The meltblown filaments23are extruded/spun from a die25, for example a multi-row capillary Biax-Fiberfilm die, at a ghm of 0.19 and a total mass flow of 93.48 g/min. The meltblown filaments23are attenuated with 14 kg/min of about 204° C. (400° F.) air. The mixture (commingled) fibers27, for example cellulose pulp fibers and synthetic meltblown filaments23are then laid on top of the already formed 1.0 gsm of meltblown fibrous structure24in the form of a co-formed fibrous structure22. An example of this process is shown inFIG.2B. Next, a 1.6 gsm meltblown fibrous structure24of the same composition as the meltblown fibrous structure24at 0.22 ghm and is attenuated with 16.4 kg/min of 204° C. (400° F.) air is laid down on top of the co-formed fibrous structure22such that the co-formed fibrous structure22is positioned between the first meltblown fibrous structure24and the second meltblown fibrous structure24forming a multi-fibrous structure. This multi-fibrous structure is then taken through a nip33formed between a steel roll37and the forming fabric (collection device31), which is backed by a rubber roll35, for example a 90 Shore A rubber roll, to form a co-formed fibrous web28(co-formed fibrous web ply), an example of which is shown inFIG.2A. The steel roll37in this example is internally heated with oil to an oil temperature of about 132° C. (270° F.) and is loaded to approximately 90 PLI. The total basis weight of this co-formed fibrous web28(co-formed fibrous web ply) is 18.4 gsm. An example of this process is shown inFIG.2B. Two of these co-formed fibrous webs28(co-formed fibrous web plies) are then combined on the outside of two paper webs, for example two wet-laid fibrous structures26(wet-laid fibrous webs or wet-laid fibrous web plies) of 21 gsm to form an article20according to the present invention, as shown inFIG.4. The paper webs, for example the wet-laid fibrous structures26are pre-formed on a continuous knuckle/discrete pillow patterned molding member with 25% knuckle area. The knuckles of the paper webs, for example the wet-laid fibrous structures are facing out relative to the article20, as are the 1.6 gsm meltblown fibrous structures24(scrims), when present, relative to the article20. In other words, when present, the meltblown fibrous structures24form at least one exterior surface of the article20. The four fibrous webs (fibrous web plies) (co-formed fibrous web ply/wet-laid fibrous web ply/wet-laid fibrous web ply/co-formed fibrous web ply) are then bonded together at 60 feet per minute in a pin-pin steel thermal bond unit, oil heated to about 143° C. (290° F.) and loaded to 200 psi of pressure on two 2.5″ diameter cylinders. Each of the 21 gsm paper webs, for example wet-laid fibrous structures26are formed on an AstenJohnson 866A forming wire (AstenJohnson, Charleston, S.C.), then vacuum transferred to the patterned molding member described above. A pulp blend of 40% lightly refined GPOP NSK pulp (Georgia-Pacific Corporation, Atlanta, Ga.), 20% Alabama River southern softwood kraft (Georgia-Pacific Corporation, Atlanta, Ga.), and 40% eucalyptus pulp (Fibria Celulose S.A., Sao Paulo, Brazil). Wet-end additives include 10#/ton Kymene, 2#/ton Finnfix CMC and 1#/T Wickit 1285 surfactant (all commercially available). The papermachine is run at 750 fpm Yankee speed in through-air-dry (TAD) mode, with 2% wet micro-contraction and 18% crepe. The wet-laid fibrous structure is creped from the Yankee with a 25 degree bevel creping blade and 81 degree impact angle. The wet-laid fibrous structure is then wound up on a papermachine reel that is run at 615 fpm to form a parent roll of a wet-laid fibrous web (wet-laid fibrous web ply). The parent roll is then unwound during the article making process. Example 2 An approximately 1.0 gsm meltblown fibrous structure24is laid down upon a collection device31, for example an Albany International Velostat 170pc740 belt (“forming fabric”) (available from Albany International, Rochester, N.H.) traveling at 240 ft/min. The meltblown filaments23of the meltblown fibrous structure24are comprised of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951 and are spun from a die25, for example a multi-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.), at a mass flow of 28 g/min and a ghm of 0.22 and is attenuated with 16.4 kg/min of 204° C. (400° F.) air. An example of this process is shown inFIG.2B. Then, fibers27, for example pulp fibers such as 440 grams per minute of Resolute CoosAbsorb ST semi-treated SSK (Resolut Forest Products, Montreal, Quebec, Canada), are fed into a hammer mill29and individualized into fibers27, for example cellulose pulp fibers, which are pneumatically conveyed into a coforming box like Example 1 above. In the coforming box, the fibers27, for example pulp fibers are commingled with meltblown filaments23. The meltblown filaments23are comprised of a blend of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951. The meltblown filaments23are extruded/spun from a die25, for example a multi-row capillary die at a ghm of 0.19 and a total mass flow of 93.48 g/min like Example 1 above. The meltblown filaments23are attenuated with 14 kg/min of 204° C. (400° F.) air. The mixture (commingled) fibers27, for example cellulose pulp fibers and synthetic meltblown filaments23are then laid on top of the already formed 1.0 gsm of meltblown fibrous structure24in the form of a co-formed fibrous structure22. An example of this process is shown inFIG.2B. Next, a 1.6 gsm meltblown fibrous structure24of the same composition as the meltblown fibrous structure24at 0.22 ghm and is attenuated with 16.4 kg/min of 204° C. (400° F.) air is laid down on top of the co-formed fibrous structure22such that the co-formed fibrous structure22is positioned between the first meltblown fibrous structure24and the second meltblown fibrous structure24to form a multi-fibrous structure. This multi-fibrous structure is then taken through a nip33formed between a steel roll37and the forming fabric (collection device31), which is backed by a rubber roll35, for example a 90 Shore A rubber roll, to form a co-formed fibrous web28(co-formed fibrous web ply), an example of which is shown inFIG.2A. The steel roll37in this example is internally heated with oil to an oil temperature of about 132° C. (270° F.) and is loaded to approximately 90 PLI. The total basis weight of this co-formed fibrous web28(co-formed fibrous web ply) is 18.4 gsm. An example of this process is shown inFIG.2B. Two of these co-formed fibrous webs28(co-formed fibrous web plies) are then combined on the outside of two paper webs, for example two wet-laid fibrous structures26(wet-laid fibrous webs or wet-laid fibrous web plies) of 21 gsm to form an article20according to the present invention, as shown inFIG.4. The paper webs, for example wet-laid fibrous structures26are pre-formed on a continuous knuckle/discrete pillow patterned molding member with 45% knuckle area. The knuckles of the paper webs, for example wet-laid fibrous structures26are facing out relative to the article20, as are the 1.6 gsm meltblown fibrous structures24(scrims), when present, relative to the article20, such that at least one of the meltblown fibrous structures24forms an exterior surface of the article20when present. The four fibrous webs (fibrous web plies) (co-formed fibrous web ply/wet-laid fibrous web ply/wet-laid fibrous web ply/co-formed fibrous web ply) are then bonded together at 60 feet per minute in a pin-pin steel thermal bond unit, oil heated to about 140° C. (285° F.) and loaded to 150 psi of pressure on two 2.5″ diameter cylinders. Each of the 21 gsm paper webs, for example wet-laid fibrous structures26is formed on an AstenJohnson 866A forming wire (AstenJohnson, Charleston, S.C.), then vacuum transferred to the patterned molding member described above. A pulp blend of 40% lightly refined GPOP NSK pulp (Georgia-Pacific Corporation, Atlanta, Ga.), 20% Alabama River southern softwood kraft (Georgia-Pacific Corporation, Atlanta, Ga.), and 40% eucalyptus pulp (Fibria Celulose S.A., Sao Paulo, Brazil). Wet-end additives include 10#/ton Kymene, 2#/ton Finnfix CMC and 1#/T Wickit 1285 surfactant (all commercially available). The papermachine is run at 700 fpm Yankee speed in through-air-dry (TAD) mode, with 2% wet micro-contraction and 18% crepe. The wet-laid fibrous structure is creped from the Yankee with a 25 degree bevel creping blade and 81 degree impact angle. The wet-laid fibrous structure is then wound up on a papermachine reel that is run at 574 fpm (feet per minute) to form a parent roll of a wet-laid fibrous web (wet-laid fibrous web ply). The parent roll is then unwound during the article making process. Example 3 A 28.2 gsm paper web, for example wet-laid fibrous structure26or wet-laid fibrous web (wet-laid fibrous web ply) made on a continuous knuckle/discrete pillow patterned molding member with 25% knuckle area is unwound upon an Albany International Velostat 170pc740 belt (Albany International) traveling at 155 fpm. Laid upon this paper web, for example wet-laid fibrous structure26is 2.0 gsm of a meltblown fibrous structure24comprising meltblown filaments23comprised of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951. The meltblown filaments23are extruded/spun from a die25, for example a multi-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.), at a ghm of 0.19 and a total mass flow of 93.48 g/min like Example 1 above. The meltblown filaments23are attenuated with 14 kg/min of 204° C. (400° F.) air. In this example this is now ply A. An approximately 1.1 gsm meltblown fibrous structure24is laid down upon a collection device31, for example an Albany International Velostat 170pc740 belt (“forming fabric”) (available from Albany International, Rochester, N.H.) traveling at 220 ft/min. The meltblown filaments23of the meltblown fibrous structure24are comprised of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951 and are spun from a die25, for example a multi-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.) at a mass flow of 28 g/min and a ghm of 0.22 and is attenuated with 16.4 kg/min of 204° C. (400° F.) air. An example of this process is shown inFIG.2B. Then, fibers27, for example pulp fibers such as 400 grams per minute of Resolute CoosAbsorb ST semi-treated SSK (Resolut Forest Products, Montreal, Quebec, Canada), are fed into a hammer mill29and individualized into fibers27, for example cellulose pulp fibers, which are pneumatically conveyed into a coforming box like Example 1 above. In the coforming box, the fibers27, for example pulp fibers are commingled with meltblown filaments23. The meltblown filaments23are comprised of a blend of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951. The meltblown filaments23are extruded/spun from a die25, for example a multi-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.) at a ghm of 0.19 and a total mass flow of 93.48 g/min like Example 1 above. The meltblown filaments23are attenuated with 14 kg/min of 204° C. (400° F.) air. The mixture (commingled) fibers27, for example cellulose pulp fibers and synthetic meltblown filaments23are then laid on top of the already formed 1.1 gsm of meltblown fibrous structure24in the form of a co-formed fibrous structure22. An example of this process is shown inFIG.2B. Next, a 1.6 gsm meltblown fibrous structure24of the same composition as the meltblown fibrous structure24at 0.22 ghm and is attenuated with 16.4 kg/min of 204° C. (400° F.) air is laid down on top of the co-formed fibrous structure22such that the co-formed fibrous structure22is positioned between the first meltblown fibrous structure24and the second meltblown fibrous structure24to form a multi-fibrous structure. This multi-fibrous structure is then taken through a nip33formed between a steel roll37and the forming fabric (collection device31), which is backed by a rubber roll35, for example a 90 Shore A rubber roll, to form a co-formed fibrous web28(co-formed fibrous web ply), an example of which is shown inFIG.2A. The steel roll37in this example is internally heated with oil to an oil temperature of about 132° C. (270° F.) and is loaded to approximately 90 PLI. The total basis weight of this co-formed fibrous web28(co-formed fibrous web ply) is 19.4 gsm. An example of this process is shown inFIG.2B. This is ply B in this example. In a separate process, two ply A paper webs, for example wet-laid fibrous structures26and/or wet-laid fibrous webs are combined with a ply B co-formed fibrous web28to form an article20as shown inFIG.18. The ply A paper webs, for example wet-laid fibrous structures26and/or wet-laid fibrous webs, are combined with the meltblown filaments24facing the outside of the article20. These plies are then bonded together at 60 feet per minute in a pin-pin steel thermal bond unit, oil heated to about 140° C. (285° F.) and loaded to 150 psi pressure on two 2.5″ diameter cylinders. The 28.2 gsm paper web, for example wet-laid fibrous structure26and/or wet-laid fibrous web (wet-laid fibrous web ply) is formed on an AstenJohnson 866A forming wire (AstenJohnson) like above, then vacuum transferred to a continuous knuckle/discrete pillow patterned molding member with 25% knuckle area. A pulp fiber blend of 40% refined (to 15 PFR) GPOP NSK pulp (Georgia-Pacific Corporation), 30% West Fraser CTMP (West Fraser, Vancouver, British Columbia, Canada), and 30% eucalyptus pulp (Fibria Celulose S.A.) is used. Wet-end additives include 15#/ton Kymene, 4.5#/ton Finnfix CMC and 1#/T Wickit 1285 surfactant (all commercially available). The papermachine is run at 600 fpm in through-air-dry (TAD) mode, with 10% wet micro-contraction and 10% crepe. The wet-laid fibrous structure is creped from the Yankee with a 25 degree bevel creping blade and 81 degree impact angle. The wet-laid fibrous structure is then wound up on a papermachine reel that is run at 555 fpm (feet per minute) to form a parent roll of a wet-laid fibrous web (wet-laid fibrous web ply). The parent roll is then unwound during the article making process. Example 4 An approximately 1.1 gsm meltblown fibrous structure24is laid down upon a collection device31, for example an Albany International Velostat 170pc740 belt (“forming fabric”) (available from Albany International, Rochester, N.H.) traveling at 215 ft/min (fpm). The meltblown filaments23of the meltblown fibrous structure24are comprised of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951 and are spun from a die25, for example a multi-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.) at a mass flow of 28 g/min and a ghm of 0.22 and is attenuated with 16.4 kg/min of 204° C. (400° F.) air. An example of this process is shown inFIG.2B. Then, fibers27, for example pulp fibers such as 495 grams per minute of Resolute CoosAbsorb ST semi-treated SSK (Resolut Forest Products, Montreal, Quebec, Canada) are fed into a hammer mill29and individualized into fibers27, for example cellulose pulp fibers, which are pneumatically conveyed into a coforming box like Example 1 above. In the coforming box, the fibers27, for example pulp fibers are commingled with meltblown filaments23. The meltblown filaments23are comprised of a blend of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951. The meltblown filaments23are extruded/spun from a die25, for example a multi-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.), at a ghm of 0.19 and a total mass flow of 93.48 g/min like Example 1 above. The meltblown filaments23are attenuated with 14 kg/min of 204° C. (400° F.) air. The mixture (commingled) fibers27, for example cellulose pulp fibers and synthetic meltblown filaments23are then laid on top of the already formed 1.1 gsm of meltblown fibrous structure24in the form of a co-formed fibrous structure22. Next, a 1.6 gsm meltblown fibrous structure24of the same composition as the meltblown fibrous structure24at 0.22 ghm and is attenuated with 16.4 kg/min of 204° C. (400° F.) air is laid down on top of the co-formed fibrous structure22such that the co-formed fibrous structure22is positioned between the first meltblown fibrous structure24and the second meltblown fibrous structure24forming a multi-fibrous structure, a co-formed fibrous web28. The total basis weight of this co-formed fibrous web28is 23.4 gsm. An example of this process is shown inFIG.2B. This is now ply A in this example. In a separate process, one ply A co-formed fibrous web28is combined between two 28.2 gsm paper webs, for example two wet-laid fibrous structures26or wet-laid fibrous webs (wet-laid fibrous web plies). These paper webs, for example wet-laid fibrous structures26and/or wet-laid fibrous webs are formed on a continuous knuckle molding member and are combined with the continuous pillow pattern facing outwards. These plies and/or fibrous structures and/or webs are then bonded together at 60 feet per minute in a pin-pin steel thermal bonding unit which is oil heated to an oil temp of about 160° C. (320° F.) and loaded to 200 psi of pressure on two 2.5″ diameter cylinders. The 28.2 gsm paper web, for example wet-laid fibrous structure26or wet-laid fibrous web (wet-laid fibrous web ply) is formed on an AstenJohnson 866A forming wire (AstenJohnson) like above, then vacuum transferred to a continuous pillow/discrete knuckle patterned molding member. A pulp fiber blend of 40% refined (to 15 PFR) GPOP NSK pulp (Georgia-Pacific Corporation), 30% West Fraser CTMP (West Fraser, Vancouver, British Columbia, Canada), and 30% eucalyptus pulp (Fibria Celulose S.A.) is used. Wet-end additives include 15#/ton Kymene, 4.5#/ton Finnfix CMC and 1#/T Wickit 1285 surfactant (all commercially available). The papermachine is run at 700 fpm in through-air-dry (TAD) mode, with 15% wet micro-contraction and +5% crepe (reel faster than Yankee). The wet-laid fibrous structure is creped from the Yankee with a 45 degree bevel creping blade and 101 degree impact angle. The wet-laid fibrous structure is then wound up on a papermachine reel that is run at 735 fpm (feet per minute) to form a parent roll of a wet-laid fibrous web (wet-laid fibrous web ply). The parent roll is then unwound during the article making process. Example 5 A 23.1 gsm paper web, for example a wet-laid fibrous structure26or wet-laid fibrous web (wet-laid fibrous web ply) which is made on a continuous knuckle/discrete pillow molding member with a 25% knuckle area is unwound onto a patterned molding member, knuckles facing away from the patterned molding member, traveling at 220 ft/minute. Next, an approximately 1.1 gsm meltblown fibrous structure24is laid down upon the paper web, for example wet-laid fibrous structure26and/or wet-laid fibrous web. The meltblown filaments23of the meltblown fibrous structure24are comprised of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951 and are spun from a die25, for example a multi-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.) at a mass flow of 28 g/min and a ghm of 0.22 and is attenuated with 16.4 kg/min of 204° C. (400° F.) air. An example of this process is shown inFIG.2B. Then, fibers27, for example pulp fibers such as 325 grams per minute of Resolute CoosAbsorb ST semi-treated SSK (Resolut Forest Products, Montreal, Quebec, Canada) are fed into a hammer mill29and individualized into fibers27, for example cellulose pulp fibers, which are pneumatically conveyed into a coforming box like Example 1 above. In the coforming box, the fibers27, for example pulp fibers are commingled with meltblown filaments23. The meltblown filaments23are comprised of a blend of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951. The meltblown filaments23are extruded/spun from a die25, for example a multi-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.) at a ghm of 0.19 and a total mass flow of 93.48 g/min like Example 1 above. The meltblown filaments23are attenuated with 14 kg/min of 204° C. (400° F.) air. The mixture (commingled) fibers27, for example cellulose pulp fibers and synthetic meltblown filaments23are then laid on top of the already formed 23.1 gsm paper web, for example wet-laid fibrous structure26and/or wet-laid fibrous web, which has its knuckles facing outward in the form of a co-formed fibrous structure22. Next, a 1.6 gsm meltblown fibrous structure24of the same composition at a ghm of 0.22 and attenuated with 16.4 kg/min of 204° C. (400° F.) air is laid down on top of the co-formed fibrous structure22to form a multi-fibrous structure. This multi-fibrous structure is then taken through a nip33formed between a steel roll37and the forming fabric (collection device31), which is backed by a rubber roll35, for example a 90 Shore A rubber roll. The steel roll37in this example is internally heated with oil to an oil temperature of about 132° C. (270° F.) and is loaded to approximately 90 PLI. The total weight of this web is about 40.1 gsm. In this example this is now ply A. Then a 2.0 gsm meltblown fibrous structure24of the same composition, ghm, and attenuation air settings as described immediately above is applied to the surface of the paper web, for example wet-laid fibrous structure26of ply A. This multi-fibrous structure is now 42.1 gsm and is referred to as ply B in this example. In a separate process, two ply B paper webs, for example two wet-laid fibrous structures26and/or wet-laid fibrous webs are combined with the paper webs, for example wet-laid fibrous structures26and/or wet-laid fibrous webs facing inward to form an article20as shown inFIGS.22A and22B. These plies, fibrous structures and/or web are then bonded together at 60 feet per minute in a pin-pin steel thermal bonding unit which is oil heated to an oil temp of about 143° C. (290° F.) and loaded to 200 psi of pressure on two 2.5″ diameter cylinders. An example of this process is shown inFIG.23B. The 23.1 gsm paper web, for example wet-laid fibrous structure26and/or wet-laid fibrous web (wet-laid fibrous web ply) is formed on an AstenJohnson 866A forming wire (AstenJohnson), then vacuum transferred to a continuous knuckle/discrete pillow patterned molding member with 25% knuckle area. A pulp fiber blend of 40% unrefined GPOP NSK pulp (Georgia-Pacific Corporation), 20% West Fraser CTMP (West Fraser, Vancouver, British Columbia, Canada), and 40% eucalyptus pulp (Fibria Celulose S.A.) is used. Wet-end additives include 15#/ton Kymene, 4.5#/ton Finnfix CMC and 1#/T Wickit 1285 surfactant (all commercially available). The papermachine is run at 700 fpm in through-air-dry (TAD) mode, with 2% wet micro-contraction and 18% crepe. The wet-laid fibrous structure is creped from the Yankee with a 25 degree bevel creping blade and 81 degree impact angle. The wet-laid fibrous structure is then wound up on a papermachine reel that is run at 574 fpm (feet per minute) to form a parent roll of a wet-laid fibrous web (wet-laid fibrous web ply). The parent roll is then unwound during the article making process. Example 6 A 23.1 gsm paper web, for example a wet-laid fibrous structure26and/or wet-laid fibrous web (wet-laid fibrous web ply) which is made on a continuous knuckle/discrete pillow molding member with a 25% knuckle area is unwound onto a patterned molding member, knuckles facing away from the patterned molding member, traveling at 220 ft/minute. Then, fibers27, for example pulp fibers such as 325 grams per minute of Resolute CoosAbsorb ST semi-treated SSK (Resolut Forest Products, Montreal, Quebec, Canada) are fed into a hammer mill29and individualized into fibers27, for example cellulose pulp fibers, which are pneumatically conveyed into a coforming box like Example 1 above. In the coforming box, the fibers27, for example pulp fibers are commingled with meltblown filaments23. The meltblown filaments23are comprised of a blend of 48% LynondellBasell MF650x, 28% LynondellBasell MF650w, 17% LyondellBasell PH835, 5% Polyvel S1416, and 2% Ampacet 412951. The meltblown filaments23are extruded/spun from a die25, for example a multi-row capillary Biax-Fiberfilm die (Biax-Fiberfilm Corporation, Greenville, Wis.) at a ghm of 0.19 and a total mass flow of 93.48 g/min like Example 1 above. The meltblown filaments23are attenuated with 14 kg/min of 204° C. (400° F.) air. The mixture (commingled) fibers27, for example cellulose pulp fibers and synthetic meltblown filaments23are then laid on top of the already formed 23.1 gsm paper web, for example wet-laid fibrous structure26and/or wet-laid fibrous web, which has its knuckles facing outward in the form of a co-formed fibrous structure22. Next, a 1.6 gsm meltblown fibrous structure24of the same composition at a ghm of 0.22 and attenuated with 16.4 kg/min of 204° C. (400° F.) air is laid down on top of the co-formed fibrous structure22forming a multi-fibrous structure. This multi-fibrous structure is then taken through a nip33formed between a steel roll37and the forming fabric (collection device31), which is backed by a rubber roll35, for example a 90 Shore A rubber roll. The steel roll37in this example is internally heated with oil to an oil temperature of about 132° C. (270° F.) and is loaded to approximately 90 PLI. The total basis weight of this combined multi-fibrous structure and/or multi-fibrous web is 39 gsm. This is now ply A in this example. Then a 2.0 gsm meltblown fibrous structure24of the same composition, ghm, and attenuation air settings as described immediately above is applied to the surface of the paper web, for example wet-laid fibrous structure26of ply A. This multi-fibrous structure is now 41 gsm and is referred to as ply B in this example. In a separate process, one ply A is combined with one ply B. These plies are then bonded together at 60 feet per minute in a pin-pin steel thermal bonding unit which is oil heated to an oil temp of about 143° C. (290° F.) and loaded to 200 psi of pressure on two 2.5″ diameter cylinders. The 23.1 gsm paper web, for example wet-laid fibrous structure26or wet-laid fibrous web (wet-laid fibrous web ply) is formed on an AstenJohnson 866A forming wire (AstenJohnson), then vacuum transferred to a continuous knuckle/discrete pillow patterned molding member with 25% knuckle area. A pulp fiber blend of 40% unrefined GPOP NSK pulp (Georgia-Pacific Corporation), 20% West Fraser CTMP (West Fraser, Vancouver, British Columbia, Canada), and 40% eucalyptus pulp (Fibria Celulose S.A.) is used. Wet-end additives include 15#/ton Kymene, 4.5#/ton Finnfix CMC and 1#/T Wickit 1285 surfactant (all commercially available). The papermachine is run at 700 fpm in through-air-dry (TAD) mode, with 2% wet micro-contraction and 18% crepe. The wet-laid fibrous structure is creped from the Yankee with a 25 degree bevel creping blade and 81 degree impact angle. The wet-laid fibrous structure is then wound up on a papermachine reel that is run at 574 fpm (feet per minute) to form a parent roll of a wet-laid fibrous web (wet-laid fibrous web ply). The parent roll is then unwound during the article making process. Test Methods Unless otherwise specified, all tests described herein including those described under the Definitions section and the following test methods are conducted on samples that have been conditioned in a conditioned room at a temperature of 23° C.±1.0° C. and a relative humidity of 50%±2% for a minimum of 24 hours prior to the test. These will be considered standard conditioning temperature and humidity. All plastic and paper board packaging articles of manufacture, if any, must be carefully removed from the samples prior to testing. The samples tested are “usable units.” “Usable units” as used herein means sheets, flats from roll stock, pre-converted flats, fibrous structure, and/or single or multi-ply products. Except where noted all tests are conducted in such conditioned room, under the same environmental conditions in such conditioned room. Discard any damaged product. Do not test samples that have defects such as wrinkles, tears, holes, and like. All instruments are calibrated according to manufacturer's specifications. The stated number of replicate samples to be tested is the minimum number. Basis Weight Test Method Basis weight of an article and/or fibrous web and/or fibrous structure is measured on stacks of eight to twelve usable units using a top loading analytical balance with a resolution of ±0.001 g. A precision cutting die, measuring 8.890 cm by 8.890 cm or 10.16 cm by 10.16 cm is used to prepare all samples. Condition samples under the standard conditioning temperature and humidity for a minimum of 10 minutes prior to cutting the sample. With a precision cutting die, cut the samples into squares. Combine the cut squares to form a stack eight to twelve samples thick. Measure the mass of the sample stack and record the result to the nearest 0.001 g. Calculations: BasisWeight,g/m2=massofstack(areaof1squareinstack)(#squaresinstack) Report result to the nearest 0.1 g/m2. Sample dimensions can be changed or varied using a similar precision cutter as mentioned above, so as at least 645 square centimeters of sample area is in the stack. Individual fibrous structures and/or fibrous webs that are ultimately combined to form and article may be collected during their respective making operation prior to combining with other fibrous web and/or fibrous structures and then the basis weight of the respective fibrous web and/or fibrous structure is measured as outlined above. Caliper Test Methods Dry caliper of a fibrous structure and/or sanitary tissue product is measured using a ProGage Thickness Tester (Thwing-Albert Instrument Company, West Berlin, N.J.) with a pressure foot diameter of 5.08 cm (area of 6.45 cm2) at a pressure of 14.73 g/cm2. Four (4) samples are prepared by cutting of a usable unit such that each cut sample is at least 16.13 cm per side, avoiding creases, folds, and obvious defects. An individual specimen is placed on the anvil with the specimen centered underneath the pressure foot. The foot is lowered at 0.076 cm/sec to an applied pressure of 14.73 g/cm2. The reading is taken after 3 sec dwell time, and the foot is raised. The measure is repeated in like fashion for the remaining 3 specimens. The caliper is calculated as the average caliper of the four specimens and is reported in mils (0.001 in) to the nearest 0.1 mils. Wet caliper is tested in the same manner, using 2 replicates. An individual replicate is placed on the anvil and wetted from the center, one drop at a time, with distilled or deionized water at the temperature of the conditioned room. Saturate the sample, adding enough water such that the sample is thoroughly wetted (from a visual perspective), with no observed dry areas anywhere on the sample. Continue with the measurement as described above. Bulk Test Method The Bulk of a fibrous structure and/or sanitary tissue product is calculated as the quotient of the Caliper and the Basis Weight (as described in the methods above) of a fibrous structure or sanitary tissue product. Values are expressed in cm3/g, by using the appropriate unit conversions. Dry Bulk is calculated using the Dry Caliper of the fibrous structure and/or sanitary tissue product; Wet Bulk is calculated using the Wet Caliper of the fibrous structure and/or sanitary tissue product. Dry Tensile Strength Test Method The Dry Tensile Strength Test Method is performed using a constant rate of extension tensile tester with computer interface (example: Thwing-Albert EJA Vantage tensile tester with Motion Analysis and Presentation software 3.0). The method reproducibly determines the dry strength of fibrous structures under fixed atmospheric conditions. The instrument is fitted with a set of grips (example: Thwing-Albert TAPPI Air Grips 733GC) into which a strip of sample is inserted. The grips are pulled in opposite directions until the sample fails (tears). Substrates are conditioned by exposing them on a horizontal, flat surface and in a configuration of no more than 2 layers high in a room under standard conditioning temperature and humidity for a minimum of ten minutes. Samples are cut 25.4×at least 178 mm, four samples in the machine direction (MD) and four samples in the cross direction (CD). Samples are aligned and centered in the grips of the tensile tester with minimal handling and handled only on the extreme ends of the strip (the portion of sample that will be engaged in the grips). The tension on the sample at test start is 0<3 g. The instrument is programmed to pull the grips in opposite directions at 10.16 cm/min while recording the forces encountered during the test. The test stops when the measured force drops to 50% of peak. The test is repeated on each of the remaining seven samples. Values reported include Peak Tensile (g/in), Elongation at Peak Tensile (% elongation) and Tensile Energy Absorbed (TEA)—the area under the tensile strength vs. tensile strain curve. Calculations:Tensile Modulus at 38 g/in (g/cm*%): calculated as a linear regression of the 5 points before and 5 points after and at the force of 38.1 g/in. The tensile modulus is the slope of this regression. TotalDryTensile=avg.MDDryTensile+avg.CDDryTensileGeometricMeanDryTEA=Avg.MDDryTEA*Avg.DryCDTEAGeometricMeanDryModulus=Avg.MDDryModulus*Avg.DryCDModulusWettoDryCDTEARatio=avg.CDWETTEAavg.CDDryTEA For each test, the stated value is the numerical average of the strips tested separately for the Machine Direction (MD) and the Cross Direction (CD). Wet Tensile Strength Test Method The Wet Tensile Strength Test Method is performed using a constant rate of extension tensile tester with computer interface (example: Thwing-Albert EJA Vantage tensile tester with Motion Analysis and Presentation software 3.0). The instrument is fitted with a set of grips (example: Thwing-Albert TAPPI Air Grips 733GC) and may be fitted with a Wet Tensile Device (example: Finch Wet Strength Device, Cat. No. 731D). If used, the device is clamped in the lower grip so that the horizontal rod is parallel to the grip faces and is otherwise symmetrically located with respect to the grips. During testing, the grips or the grip and device are pulled in opposite directions until the wetted sample fails (tears). Substrates are conditioned by exposing them on a horizontal, flat surface and in a configuration of no more than 2 layers high in a room under standard conditioning temperature and humidity for a minimum of ten minutes. For sheets with a length greater than 15.24 cm, samples are cut 2.54 cm×at least 15.2 cm each, four replicates in the machine direction and four replicates in the cross direction. The distance between the axis of the horizontal bar of the Wet strength device and the upper grip of the tensile tester is set to 10.16 cm. The liquid container of the Wet Strength Device is moved to its lowest position and filled with distilled water to within 3.2 mm of the top of the container. The horizontal rod and its supports are dried and the sample is threaded under the rod of the Wet Strength Device. The ends of the sample are placed together, removing any slack, centered with respect to the horizontal rod and the upper grip, and clamped in the upper grip of the tensile tester. The liquid container is raised so that it locks in its upper most position, immersing the looped end of the specimen to a depth of at least 1.91 cm. Exactly five seconds after the liquid container is raised in place and with the liquid container remaining in place, the tensile tester is engaged. The instrument is programmed to pull the grips in opposite directions at a speed of 10.16 cm/min. while recording the forces encountered during the test. The test is repeated on each of the remaining replicates. Tensile strength is calculated by: avg.wettensilestrength=∑peakloadsforeachtest2*n For samples less than 15.24 cm in length, four strips are cut 2.54 cm×6.35 cm (at a minimum, preferably 10.16 cm long), two in the MD and tow in the CD. The Wet Tensile Device is replaced with another set of grips. In such cases, the grips are set to a distance of 5.08 cm apart and one end of the sample is placed in each grip. The sample should be nearly straight between the grips with no more than 5.0 g of force on the load cell. The sample is squirted with distilled or deionized water from a spray bottle to the point of saturation (until no dry area is observed) at which point the instrument is engaged. The grips are separated at a speed of 5.08 cm/min. and the force at tearing is recorded. The test is repeated on each of the remaining replicates. Tensile strength is calculated by: avg.wettensilestrength=∑(peakloadsforeachtest)#reps The test stops when the measured force drops to 50% of peak. The test outputs:Peak Tensile (g/in): The measured value is divided by 2 for the full sheet because the sample curves around the Finch cup and returns.Elongation at Peak Tensile (% elongation)TEA (g*in/in2): Tensile Energy Absorbed: area under the tensile strength vs. tensile strain curve.Tensile Modulus at 38 g/in (g/cm*%)Linear regression of the 5 points before, 5 points after and at the force of 38.1 g/in. The tensile modulus is the slope of this regression.Total Wet Tensile: TotalWetTensile=AverageMDWetTensile+AverageCDWetTensileGeometric Mean Wet TEA: GeometricMeanWetTEA=AverageMDWetTEA*AverageCDWetTEA For each test, the stated value is the numerical average of the strips tested separately for the Machine Direction (MD) and Cross Direction (CD). Flexural Rigidity and Bending Modulus Test Method The Flexural Rigidity Method determines the overhang length of the present invention based on the cantilever beam principal. The distance a strip of sample can be extended beyond a flat platform before it bends through a specific angle is measured. The inter-action between sheet weight and sheet stiffness measured as the sheet bends or drapes under its own weight through the given angle under specified test conditions is used to calculate the sample Bend Length, Flexural Rigidity, and Bending Modulus. The method is performed by cutting rectangular strips of samples of the fibrous structure to be tested, in both the cross direction and the machine direction. The Basis Weight of the sample is determined and the Dry Caliper of the samples is measured (as detailed previously). The sample is placed on a test apparatus that is leveled so as to be perfectly horizontal (ex: with a bubble level) and the short edge of the sample is aligned with the test edge of the apparatus. The sample is gently moved over the edge of the apparatus until it falls under its own weight to a specified angle. At that point, the length of sample overhanging the edge of the instrument is measured. The apparatus for determining the Flexural Rigidity of fibrous structures is comprised of a rectangular sample support with a micrometer and fixed angle monitor. The sample support is comprised of a horizontal plane upon which the sample rectangle can comfortably be supported without any interference at the start of the test. As it is slowly pushed over the edge of the apparatus, it will bend until it breaks the plane of the fixed angle monitor, at which point the micrometer measures the length of overhang. Eight samples of 25.4×101.5−152.0 mm are cut in the machine direction (MD); eight more samples of the same size are cut in the cross direction (CD). It is important that adjacent cuts are made exactly perpendicular to each other so that each angle is exactly 90 degrees. Samples are arranged such that the same surface is facing up. Four of the MD samples are overturned and four of the CD samples are overturned and marks are made at the extreme end of each, such that four MD samples will be tested with one side facing up and the other four MD samples will be tested with the other side facing up. The same is true for the CD samples with four being tested with one side up and four with the other side facing up. A sample is then centered in a channel on the horizontal plane of the apparatus with one short edge exactly aligned with the edge of the apparatus. The channel is slightly oversized for the sample that was cut and aligns with the orientation of the rectangular support, such that the sample does not contact the sides of the channel. A lightweight slide bar is lowered over the sample resting in the groove such that the bar can make good contact with the sample and push it forward over the edge of the apparatus. The leading edge of the slide bar is also aligned with the edge of the apparatus and completely covers the sample. The micrometer is aligned with the slide bar and measures the distance the slide bar, thus the sample, advances. From the back edge of the slide bar, the bar and sample are pushed forward at a rate of approximately 8-13 cm per second until the leading edge of the sample strip bends down and breaks the plane of the fixed angle measurement, set to 45°. At this point, the measurement for overhang is made by reading the micrometer to the nearest 0.5 mm and is reported in units of cm. The procedure is repeated for each of the 15 remaining samples of the fibrous structure. Calculations:Flexural Rigidity is calculated from the overhang length as follows: BendLength=OverhangLength/2Where overhang length is the average of the 16 results collected.The calculation for Flexural Rigidity (G) is: G=0.1629*W*C3(mg·cm) Where W is the sample basis weight in pounds/3000 ft2 and C is the bend length in cm. The constant 0.1629 converts units to yield Flexural Rigidity (G) in units of milligram·cm·grams. Bending Modulus (Q)=Flexural Rigidity (G)/Moment of Inertia (I) per unit area. Q=G/IQ=732*GCaliper(mils)3 Plate Stiffness Test Method As used herein, the “Plate Stiffness” test is a measure of stiffness of a flat sample of a fibrous structure and/or sanitary tissue product as it is deformed downward into a hole beneath the sample. For the test, the sample is modeled as an infinite plate with thickness “t” that resides on a flat surface where it is centered over a hole with radius “R”. A central force “F” applied to the tissue directly over the center of the hole deflects the tissue down into the hole by a distance “w”. For a linear elastic material the deflection can be predicted by: w=3F4πEt3(1-v)(3+v)R2 where “E” is the effective linear elastic modulus, “v” is the Poisson's ratio, “R” is the radius of the hole, and “t” is the thickness of the tissue, taken as the caliper in millimeters measured on a stack of 4 or 5 tissues under a load of about 0.29 psi. Taking Poisson's ratio as 0.1 (the solution is not highly sensitive to this parameter, so the inaccuracy due to the assumed value is likely to be minor), the previous equation can be rewritten for “w” to estimate the effective modulus as a function of the flexibility test results: E≈3R24t3Fw The test results are carried out using an MTS Alliance RT/1, Insight Renew, or similar model testing machine (MTS Systems Corp., Eden Prairie, Minn.), with a 50 newton load cell, and data acquisition rate of at least 25 force points per second. As a stack of four tissue sheets (created without any bending, pressing, or straining) at least 2.5-inches by 2.5 inches, but no more than 5.0 inches by 5.0 inches, oriented in the same direction, sits centered over a hole of radius 15.75 mm on a support plate, a blunt probe of 3.15 mm radius descends at a speed of 20 mm/min. When the probe tip descends to 1 mm below the plane of the support plate, the test is terminated. The maximum slope (using least squares regression) in grams of force/mm over any 0.5 mm span during the test is recorded (this maximum slope generally occurs at the end of the stroke). The load cell monitors the applied force and the position of the probe tip relative to the plane of the support plate is also monitored. The peak load is recorded, and “E” is estimated using the above equation. Calculations:The Plate Stiffness “S” per unit width can then be calculated as: S=Et312and is expressed in units of Newtons*millimeters. The Testworks program uses the following formula to calculate stiffness (or can be calculated manually from the raw data output): S=(Fw)[(3+v)R216π]wherein “F/w” is max slope (force divided by deflection), “v” is Poisson's ratio taken as 0.1, and “R” is the ring radius. The same sample stack (as used above) is then flipped upside down and retested in the same manner as previously described. This test is run three more times (with the different sample stacks). Thus, eight S values are calculated from four 4-sheet stacks of the same sample. The numerical average of these eight S values is reported as Plate Stiffness for the sample. Plate Stiffness, Basis Weight Normalized is the quotient of the Average Plate Stiffness, S, in N·mm and the Basis Weight, in grams per square meter (gsm), per the Basis Weight Test Method. PlateStiffness,BWNormalized=AvgPlateStiffness,′S′(N*mm)BW(gsm) Dry Compressive Modulus Test Method Compression caliper and compressive modulus are determined using a tensile tester (Ex. EJA Vantage, Thwing-Albert, West Berlin N.J.) fitted with the appropriate compression fixtures (such as a compression foot that has an area of 6.45 cm and an anvil that has an area of 31.67 cm). The thickness (caliper in mils) is measured at various pressure values ranging from 10-1500 g/in2in both the compression and relaxation directions. Condition the samples by placing them out on a flat surface, no more than 2 layers high, in a room at standard conditioning temperature and pressure for a minimum of 10 minutes. For large samples (larger than 27.94 cm on each side), measurements are taken at the 4 corners, at least 1.5 cm from the edges. For samples smaller than this, take measurements at least 1.5 cm from the edge on multiple sheets if necessary to record measurements from 4 reps. Place the sample portion on the anvil fixture. Ensure the sample portion is centered under the foot so that when contact is made the edges of the sample will be avoided. Measure four replicates per sample at a crosshead speed of 0.254 cm/min. The values reported under each pressure value are the compressive caliper values. Report the average of the 4 compressive caliper replicates for each sample. The thickness (mils) vs. pressure data (g/in2, or gsi) is used to calculate the sample's compressibility, “near-zero load caliper” and compressive modulus. A least-squares linear regressions performed on the thickness vs. the logarithm (base10) of the applied pressure data between and including 10 gsi and 300 gsi. For the 1500 gsi script that is referenced and applied in this method, this involves 9 data points at pressures at 10, 25, 50, 75, 100, 125, 150, 200, 300 gsi and their respective thickness readings. Compressibility (m) equals the slope of the linear regression line, with units of mils/log(gsi). The higher the magnitude of the negative value the more “compressible” the sample is. Near-zero load caliper (b) equals the y-intercept of the linear regression line, with units of mils. This is the extrapolated thickness at log(1 gsi pressure). Compressive Modulus is calculated as the y-intercept divided by the negative slope (−b/m) with units of log(gsi). Dry Thick Compression=−1*Near-Zero Load Caliper (b)*Compressibility (m), with units of mils*mils/log (gr force/in2). Multiplication by −1 turns formula into a positive. Larger results represent thick products that compress when a pressure is applied. Dry Thick Compressive Recovery=−1*Near-Zero Load Caliper (b)*Compressibility (m)*Recovered thickness at 10 g/in2/Compressed thickness at 10 g/in2, with units of mils*mils/log (g force/in2). Multiplication by −1 turns formula into a positive. Larger results represent thick products that compress when a pressure is applied and maintain fraction recovery at 10 g/in2. Compressed thickness at 10 g/in2is the thickness of the material at 10 g/in2pressure during the compressive portion of the test. Recovered thickness at 10 g/in2is the thickness of the material at 10 g/in2pressure during the recovery portion of the test. Report the thickness readings to the nearest 0.1 mils for the average of the 4 replicate measurements for each compression pressures of interest. Report the average of the 4 replicate measurements for each calculated value: slope to the nearest 0.01 mils/log(gsi); near-zero load caliper to the nearest 0.1 mils and compressive modulus to the nearest 0.01 log(gsi). Wet Compressive Modulus Test Method Compression caliper and compressive modulus are determined using a tensile tester (Ex. EJA Vantage, Thwing-Albert, West Berlin N.J.) fitted with the appropriate compression fixtures (such as a compression foot that has an area of 6.45 cm and an anvil that has an area of 31.67 cm). The thickness (caliper in mils) is measured at various pressure values ranging from 10-1500 g/in2in both the compression and relaxation directions, on a fully wetted fibrous structure. Samples should be cut slightly larger than the compression anvil, but small enough that the sample does not hang over the sides of the compression fixture top plate. Take measurements at least 1.5 cm from the edges to record measurements from 3 reps. Place the sample portion on the anvil fixture. Ensure the sample portion is centered under the foot so that when contact is made the edges of the sample will be avoided. Saturate the sample with distilled or deionized water until there is no observable dry area remaining. Sample should be saturated but not so wet as to run off the sample. Measure four replicates per sample at a crosshead speed of 0.254 cm/min. The values reported under each pressure value are the compressive caliper values. Report the average of the 3 compressive caliper replicates for each sample. The thickness (mils) vs. pressure data (g/in2, or gsi) is used to calculate the sample's compressibility, “near-zero load caliper” and compressive modulus. A least-squares linear regressions performed on the thickness vs. the logarithm (base10) of the applied pressure data between and including 10 gsi and 300 gsi. For the 1500 gsi script that is referenced and applied in this method, this involves 9 data points at pressures at 10, 25, 50, 75, 100, 125, 150, 200, 300 gsi and their respective thickness readings. Compressibility (m) equals the slope of the linear regression line, with units of mils/log(gsi). The higher the magnitude of the negative value the more “compressible” the sample is. Near-zero load caliper (b) equals the y-intercept of the linear regression line, with units of mils. This is the extrapolated thickness at log(1 gsi pressure). Compressive Modulus is calculated as the y-intercept divided by the negative slope (−b/m) with units of log(gsi). Wet Thick Compression=−1*Near-Zero Load Caliper (b)*Compressibility (m), with units of mils*mils/log (gr force/in2). Multiplication by −1 turns formula into a positive. Larger results represent thick products that compress when a pressure is applied. Wet Thick Compressive Recovery=−1*Near-Zero Load Caliper (b)*Compressibility (m)*Recovered thickness at 10 g/in2/Compressed thickness at 10 g/in2, with units of mils*mils/log (g force/in2). Multiplication by −1 turns formula into a positive. Larger results represent thick products that compress when a pressure is applied and maintain fraction recovery at 10 g/in2. Compressed thickness at 10 g/in2is the thickness of the material at 10 g/in2pressure during the compressive portion of the test. Recovered thickness at 10 g/in2is the thickness of the material at 10 g/in2pressure during the recovery portion of the test. Report the thickness readings to the nearest 0.1 mils for the average of the 3 replicate measurements for each compression pressures of interest. Report the average of the 3 replicate measurements for each calculated value: slope to the nearest 0.01 mils/log(gsi); near-zero load caliper to the nearest 0.1 mils and compressive modulus to the nearest 0.01 log(gsi). Low Load Wet Resiliency Test Method Low Load Wet Resiliency is the ratio of C10 Wet (Compressed wet thickness at 10 g/in2) as measured according to the Wet Compressive Modulus Test Method above to C10 Dry (Compressed dry thickness at 10 g/in2) as measured according to the Dry Compressive Modulus Test Method above. Mid Load Wet Resiliency Test Method Mid Load Wet Resiliency is the ratio of C100 Wet (Compressed wet thickness at 100 g/in2) as measured according to the Wet Compressive Modulus Test Method above to C100 Dry (Compressed dry thickness at 100 g/in2) as measured according to the Dry Compressive Modulus Test Method above. Absorptive Rate and Capacity CRT Test Method The absorption (wicking) of water by a fibrous structure is measured over time by a CRT device. The device consists of a balance (sensitive to 0.001 g) on which rests a sample platform made of a woven grid (using nylon monofilament line having a 0.356 mm diameter) placed over a small reservoir with a delivery tube (8 mm I.D.) in the center. This reservoir is filled with distilled or deionized water by the action of solenoid valves, which connect the sample supply reservoir to an intermediate reservoir, the water level of which is monitored by an optical sensor. The device is connected to software that records the weight of the water absorbed over 2 seconds time by the fibrous structure. Final weight is also recorded at saturation. For this method, a usable unit is described as one finished product unit regardless of the number of plies. Samples are placed no more than 2 layers high on a flat surface at standard conditioning temperature and humidity for a minimum of 10 minutes. Cut samples into circles of 7.62 cm, at least 2.54 cm from any edge, cutting 2 replicates for each test. Set the supply tube 2 mm below the woven grid and place the circular sample on the grid. The software records the weight of water acquisition and the time and from this calculates the rate (in g/second) and the capacity (grams water/gram fibrous structure). Slope of the Square Root of Time (SST) Test Method This method is a modification of the CRT method described previously. Samples are cut to a diameter of 8.57 cm and a cover is used to increase the contact of the sample with the woven support. The device is the same structure and the software records the rate of acquisition between 2 and 15 seconds. The calculated result is the slope of the line plotting the cumulative water absorption (g) and the square root of the acquisition time (sec0.5) resulting in SST units of g/sec0.5. Pore Volume Distribution Test Method Pore Volume Distribution measurements are made on a TRI/Autoporosimeter (TRI/Princeton Inc. of Princeton, N.J.). The TRI/Autoporosimeter is an automated computer-controlled instrument for measuring pore volume distributions in porous materials (e.g., the volumes of different size pores within the range from 1 to 1000 μm effective pore radii). Complimentary Automated Instrument Software, Release 2000.1, and Data Treatment Software, Release 2000.1 is used to capture, analyze and output the data. More information on the TRI/Autoporosimeter, its operation and data treatments can be found in The Journal of Colloid and Interface Science 162 (1994), pgs 163-170, incorporated here by reference. As used in this application, determining Pore Volume Distribution involves recording the increment of liquid that enters a porous material as the surrounding air pressure changes. A sample in the test chamber is exposed to precisely controlled changes in air pressure. The size (radius) of the largest pore able to hold liquid is a function of the air pressure. As the air pressure increases (decreases), different size pore groups drain (absorb) liquid. The pore volume of each group is equal to this amount of liquid, as measured by the instrument at the corresponding pressure. The effective radius of a pore is related to the pressure differential by the following relationship. Pressuredifferential=[(2)γcosΘ]/effectiveradius where γ=liquid surface tension, and Θ=contact angle. Typically pores are thought of in terms such as voids, holes or conduits in a porous material. It is important to note that this method uses the above equation to calculate effective pore radii based on the constants and equipment controlled pressures. The above equation assumes uniform cylindrical pores. Usually, the pores in natural and manufactured porous materials are not perfectly cylindrical, nor all uniform. Therefore, the effective radii reported here may not equate exactly to measurements of void dimensions obtained by other methods such as microscopy. However, these measurements do provide an accepted means to characterize relative differences in void structure between materials. The equipment operates by changing the test chamber air pressure in user-specified increments, either by decreasing pressure (increasing pore size) to absorb liquid, or increasing pressure (decreasing pore size) to drain liquid. The liquid volume absorbed at each pressure increment is the cumulative volume for the group of all pores between the preceding pressure setting and the current setting. In this application of the TRI/Autoporosimeter, the liquid is a 0.2 weight % solution of octylphenoxy polyethoxy ethanol (Triton X-100 from Sigma-Aldrich) in distilled water. The instrument calculation constants are as follows: ρ (density)=1 g/cm3; γ (surface tension)=31 dynes/cm; cos Θ=1. A 1.2 μm Millipore Glass Filter (Millipore Corporation of Bedford, Mass.; Catalog #GSWP09025) is employed on the test chamber's porous plate. A plexiglass plate weighing about 34 g (supplied with the instrument) is placed on the sample to ensure the sample rests flat on the Millipore Filter. No additional weight is placed on the sample. The remaining user specified inputs are described below. The sequence of pore sizes (pressures) for this application is as follows (effective pore radius in μm): 1, 2.5, 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, 120, 140, 160, 180, 200, 225, 250, 275, 300, 350, 400, 500, 600, 800, 1000. This sequence starts with the sample dry, saturates it as the pore settings increase (typically referred to with respect to the procedure and instrument as the 1stabsorption). In addition to the test materials, a blank condition (no sample between plexiglass plate and Millipore Filter) is run to account for any surface and/or edge effects within the chamber. Any pore volume measured for this blank run is subtracted from the applicable pore grouping of the test sample. Any potential negative values are given a value of zero. This data treatment can be accomplished manually or with the available TRI/Autoporosimeter Data Treatment Software, Release 2000.1. Percent (%) Total Pore Volume is a percentage calculated by taking the volume of fluid in the specific pore radii range divided by the Total Pore Volume. The Total Pore Volume is the sum of the fluid absorbed between 2.5-1000 micron radii. The TRI/Autoporosimeter outputs the volume of fluid within a range of pore radii. The first data obtained is for the “5 micron” pore radii which includes fluid absorbed between the pore sizes of 2.5 to 5 micron radius. The next data obtained is for “10 micron” pore radii, which includes fluid absorbed between the 5 and 10 micron radii, and so on. Following this logic, to obtain the volume held within the range of 91-140 micron radii, one would sum the volumes obtained in the range, or bucket, titled “100 micron”, “110 micron”, “120 micron”, “130 micron”, and finally the “140 micron” pore radii ranges. For example, % Total Pore Volume 91-140 micron pore radii=(volume of fluid between 91-140 micron pore radii)/Total Pore Volume.2.5-30 micron % Total Volume 2.5-30micron%TotalVolume=∑5,10,15,20,30micronPoreBucketsTotalPoreVolume*100301-600 micron % Total Volume 301-600micron%TotalVolume=∑350,400,500,600micronPoreBucketsTotalPoreVolume*100>225 micron % Total Volume >225micron%TotalVolume=∑250,275,300,350,400,500,600,800,1000micronPoreBucketsTotalPoreVolume*100 Horizontal Full Sheet (HFS) Test Method The Horizontal Full Sheet (HFS) test method determines the amount of distilled water absorbed and retained by a fibrous structure of the present invention. This method is performed by first weighing a sample of the fibrous structure to be tested (referred to herein as the “dry weight of the sample”), then thoroughly wetting the sample, draining the wetted sample in a horizontal position and then reweighing (referred to herein as “wet weight of the sample”). The absorptive capacity of the sample is then computed as the amount of water retained in units of grams of water absorbed by the sample. When evaluating different fibrous structure samples, the same size of fibrous structure is used for all samples tested. The apparatus for determining the HFS capacity of fibrous structures comprises the following: An electronic balance with a sensitivity of at least ±0.01 grams and a minimum capacity of 1200 grams. The balance should have a special balance pan to be able to handle the size of the sample tested (i.e.; a fibrous structure sample of about 27.9 cm by 27.9 cm). A sample support rack (FIGS.31and31A) and sample support rack cover (FIGS.32and32A) is also required. Both the support rack (FIGS.31and31A) and support rack cover (FIGS.32and32A) are comprised of a lightweight metal frame, strung with 0.305 cm diameter monofilament so as to form a grid as shown inFIG.31. The size of the support rack (FIGS.31and31A) and support rack cover (FIGS.32and32A) is such that the sample size can be conveniently placed between the two. The HFS test is performed in an environment maintained at 23±1° C. and 50±2% relative humidity. A water reservoir or tub is filled with distilled water at 23±1° C. to a depth of 3 inches (7.6 cm). Samples are tested in duplicate. The dry weight of each sample is reported to the nearest 0.01 grams. The empty sample support rack (FIGS.31and31A) is placed on the balance with the special balance pan described above. The balance is then zeroed (tared). One sample is carefully placed on the sample support rack (FIGS.31and31A), “face up” or with the outside of the sample facing up, away from the sample support rack (FIGS.31and31A). The support rack cover (FIGS.32and32A) is placed on top of the support rack (FIGS.31and31A). The sample (now sandwiched between the rack and cover) is submerged in the water reservoir. After the sample is submerged for 30±3 seconds, the sample support rack (FIGS.31and31A) and support rack cover (FIGS.32and32A) are gently raised out of the reservoir. The sample, support rack (FIGS.31and31A) and support rack cover (FIGS.32and32A) are allowed to drain horizontally for 120±5 seconds, taking care not to excessively shake or vibrate the sample. While the sample is draining, the support rack cover (FIGS.32and32A) is carefully removed and all excess water is wiped from the support rack (FIGS.32and32A). The wet sample and the support rack (FIGS.31and31A) are weighed on the previously tared balance. The weight is recorded to the nearest 0.01 g. This is the wet weight of the sample. The horizontal absorbent capacity (HAC) is defined as: absorbent capacity=(wet weight of the sample−dry weight of the sample)/(dry weight of the sample) and has a unit of gram/gram. Vertical Full Sheet (VFS) Test Method The Vertical Full Sheet (VFS) test method is similar to the HFS method described previously, and determines the amount of distilled water absorbed and retained by a fibrous structure when held at an angle of 60° to 75°. After taking weights for the HFS method, the support rack (FIGS.31and31A) and sample are removed from the balance and inclined at an angle of 60°-90° and allowed to drain for 60±5 seconds. Care should be taken so that the sample does not slide or move relative to the support rack (FIGS.31and31A). If there is difficulty keeping the sample from sliding down the support rack (FIGS.31and31A) sample can be held with the fingers. At the end of this time frame, carefully bring the sample and support rack (FIGS.31and31A) to the horizontal position and wipe the bottom edge of the sample support rack (FIGS.31and31A) that water dripped onto during vertical drainage. Return the sample and support rack (FIGS.31and31A) to the balance and take the weight to the nearest 0.01 g. The gram per fibrous structure sample absorptive capacity of the sample is defined as (wet weight of the sample−dry weight of the sample). The calculated VFS is the average of the absorptive capacities of the two samples of the fibrous structure. Wet Burst Test Method This Wet Burst Test Method measures the push through force required to burst wetted fibrous structures using a tensile tester with the appropriate attachments (ex: Thwing-Albert EJA Vantage Burst Tester) and run at a speed of 12.7 cm/second. A useable unit here is one finished product unit, regardless of the number of plies. Cut samples into squares or rectangles not less than 28 cm per side, in replicates of 4 per sample. Fill a sample pan with distilled or deionized water to a depth of 2.54 cm. Holding a sample by the outermost edges, dip the center of the sample into the pan, leaving the sample in the water for 4±0.5 seconds. Remove the sample and drain in a vertical position for 3±0.5 seconds Immediately center the wet sample on the lower ring of the sample holding device, with the outside surface positioned away from the burst device. The sample must be large enough to allow clamping without slippage. Lower the upper ring of the pneumatic holding device to secure the sample. The test measurement starts at a pre-tension of 4.45 g. Start the plunger and record the maximum force when the plunger ruptures the sample. The test is over when the load falls 20 g from the peak force. Some Burst testers use an upward force measurement and some a downward force measurement. For the former, take care to deduct the sample weight that adds to the upward force used to burst. In some cases, it is desirable to measure an aged sample to better predict product performance after aging in a warehouse, during shipping or in the marketplace. One way to rapidly age a sample is attach a paperclip to an outer edge of the 4 replicate stack, fan out the unclipped end of the sample stack and suspend them in a forced draft oven set to 105±1° C. for 5 minutes±10 seconds. Remove the sample stack from the oven and cool for a minimum of 3 minutes before testing. Calculations: WetBurst=∑peakloadreadings#replicates The Burst Energy Absorption (BEA) is the area of the stress/strain curve between pre-tension and peak load. Dry Burst Test Method The Dry Burst Test Method is similar to the Wet Burst Test Method previously described. Samples are cut as in the Wet Burst method and tested dry, in replicates of 4. Calculations: DryBurst=∑peakloadreadings#replicates The Burst Energy Absorption (BEA) is the area of the stress/strain curve between pre-tension and peak load. Liquid Breakthrough Test Method This method measures the breakthrough capacity of a fibrous substance subjected to a stream of water, which corresponds to hand protection herein. The apparatus consists of a balance (accurate to 0.01 g) and able to output data to a software interface at 10 hz. A shallow pan is placed on the balance and a rack, capable of holding the sample, is set 15.24 cm above the balance. A reservoir is filled with distilled or deionized water and this water is pumped at 5 mL/second to an outlet just above the rack holding the sample. Two rectangular pieces of impermeable material are cut such that there is an opening of 5×10 inches. The fibrous substance is placed between these 2 templates, MD along the 5 inch side and CD along the 10 inch side, and clamped tightly. The template holding the sample is placed in the rack, outside of the sample facing up. (Sample could also be tested outside facing down, if noted.) The outlet of the tubing (4.76 mm ID) is placed such that the discharge of the tube is horizontal and located just above the top surface of the sample, approximately 1 inch from one MD edge and in the center of the CD dimension. The tube is oriented so that the discharge of the water is in the MD direction. Water is pumped at 5 mL/second±0.25 mL onto the top of the sample. A timer starts when the water hits the top of the sample and the scale begins outputting weight every 0.1 seconds to an electronic file. A blank is run, before testing any samples, recording the time from the very start of water leaving the tube to the point at which 0.15 g of water is collected in the pan. This “blank time” is a function of the experimental geometry and not the sample being tested. The value reported is the time that it takes for 0.15 g of water to pass through the sample and into the pan, minus the blank time, recording which side of the sample was upward facing. Emtec Test Method TS7 and TS750 values are measured using an EMTEC Tissue Softness Analyzer (“Emtec TSA”) (Emtec Electronic GmbH, Leipzig, Germany) interfaced with a computer running Emtec TSA software (version 3.19 or equivalent). The Emtec TSA comprises a rotor with vertical blades which rotate on the test sample at a defined and calibrated rotational speed (set by manufacturer) and contact force of 100 mN. Contact between the vertical blades and the test piece creates vibrations, which create sound that is recorded by a microphone within the instrument. The recorded sound file is then analyzed by the Emtec TSA software. The sample preparation, instrument operation and testing procedures are performed according the instrument manufacture's specifications. Test samples are prepared by cutting square or circular samples from a finished product. Test samples are cut to a length and width (or diameter if circular) of no less than about 90 mm, and no greater than about 120 mm, in any of these dimensions. Prepare 8 substantially similar replicate samples for testing. Mount the test sample into the instrument, and perform the test according to the manufacturer's instructions. When complete, the software displays values for TS7 and TS750. Record each of these values to the nearest 0.01 dB V2rms. The test piece is then removed from the instrument and discarded. This testing is performed individually on the top surface (outer facing surface of a rolled product) of four of the replicate samples, and on the bottom surface (inner facing surface of a rolled product) of the other four replicate samples. The four test result values for TS7 and TS750 from the top surface are averaged (using a simple numerical average); the same is done for the four test result values for TS7 and TS750 from the bottom surface. Report the individual average values of TS7 and TS750 for both the top and bottom surfaces on a particular test sample to the nearest 0.01 dB V2rms. Additionally, average together all eight test value results for TS7 and TS750, and report the overall average values for TS7 and TS750 on a particular test sample to the nearest 0.01 dB V2rms. Average Diameter Test Method There are many ways to measure the diameter of a fiber. One way is by optical measurement. An article and/or fibrous web and/or fibrous structure comprising filaments is cut into a rectangular shape sample, approximately 20 mm by 35 mm. The sample is then coated using a SEM sputter coater (EMS Inc, PA, USA) with gold so as to make the filaments relatively opaque. Typical coating thickness is between 50 and 250 nm. The sample is then mounted between two standard microscope slides and compressed together using small binder clips. The sample is imaged using a 10× objective on an Olympus BHS microscope with the microscope light-collimating lens moved as far from the objective lens as possible. Images are captured using a Nikon D1 digital camera. A Glass microscope micrometer is used to calibrate the spatial distances of the images. The approximate resolution of the images is 1 μm/pixel. Images will typically show a distinct bimodal distribution in the intensity histogram corresponding to the filaments and the background. Camera adjustments or different basis weights are used to achieve an acceptable bimodal distribution. Typically 10 images per sample are taken and the image analysis results averaged. The images are analyzed in a similar manner to that described by B. Pourdeyhimi, R. and R. Dent in “Measuring fiber diameter distribution in nonwovens” (Textile Res. J. 69(4) 233-236, 1999). Digital images are analyzed by computer using the MATLAB (Version. 6.1) and the MATLAB Image Processing Tool Box (Version 3.) The image is first converted into a grayscale. The image is then binarized into black and white pixels using a threshold value that minimizes the intraclass variance of the thresholded black and white pixels. Once the image has been binarized, the image is skeletonized to locate the center of each fiber in the image. The distance transform of the binarized image is also computed. The scalar product of the skeletonized image and the distance map provides an image whose pixel intensity is either zero or the radius of the fiber at that location. Pixels within one radius of the junction between two overlapping fibers are not counted if the distance they represent is smaller than the radius of the junction. The remaining pixels are then used to compute a length-weighted histogram of filament diameters contained in the image. Roll Firmness Test Method Roll Firmness is measured on a constant rate of extension tensile tester with computer interface (a suitable instrument is the MTS Alliance using Testworks 4.0 Software, as available from MTS Systems Corp., Eden Prairie, Minn.) using a load cell for which the forces measured are within 10% to 90% of the limit of the cell. The roll product is held horizontally, a cylindrical probe is pressed into the test roll, and the compressive force is measured versus the depth of penetration. All testing is performed in a conditioned room maintained at 23° C.±2 C° and 50%±2% relative humidity. Referring toFIG.33below, the upper movable fixture1000consist of a cylindrical probe1001made of machined aluminum with a 19.00±0.05 mm diameter and a length of 38 mm. The end of the cylindrical probe1002is hemispheric (radius of 9.50±0.05 mm) with the opposing end1003machined to fit the crosshead of the tensile tester. The fixture includes a locking collar1004to stabilize the probe and maintain alignment orthogonal to the lower fixture. The lower stationary fixture1100is an aluminum fork with vertical prongs1101that supports a smooth aluminum sample shaft1101in a horizontal position perpendicular to the probe. The lower fixture has a vertical post1102machined to fit its base of the tensile tester and also uses a locking collar1103to stabilize the fixture orthogonal to the upper fixture. The sample shaft1101has a diameter that is 85% to 95% of the inner diameter of the roll and longer than the width of the roll. The ends of sample shaft are secured on the vertical prongs with a screw cap1104to prevent rotation of the shaft during testing. The height of the vertical prongs1101should be sufficient to assure that the test roll does not contact the horizontal base of the fork during testing. The horizontal distance between the prongs must exceed the length of the test roll. Program the tensile tester to perform a compression test, collecting force and crosshead extension data at an acquisition rate of 100 Hz. Lower the crosshead at a rate of 10 mm/min until 5.00 g is detected at the load cell. Set the current crosshead position as the corrected gage length and zero the crosshead position. Begin data collection and lower the crosshead at a rate of 50 mm/min until the force reaches 10 N. Return the crosshead to the original gage length. Remove all of the test rolls from their packaging and allow them to condition at about 23° C.±2° C. and about 50%±2% relative humidity for 2 hours prior to testing. Rolls with cores that are crushed, bent or damaged should not be tested. Insert sample shaft through the test roll's core and then mount the roll and shaft onto the lower stationary fixture. Secure the sample shaft to the vertical prongs then align the midpoint of the roll's width with the probe. Orient the test roll's tail seal so that it faces upward toward the probe. Rotate the roll 90 degrees toward the operator to align it for the initial compression. Position the tip of the probe approximately 2 cm above the surface of the sample roll. Zero the crosshead position and load cell and start the tensile program. After the crosshead has returned to its starting position, rotate the roll toward the operator 120 degrees and in like fashion acquire a second measurement on the same sample roll. From the resulting Force (N) verses Distance (mm) curves, read at the data point closest to 7.00 N as the Roll Firmness and record to the nearest 0.1 mm. In like fashion analyze a total of ten (10) replicate sample rolls. Calculate the arithmetic mean of the 20 values and report Roll Firmness to the nearest 0.1 mm. Wet Web-Web CoF Test Method This method measures wet coefficient of friction (“CoF”) of a fibrous structure using a Thwing-Albert Vantage Materials Tester with a 5N load cell, along with a horizontal platform, pulley, and connecting wire (Thwing-Albert item #769-3000). The platform is horizontally level, 50.8 cm long, by 15.24 cm wide. The pulley is secured to the platform directly below the load cell in a position such that the connecting wire is vertically straight from its load cell connection point to its contact with the pulley, and horizontally level from the pulley to a Plexiglas sled. A sheet of abrasive cloth (utility cloth sheet, aluminum oxide P120) 7.62 cm wide by 15.24 cm long is adhered to the central region of testing platform (long side parallel to long dimension of platform). The Plexiglas sled (2.9 cm in length, 2.54 cm in width, 1.0 cm in height, with a leading edge round curve (0.3 cm radius) extending from the bottom of the front of the sled with the radius extending from the center of a 0.08 cm diameter hole cut through the width of the sled at a point 0.3 cm from bottom of sled and 0.3 cm from leading edge of sled. The sled handle is connected through the 0.08 cm diameter hole drilled though the sled. A 0.08 cm diameter stainless steel wire is bent in a triangular shape for attaching the o-ring of the connecting wire to the sled. A 2.54 cm wide strip of abrasive cloth (utility cloth sheet, aluminum oxide P120) is adhered to the sled from the trailing edge of the bottom face, around the leading edge, to the trailing edge on the top face. The edges of the sled and the abrasive cloth should be flush. The complete sled apparatus (minus the extra weights, described below) should weigh 9.25 (+/−2) grams. Other equipment and supplies include a weight: 200 g cylindrical shaped, 2.86 cm diameter and 3.81 cm tall; a calibrated adjustable pipette, capable of delivering between 0 to 1 milliliters of volume, accurate to 0.005 ml; deionized (DI) water; and a top loading balance with a minimum resolution of 0.001 g. The wet web-to-web CoF, as described here, is measured by rubbing one stack of wet usable unit (uu) material against another stack of wet uu material, at a speed of 15.24 cm/min, over two intervals of distance of 1.27 cm each. The average of the two peak forces (one from each 1.27 cm interval) is divided by the normal force applied to obtain a wet web-to-web CoF reading. Cut two or more strips from a usable unit (uu) of sample to be tested, 5.0-6.5 cm long in the MD, and 2.54 (+/−0.05) cm wide in the CD (all cut strips should be the exact same dimensions). Stack the strips on top one another, with the sample sides of interest facing outwards. The number of strips used in the stack depends on the uu basis weight, according to the following calculation (INT function rounds down to the nearest integer): Nstrips=INT(70/BWuu)+1 where: Nstrips=Number of uu strips in stackBWuu=basis weight of usable unit in grams per square meter (gsm). This stack is henceforth referred to as the “sled-stack”. Cut another equal number of strips from one or more uus of test material, 7.5-10 cm long in the MD, and 4.5-6.5 cm wide in the CD (all cut strips should be the exact same dimensions). Stack these strips on top one another, with the sample sides of interest facing outward, and all edges aligned on top one another. This stack is referred to henceforth as the “base-stack”. Using the calibrated balance, measure the weight (to the nearest 0.001 g) of the sled-stack (Wsled-stack1), then the base-stack (Wbase-stack). Place the “sled-stack” on the bottom (rounded) side of sled (i.e., the side with the abrasive surface), with one short-side end aligned with the trailing end of the sled. Place the “base stack” on the abrasive fabric adhered to the testing platform, with its long side parallel to the long-side of the abrasive fabric. Add DI water in the amount of 4.0 times the dry mass of each stack. Use a calibrated pipette, and adjust to nearest 0.005 ml. Deliver the liquid one drop at a time, in such a way that the exposed stack surface receives an equal distribution of the total volume. Gently wrap the wetted “sled stack” around the sled (through the wire sled handle), ensuring that the back edge of the stack is flush with the trailing edge of the sled, wrinkle-free, and not overly strained. Next, gently place the sled (with stack attached) down on top of the wetted “base web” in a position such that the sled's trailing edge is between 1-1.5 cm from the back edge of the “base stack” (i.e., edge furthest from pulley). After ensuring that the connecting wire is aligned properly in the pulley groove, attach the connecting-wire loop to the sled hook. The force reading on the instrument may show a little tension—20 grams or less. Place 200 g weight on top of the sled, positioned such that the back edge of the weight is even with the back (trailing) edge of the sled. Set the program to move the cross-head at a speed of 15.24 cm/min for a distance of 1.27 cm (Pull #1), collecting data at a rate of 25 data points/sec. After Pull #1, the cross-head pauses for 10 seconds, then restarts again at 1.27 cm/min for another 0.5 inches (Pull #2). The script captures the peak force from pull #1 and #2, calculates an average of the 2 peaks, and divides this value by the normal force applied (e.g., 200 g weight plus the ≈9 g sled weight). Repeat the measurement three more times. Reported value is the average of the four. The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.” Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | 192,932 |
11858246 | DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION Reference will now be made in detail to various exemplary embodiments of the invention. It is to be understood that the following discussion of exemplary embodiments is not intended as a limitation on the invention. Rather, the following discussion is provided to give the reader a more detailed understanding of certain aspects and features of the invention. As used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. The term “about” can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from the context, all numerical values provided herein are modified by the term “about.” As used herein, the term “metallized” (as in “metallized” Mylar®) refers to a material such as a polymer film which has been coated with a thin layer of metal, such as aluminum, chromium, or nickel, typically through a physical vapor deposition (PVD) process. The thin layer of metal can be coated on one surface of the material or both surfaces. As used herein, the term “laminated” (or variations including “laminate”, “lamination”, and the like) refers to the process or result of creating a composite material by joining two layers together, typically under heat and pressure and/or through use of an adhesive. As used herein, “Mylar®” may be used interchangeably with “biaxially-oriented polyethylene terephthalate (PET) film”, “polyethylene terephthalate (PET) film”, “polyester film”, and similar terminology. According to embodiments, the protective sleeve may include two layers (outer, inner), three layers (outer, middle and inner), or four layers (outer, first middle layer, second middle layer, inner layer). In embodiments, the protective sleeve may include one or more layer of material in any number of layers. One or more of the layers of the protective sleeve may be bonded together or may not be bonded together. In embodiments, some, all or none of the layers of material of the protective sleeve may be bonded to another layer in the protective sleeve. In embodiments, some, all or none of the layers of material of the protective sleeve may be bonded to another layer in the protective sleeve. In embodiments, some, all or none of the layers of material of the protective sleeve may be joined together. Various embodiments described below include a reflective layer such as a metallized Mylar® polyester film laminated to another material such as a Rip Stop Nylon to create a composite material. According to embodiments, the reflective layer may have a reflective surface (e.g. a surface which includes a thin metallic film which is deposited through metallization) and a non-reflective surface, or two reflective surfaces. In some embodiments where the reflective layer has one reflective surface, the composite may be manufactured such that the non-reflective surface is bound directly to the Rip Stop Nylon, such that the reflective surface remains exposed. In other embodiments where the reflective layer has one reflective surface, the composite may be manufactured such that that the reflective surface is bound directly to the Rip Stop Nylon such that the reflective surface is hidden. In embodiments where the reflective layer has two reflective surfaces, one reflective surface will be bound directly to the Rip Stop Nylon and hidden, and one will remain exposed. Thus, in embodiments of the protective sleeve which follow, a reflective surface may face outward (away from the electronic device), inward (toward the electronic device), or both inward and outward. The orientation of the reflective surfaces will depend on the particular application of the protective sleeve (e.g. whether it is intended to protect the device from heat, cold, or both). Further, the reflective surface(s) may be hidden (e.g. covered by another layer) or exposed. Not wishing to be bound by theory, it is the reflective surface(s) of the reflective layer which are believed to primarily trap/reflect infrared energy within or keep infrared energy out of the protective sleeve. A two-layer embodiment of the invention provides an outer reflective layer and inner protective layer. The outer reflective layer may include Mylar® polyester film, such as a highly-reflective “continuous” metalized Mylar® polyester film, or aluminized polyester film laminated to a Rip Stop Nylon or similar material, and the emissivity of the outer layer may be in the range of about 0.05 to 0.40, such as less than 0.40, less than 0.30, less than 0.20, or less than 0.10. For example, the emissivity can be 0.1 to 0.2, or 0.02 to 0.35, or 0.01 to 0.25, or 0.04 to 0.15, and so on. Further, in embodiments, the outer metalized surface of the outer reflective layer has a reflectivity in the range of between 80% and 100%, with a preferred range between 90% and 100%. The inner protective layer may include a micro-fleece type material (lining) which is capable of protecting the touch screen on the device and preventing scratches. A three-layer embodiment provides an outer reflective layer, a middle insulation/air space layer, and an inner protective layer. The outer reflective layer may include Mylar® polyester film such as a highly-reflective “continuous” metalized Mylar® polyester film, or aluminized polyester film laminated to a Rip Stop Nylon or similar material, and the emissivity of the outer layer may be less than 0.40 (0.05-0.40 is a preferred range), or in any range provided herein. Further, in embodiments, the outer metalized surface of the outer reflective layer has a reflectivity in the range of between 80% and 100%, with a preferred range between 90% and 100%. The middle insulation layer may include ⅛-⅜″ thick insulation foam (which can be either open cell or closed cell) which provides buoyancy and additional drop/shock protection for the device. The inside protective layer may include a micro-fleece type material (lining) which protects the touch screen on the device and prevents scratches. A first four-layer embodiment provides an outer reflective layer, a first middle insulation layer, a second middle insulation layer, an inner protective layer. The outside reflective layer may include Mylar® polyester film or aluminized polyester film or similar material, and the emissivity of outer layer may be less than 0.40 (0.05-0.40 is a preferred range), or in any range provided herein. The first middle insulation layer may include nylon or polyester Rip Stop material similar to 70D Rip Stop Nylon. The second middle insulation layer may include a ⅛-⅜″ thick open cell insulation foam which provides buoyancy and additional drop/shock protection for the device. The inside protective layer may include a micro-fleece type material (lining) which protects the touch screen on the device and prevents scratches. A second four-layer embodiment provides an outer protective double layer which includes a layer of printed Rip Stop Nylon or similar material and a highly reflective “continuous” metalized Mylar® polyester film, or aluminized polyester film laminated to a Rip Stop Nylon or similar material. Further, in embodiments, the surface of the outer reflective layer has a reflectivity in the range of between 80% and 100%, with a preferred range between 90% and 100%. Further, this embodiment includes a middle insulation/air space layer and an inner protective layer. The middle insulation layer may include ⅛-⅜″ thick open cell insulation foam which provides buoyancy and additional drop/shock protection for the device. The inside protective layer may include a micro-fleece type material (lining) which protects the touch screen on the device and prevents scratches. A third four-layer embodiment provides an outer reflective layer, a first middle insulation layer, a second middle insulation layer, an inner protective layer. The outside reflective layer may include Mylar® polyester film, such as a highly-reflective “continuous” metalized Mylar® polyester film, or aluminized polyester film laminated to a Rip Stop Nylon or similar material, and the emissivity of outer layer may be less than 0.40 (0.05-0.40 is a preferred range), or in any range provided herein. Further, in embodiments, the outer metalized surface of the outer reflective layer has a reflectivity in the range of between 80% and 100%, with a preferred range between 90% and 100%. The first middle insulation layer may include nylon or polyester Rip Stop material similar to 70D Rip Stop Nylon. The second middle insulation layer may include a ⅛-⅜″ thick insulation foam (which can be either open cell or closed cell) which provides buoyancy and additional drop/shock protection for the device. The inside protective layer may include a micro-fleece type material (lining) which protects the touch screen on the device and prevents scratches. In aspects, an additional layer may be included between the third and fourth layer, between an innermost layer and another layer, or between any layer, wherein the additional layer may comprise a phase change material (PCM), aerogel (e.g., a synthetic porous ultralight material derived from a gel, in which the liquid component for the gel has been replaced with a gas without significant collapse of the gel structure, resulting in a solid with low density and low thermal conductivity), or similar low conductivity material as would be understood by one of skill in the art. According to embodiments, a closure can be provided to close the protective sleeve, which closure may be a plastic spring strip closure or other closure system such as a hook and loop closure or similar type of closure. However, according to embodiments, the closure may be configured so that it does not seal the sleeve and thus allows thermal energy to dissipate through. Further, any embodiment may include a woven tag which provides a user ID on the tag. Turning now to the figures,FIG.1Ashows an embodiment of a protective sleeve101during use. At the top of the protective sleeve101is a reinforced closure105for closing the sleeve over a cell phone during use. Also shown are one or more internal seams115which can be used to bind together the various layers of the protective sleeve. The internal seams may be provided at the bottom and sides of the protective sleeve to join the various layers together, while leaving an opening at the top of the protective sleeve where the reinforced closure is provided. At the bottom left is a woven tag195for indicating branding or personal identification indicia, however, such a tag can be placed anywhere on the protective sleeve. Further visible is a window120and a cover122connected to the sleeve101.FIG.1Bschematically shows that the structure100A of the various layers of a 4-layer embodiment may be generally implemented as an outer reflective layer125, a first middle layer below the outer reflective layer which is a durability layer130, a second middle layer below the first middle layer which is an insulation layer135, and an inner layer below the insulation layer which is a protective layer140. It should be pointed out that the inner layer may or may not be an antimicrobial layer.FIG.1Cshows that this structure100B of the 4-layer embodiment may be specifically implemented as an outer Mylar® layer155, a first middle layer which is Rip Stop Nylon160, a second middle layer which is open cell foam165, and an inner or interior layer which is by way of example only, one of a micro fleece, polyester, fabric, or textile liner170. Additional or fewer layers may be incorporated. In certain embodiments the inner layer170is treated with an antimicrobial agent. In certain embodiments the material of inner layer170is fabricated with an antimicrobial agent. FIGS.2and3show different perspective views of the composition of a 4-layer (or 4-material) embodiment, whereFIG.2illustrates the layered composition itself200andFIG.3shows a cross-section of the protective sleeve301to further illustrate the arrangement of layers in this embodiment. The outer layer220,320(Material A) is an IR Reflective material with an emissivity in the range of about 0.05-0.2 constructed of Mylar® such as a highly reflective “continuous” metalized Mylar® or material with similar properties. The first middle layer240,340(Material B) may be nylon or polyester Rip Stop material similar to 70D Rip Stop Nylon. The second middle layer260,360(Material C) is open cell foam or similar material. The inner or interior layer280,380(Material D) is by way of example only, one of a micro-fleece, polyester, fabric, or textile material. Material D can be treated with an antimicrobial agent. Material D can be fabricated with an antimicrobial agent present. Material D can be that of an antimicrobial fabric or antimicrobial textile. In embodiments, the foam of Material C can be that of an open cell foam or closed cell foam material. In certain embodiments, the open cell foam is provided with a thickness of ⅛ of an inch or greater. In other embodiments, the closed cell foam is provided with a thickness of 1/16 of an inch or greater. In another embodiment (shown inFIG.3), the outer layer320(Material A) is printed Rip Stop Nylon or similar material. The first middle layer340(Material B) is an IR Reflective material with an emissivity in the range of about 0.05-0.2 constructed of Mylar® or material with similar properties. The second middle layer360(Material C) is open cell foam or similar material. The inner or interior layer380(Material D) is polyester microfleece or similar type material. In embodiments, the open cell foam of Material C is provided as the thickest layer of the construction. In embodiments, the open cell foam is provided at a thickness of at least ⅜ of an inch. Turning now toFIG.4A, shown in this embodiment401is the direction of placement or removal of a mobile electronic device from a protective sleeve.FIG.4Bshows an outer view of another embodiment of a protective sleeve with the device removed, including, at the top, a reinforced opening/closure system405, below that, the body of the protective sleeve itself401to protect the mobile electronic device, and at the bottom left, the branding or user ID tag495. FIGS.5A-5Cshow various dimensions of a particular embodiment of the protective sleeve, whereFIG.5Ashows that the protective sleeve has a thickness of, in one embodiment, 13.65 mm,FIG.5BandFIG.5Cshow that the protective sleeve has a width of, in one embodiment, 84.29 mm andFIG.5Bshows the protective sleeve has a height of, in one embodiment, 164.57 mm.FIGS.6A-6Cshow various dimensions of another embodiment of the protective sleeve, whereFIG.6Ashows that the protective sleeve has a thickness of, in one embodiment, 13.45 mm,FIG.5BandFIG.5Cshows that the protective sleeve has a width of, in one embodiment, 73.47 mm andFIG.5Bshows the protective sleeve has a height of, in one embodiment, 144.64 mm. FIG.7shows a cross-section of a 5-layer (or 5-material) embodiment of the protective sleeve701which includes an outer layer710, first middle layer720, second middle layer740, third middle layer760, and an inner layer780. The outer layer710(Material A) is printed Rip Stop Nylon or similar material. The first middle layer720(Material B) is an IR Reflective material with an emissivity in the range of about 0.05-0.2 constructed of Mylar®, such as a highly reflective “continuous” metalized Mylar® or material with similar properties. The second middle layer740(Material C) is nylon or polyester Rip Stop material similar to, in one embodiment, 70D Rip Stop Nylon. The third middle layer760(Material D) is open cell foam or similar material. The inner layer780(Material E) is polyester microfleece or similar-type material. In embodiments, the open cell foam of Material D is provided as the thickest layer of the construction. In embodiments, the open cell foam is provided at a thickness of at least ⅜ of an inch. FIG.8shows an outer printed layer810of a protective sleeve801according to an embodiment of the invention. According to this embodiment, the reflective layer is located beneath the outer printed layer810. Further, the outer printed layer810can include Rip Stop Nylon or a coated membrane fabric, and can be printed to include, for example, camouflage, logos, decorative images, designs, and photos. Further, the outer printed layer810should not reduce the emissivity of the reflective layer by, in embodiments, more than 15%, such that the overall emissivity of the protective sleeve is in the range of 0.1 to 0.4. Additionally, the outer printed layer810should be relatively light such that it weighs, in a preferred embodiment, less than 6 ounces. In any embodiment of the invention, the outer surface or layer can be coated with any one or more of a water repellant coating, a non-breathable coating, a non-porous coating, a hydrophobic coating, a UV blocking coating, or a UV filtering coating. Further, any embodiment of the invention can include a closure such as a plastic spring strip closure, hook and loop closure, magnetic closure, and the like. Further, it is preferred that the closure does not seal the sleeve completely to allow thermal energy to dissipate through. Additionally, any embodiment may include additional features such as a woven tag, easy open pull tabs made of PVC rubber, nylon webbing, or similar materials, one or more tether attachment points, a User ID, and a radiofrequency identification (RFID) or Bluetooth low energy (BLW) beacon system or similar technology for alerting the location of the protective sleeve. Further, in certain embodiments, the protective sleeve may include one or more pockets for holding miscellaneous items. The one or more pockets can be formed on the outside or inside surface(s) of the sleeve and have the same or different material construction as the case or sleeve. FIGS.9and10show a protective sleeve or case901,1001embodiment for protecting a tablet or laptop computer. According to this embodiment, the protective case901,1001is constructed to include a magnetic or zippered closure system905,1005and may be open or closed by way of rubber of PVC silicone pull tabs904,1004. Additionally, the protective case can include one or more pockets, including pockets dimensioned to hold one or more accessories934such as an AC adapter/power supply/plug/charger/cord944,1044. An additional pocket may be dimensioned to hold a phone954,1054. The one or more pockets may be secured through a hook and loop closure system924,1024and may be open or closed with nylon or webbing pull tabs914,1014. In this embodiment, the construction900of the protective case has, in an example, an outermost layer910which is Rip Stop Nylon or coated membrane fabric which is light in weight (less than 6 ounces). The first middle layer920is a reflective layer, the second middle layer is Rip Stop Nylon940, the third middle layer is an impact layer960, and the inner layer is a protective liner980.FIG.10shows that the construction1000of the multilayer composite material making up the protective case embodiment may also include a layer of colored or non-colored ballistic nylon as the outer layer1010, a reflective layer1020, a layer of impact foam as one of the middle layers1060, and a liner1080. FIG.11is a photographic image showing a layer of Rip Stop Nylon1110(top of image) and a reflective continuous metalized Mylar® layer1120(bottom of image) which together are laminated to form an outer or internal laminated layer in various embodiments of the protective sleeve. Interwoven reinforcement threads1199are also shown arranged in a cross-hatch pattern. In an additional embodiment, the protective sleeve can be releasably attached to a garment to form a pocket. The attachment mechanism can be that of any mechanical, physical, electric, or magnetic attachment. By way of example only, the attachment mechanism may be one or more of: a zipper, button, magnet, hook and loop, clip, snap, or Velcro. The protective sleeve can be attached to the external covering of a garment. The protective sleeve can be attached to an internal material of a garment. The protective sleeve can be attached, removed and then reattached multiple times. A garment can be that of any garment worn by a wearer, including but not limited to clothing apparel or a backpack. In another embodiment, the protective sleeve (whether a releasably attachable sleeve/pocket attachable to a garment, or that of a standalone protective sleeve) can comprise a transparent or substantially transparent window, such as window120ofFIG.1A. The transparent window can be made of a plastic or other material that is capable of transmitting, conveying, or communicating human touch to an electronic device that is housed within the protective sleeve. Such transmission or communication can, by way of example only, cause one or more of a key, switch, or sensor of such electronic device to provide an electrical signal or response to said human touch through the transparent window, such as a human using a finger(s) to interact with an electronic device's touchscreen. The electronic device can be, by way of example only, one or more of: a computerized device, laptop, tablet, mobile phone, cell phone, pager, medical device, or healthcare monitoring device. In certain embodiments, the transparent window can be opened and closed by way of any closure, such as a mechanical closure. Such a mechanical closure can be by way of example only: a snap, zipper, button, Velcro, clip, pressure clamp, or magnets. In other embodiments, the protective sleeve comprises a protective sleeve made of layers of materials provided in various embodiments as disclosed herein with a transparent window. This transparent window is then releasably or reversibly covered with a covering, such as covering122ofFIG.1A. comprising layers of materials provided in the various embodiments as disclosed herein. This covering can be that of an extension of the materials that form the side of the protective sleeve opposite that of the transparent window. The covering can form that of a releasably or reversibly attachable flap of the protective sleeve. The transparent window can be made of any transparent or semi-transparent material capable of transmitting or communicating human touch through the transparent window to that of a housed electronic device. By way of example only, the window can be made of one or more of: a plastic material, glass material, a combination thereof. In still another embodiment, the protective capsule, or sleeve or pocket, comprises a bladder. The bladder can be that of a releasably attachable bladder. The bladder can be that of a replaceable bladder. The bladder can house, by way of example only, one or more of: a liquid, ice, or gas. This bladder allows the protective sleeve to further influence the temperature of, by way of example only, one or more of: a housed electronic device, medical device, or pharmaceutical. Such influence can be to maintain the temperature within a known range or to alter the temperature of the housed electronic device, medical device, or pharmaceutical. This can be helpful with transporting or housing medical devices that may also contain pharmaceuticals, temperature or thermally sensitive pharmaceuticals, or electronic devices comprising temperature sensitive components. In aspects, the thermal capsule or sleeve comprises dry ice or a bladder or container holding dry ice. In aspects, the dry ice or bladder or container holding dry ice may be located adjacent to the temperature sensitive pharmaceutical or electronic device. In yet another embodiments, the capsule or sleeve comprises a phase change material that in aspects is located adjacent to the temperature sensitive pharmaceutical or electronic device. In other aspects, the capsule or sleeve comprises or supports having a temperature measuring device or mechanism, including a thermometer or a thermally-sensitive material that is capable of changing color, tint, or hue based on differing temperatures, wherein the temperature measuring device or mechanism is capable of indicating an internal temperature of the sleeve or capsule. The temperature measuring device or mechanism is, in aspects, located on the exterior of the sleeve or capsule or visible from the exterior of the sleeve or capsule. The temperature measuring device or mechanism, in aspects, may also be capable of communicating with an electronic device so that a user can monitor the temperature on, for example, a smartphone or computer. In other aspects, the sleeve contains an electronic device, such as a tablet computer, that is mounted to a vehicle, such as a vehicle dashboard. In aspects, the sleeve opening or another opening, such as on a back side of the sleeve, allows for or accommodates attaching or connecting the electronic device to a mount. In embodiments, the sleeve or capsule may cover or include a plastic housing and/or layered housing for a tablet computer mounted to a vehicle dashboard. In aspects, the sleeve or capsule may unzip around the sides and bottom of the sleeve or capsule so that the front cover of the sleeve or capsule can be lifted up and used as a sun shade. In aspects, wings, in some cases which may comprise plastic material and/or layered material, are sewn or attached into the inner portion of the top panel to support the shading element (seeFIG.23A). When not in use, the wings may fold flat and the sleeve or capsule can be zipped or otherwise closed or sealed around the tablet computer (seeFIG.23B). In aspects, when the tablet is in the sleeve or capsule (2401), then the wings (2402) can support the cover (2403) of the tablet computer and make it capable of shading the tablet from, for example, the sun. (See,FIG.24.) In aspects, in the side view (seeFIG.24), the wings may be covered in AGION® fabric, such as gray fabric. The wings may be sewn into the top panel so that they unfold down to the sides to support the top panel. The top panel may comprise a layered construction as described herein. The back panel may be comprised of the layered construction described herein. In aspects, the back panel may use harder or stiffer foam or other material as in aspects the back panel will comprise an opening, hole, or cut-out to attach the tablet computer to a mount. In aspects, the sleeve or capsule comprises a zipper, such as a water-resistant zipper, and PVC gusset(s).FIG.25shows a front view of the sleeve or capsule opened to where the tablet computer can be placed, including a showing of the opening, cut-out or hole in the back panel where a mount can be attached to the tablet computer or a mount can enter the sleeve or capsule, or where another aspect of the tablet computer or mount can extend outside the capsule or sleeve. In aspects, the sleeve or capsule comprises a water resistant zipper2501, wings optionally covered in AGION® fabric2502, zipper pulls2503, elastic tabs2504on each corner to secure the cover to the tablet computer, and/or PVC gussets2505. In aspects, the depth is about 2-5 cm, the width is about 20-30 cm, and the height is about 10 to 20 cm. In aspects the opening, hole or cut-out may be about 5-10 cm in width and 5-15 cm in height. In aspects, the sleeve or capsule may comprise a layered construction as described herein, foam, EVA, EVA 5 mm foam, AGION® fabric, stitching lining, edging material, or bonded materials. In aspects, the electronic device herein refers to a camera or video camera battery and in aspects the sleeves or capsules as described herein may be designed to hold one or more camera or video camera batteries. In aspects, the sleeve or capsule will protect the battery from heat or cold. In aspects, protecting the battery will prolong battery life or keep the battery viable (e.g., keep the battery from dying or losing charge sufficient to power the camera or video camera). Additional embodiments include a thermal masking material which includes a colored or printed nylon outer layer and an IR reflective layer with an emissivity within the range of 0.05 to 0.2 constructed of a highly reflective continuous metalized reflective layer such as a metalized reflective polyethylene terephthalate (PET) film (e.g. Mylar®) disposed beneath the colored or printed outer layer. Various materials of the thermal masking material include the following layers of materials: Material A: Printed Rip Stop Nylon Material B: IR Reflective material with an emissivity within the range of 0.05-0.2 constructed and constructed of a highly reflective “continuous” metalized Mylar or similar material Material C: Nylon or polyester ripstop material similar to 70D Rip Stop Nylon Material D: Layer of open cell flat foam surface or similar consisting of no less than ⅜ of an inch thickness Material E: Polyester micro-fleece or similar type material The above materials can be utilized in the thermal masking material in any order, such as in the embodiments below: Embodiment #1 which is reversible provides the layers/materials in the following order: A, B, C, D, C, B, A. Embodiment #2 which also is reversible provides the layers/materials in the following order: A, B, C, D, E, D, C, B, A. Embodiment #3 which is not reversible provides the layers/materials in the following order: A, B, C, D, E. Embodiment #4 which is not reversible provides the layers in the following order: A, B, C, D. Embodiment #5 which is not reversible provides the layers in the following order; A, B, C. Variations of the above embodiments are contemplated which have less layers/materials or layers/materials arranged in a different order, provided that, in embodiments, Material B is always present in at least one layer of the layered construction. The thermal masking material may have a variety of uses.FIGS.12-14show various thermal images which illustrate infrared heat emanating from a human body (FIG.12), a train and multiple individuals (FIG.13), and a human running away (FIG.14), andFIGS.15-16shows the results of thermal testing of embodiments of the invention using a FLIR camera.FIGS.17-22show that the thermal masking material may have a variety of uses such as, for example, camouflage outerwear for hunting or military applications (FIGS.17-19), a sniper blind (FIG.20), a tank covering (FIG.21), and a thermal masking tape (FIG.22). Any of the products shown inFIGS.17-22are contemplated as within the scope of the invention, including any variations which can be conceived by a skilled artisan. In aspects, the invention includes a material comprising a colored or printed outer surface and a continuous metalized reflective surface there beneath. In aspects, the invention includes a material comprising a colored or printed outer surface and a continuous metalized reflective surface there beneath, wherein the reflective surface is an inner liner. In aspects, the invention includes a reflective surface disposed between an inner liner and the outer surface. In aspects, the invention includes a material comprising a colored or printed outer surface and a continuous metalized reflective surface there beneath, wherein the outer surface comprises nylon and the continuous metalized reflective surface is attached or bonded to an underside of the nylon. In aspects, the invention covers a material comprising a colored or printed outer surface and a continuous metalized reflective surface there beneath, wherein the outer surface comprises Ripstop or nylon with interwoven reinforcement threads arranged in a cross hatch pattern. In aspects, the invention includes a material comprising a colored or printed outer surface and a continuous metalized reflective surface there beneath, wherein the reflective surface is disposed between the outer layer and an inner layer and the inner layer is water resistant. In aspects, the invention includes a material comprising a colored or printed outer surface and a continuous metalized reflective surface there beneath, wherein the reflective surface is disposed between the outer layer, which is water resistant, and an inner layer, which is porous. In aspects, the invention includes tape comprising a colored or printed outer surface or layer, a continuous metalized reflective middle layer, and an innermost surface or layer comprising an adhesive. In aspects, the invention includes a method of using said tape for one or more of a sniper blind, clothing, camouflage clothing, camouflage covering, or camouflage sniper blind, or combinations thereof. In aspects, the invention includes a method of using said tape to cover equipment, whereby an air gap is disposed between the equipment and the material. This method may further comprise circulating cooled air in the air gap. In aspects, the invention includes a method of using said tape to cover a human, whereby an air gap is disposed between the human and the material. This method may further comprise circulating cooled air in the air gap. In aspects, the invention includes a thermal masking product comprising a first, second, and third surface layered together, wherein the second surface is a reflective surface and is disposed between the first surface and the third surface such that the reflective surface of the second surface is completely or partially covered. In aspects of the thermal masking product, the second surface is infrared (IR) reflective with an emissivity of 0.5 to 0.20. In aspects of the thermal masking product, the second surface comprises metalized polyester film. In aspects of the thermal masking product, the thermal masking product is a thermal masking tape wherein the first and/or third surfaces comprise an adhesive. In aspects of the thermal masking product, the first surface comprises printed Rip Stop Nylon, nylon with interwoven reinforcement threads arranged in a cross hatch pattern, or a coated membrane fabric. In aspects of the thermal masking product, the product is an article of clothing. In aspects of the thermal masking product, the second surface is laminated to the first surface, and the first or third surfaces comprise nylon. In aspects of the thermal masking product, the second surface comprises metalized polyester film. In aspects of the thermal masking product, the metalized polyester film has a reflectivity in the range of 80% to 100%. In aspects of the thermal masking product, the second layer of material further comprises interwoven reinforcement threads arranged in a cross hatch pattern. In aspects of the thermal masking product, the first surface is an outer surface comprising a coating chosen from one or more of a water repellant coating, a non-breathable coating, a non-porous coating, a hydrophobic coating, a UV blocking coating, or a UV filtering coating, or combinations thereof. In aspects, the invention includes a thermal masking product comprising three or more of the following layers:A. printed Rip Stop Nylon;B. an IR Reflective material with an emissivity within the range of 0.05 to 0.4;C. nylon;D. open or closed cell insulation foam; and/orE. microfleece or similar material wherein layer “B” is always present in the thermal masking product and is disposed between any one or more of layers A, C, D, or E. In aspects, the thermal masking product is reversible and comprises the layers in the following order: A, B, C, D, C, B, and A. In other aspects, the thermal masking product is not reversible and comprises the layers in the following order: A, B, C, D, C, B, and A. In other aspects, the thermal masking product is reversible and comprises the layers in the following order: A, B, C, D, E, D, C, B, and A. In other aspects, the thermal masking product is not reversible and comprises the layers in the following order: A, B, C, D, E, D, C, B, and A. In other aspects, the thermal masking product is reversible and comprises the layers in the following order: A, B, C, D, and E. In other aspects, the thermal masking product is not reversible and comprises the layers in the following order: A, B, C, D, and E. In other aspects, the thermal masking product is reversible and comprises the layers in the following order: A, B, C, and D. In other aspects, the thermal masking product is not reversible and comprises the layers in the following order: A, B, C, and D. In other aspects, the thermal masking product is reversible and comprises the layers in the following order: A, B, and C. In other aspects, the thermal masking product is not reversible and comprises the layers in the following order: A, B, and C. In other aspects, the thermal masking product is reversible and comprises the layers in the following order: C, B, and A. In other aspects, the thermal masking product is not reversible and comprises the layers in the following order: C, B, and A. In other aspects, the thermal masking product is an article of clothing. In other aspects of the thermal masking product, layer B is laminated to layer A or layer C. In aspects of the thermal masking product, layer B comprises polyester film. In aspects of the thermal masking product, layer B comprises metalized polyester film. In aspects of the thermal masking product, layer B is laminated to layer A or layer C and the thermal masking product comprises nylon with interwoven reinforcement threads arranged in a cross hatch pattern. In aspects of the thermal masking product, the metalized polyester film has a reflectivity in the range of 80% to 100%. In aspects of the thermal masking product, it is a plurality of plates configured to fit together to cover a piece of equipment. Various dimensions, materials, designs and embodiments provided in this disclosure are not intended to be limiting but are rather provided by way of example only. An artisan of ordinary skill is capable of modifying the dimensions of the protective sleeve to accommodate mobile or portable electronic devices of different dimensions, including a flip phone, smart phone, tablet, and laptop computer, according to the manufacturing specifications of a particular electronic device. The interior dimensions can thus be modified to accommodate electronic devices of different sizes. Further, other embodiments of the invention may include materials which have equivalent capabilities to those discussed herein, which may be apparent to a person who is skilled in the art. The present invention has been described with reference to particular embodiments having various features. In light of the disclosure provided above, it will be apparent to those skilled in the art that various modifications and variations can be made in the practice of the present invention without departing from the scope or spirit of the invention. One skilled in the art will recognize that the disclosed features may be used singularly, in any combination, or omitted based on the requirements and specifications of a given application or design. When an embodiment refers to “comprising” certain features, it is to be understood that the embodiments can alternatively “consist of” or “consist essentially of” any one or more of the features. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention. It is noted in particular that where a range of values is provided in this specification, each value between the upper and lower limits of that range is also specifically disclosed. The upper and lower limits of these smaller ranges may independently be included or excluded in the range as well. The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. It is intended that the specification and examples be considered as exemplary in nature and that variations that do not depart from the essence of the invention fall within the scope of the invention. Further, all of the references cited in this disclosure are each individually incorporated by reference herein in their entireties and as such are intended to provide an efficient way of supplementing the enabling disclosure of this invention as well as provide background detailing the level of ordinary skill in the art. | 40,408 |
11858247 | InFIG.1a connection of a first part A of a nonwoven carrier material1and a second part B of a nonwoven carrier material1is schematically shown (prior art). The first part A has a first thermoplastic fiber layer A1and a second thermoplastic fiber layer A2. The second part B has also a first thermoplastic fiber layer B1and a second thermoplastic fiber layer B2. For connecting the first part A and the second part B in a connecting area3the first part A is laid on top of the second part B. In the connection area3four fiber layers are arranged. Due to this the thickness and weight of the nonwoven carrier material1increases in the connecting area3. InFIGS.2A and2Ban alternative embodiment of the prior art is shown. The nonwoven carrier material1comprises a first part A with a single fiber layer and a second part B with also a single fiber layer. Part A is laid on top of part B and then both parts A, B are permanent consolidated, for example by using a hot wire or an ultrasonic bonding/cutting step to simultaneously cut and consolidate part A and part B together. Thereafter part A and part B are folded open, whereby they are connected in the connecting area3. Also in this embodiment is the thickness (and weight) of the nonwoven carrier material1increased in the connecting area3. Furthermore, the strength of the nonwoven carrier material at the connecting area is lower than in the remainder of the nonwoven carrier material. InFIG.3is shown a top view of a nonwoven carrier material1according to this disclosure. The nonwoven carrier material1comprises a first part A and a second part B. The first part A and the second part B are connected to each other in a connecting area3. The connecting area3extends perpendicular to the main extension direction (see arrow X inFIG.5) of the nonwoven carrier material1or in an angle α to the main extension direction (arrow X) of the nonwoven carrier material1. FIG.4shows a side view of a nonwoven carrier material1comprising a first part A with a first fiber layer A1and a second fiber layer A2and a second part B with a first fiber layer B1and a second fiber layer B2. The first fiber layer A1of the first part A has a different length than the second fiber layer A2of the first part A. The first fiber layer B1of the second part B has also a different length than the second fiber layer B2of the second part B. However, the sum of the length of the first fiber layer A1of the first part A and the length of the first fiber layer B1of the second part B is equal to the sum of the length of the second fiber layer A2of the first part A and the length of the second fiber layer B2of the second part B. Due to this the first part A and the second part B fit together like puzzle parts. FIG.5shows a connection of the first part A and the second part B ofFIG.4to create a nonwoven carrier material1. The first part A and the second part B have a form-fit connection, whereby no thickness variation occurs (measured perpendicular (arrow Y) to the main extension direction (arrow X)) of the nonwoven carrier material1. Due to this form-fit connection also a kind of force-fit connection is created and the first part A and the second part B can easily be (permanently) consolidated without slipping of one or more fiber layers during the process. The obtained material is a connected nonwoven carrier material1. FIG.6shows an embodiment ofFIGS.4and5whereby a scrim4is arranged between the thermoplastic fiber layers A1, A2and B1, B2. The scrim is arranged between the first and second fiber layers A1, A2, B1, B2of the first part and second part A, B or only the first part A or the second part B comprises a scrim4(between the fiber layers). In the second embodiment a removing step removes also the scrim from the first part A or the second part B. FIG.7shows an embodiment of the present disclosure with more than two thermoplastic fiber layers for every part. The first part A comprises a first thermoplastic fiber layer A1, a second thermoplastic fiber layer A2and a third thermoplastic fiber layer A3. The length of the first thermoplastic fiber layer A1differs from the length of the second and third thermoplastic fiber layer A2, A3. Whereby also in this example is the sum of the length of the first fiber layer A1of the first part A and the length of the first fiber layer B1of the second part B is equal to the sum of the length of the second fiber layer A2(A3) of the first part A and the length of the second fiber layer B2(B3) of the second part B. Thus, the present invention also works for nonwoven carrier materials comprising more than two fiber layers in one part. It should be understood, that one or more of the layers A1, A2, A3, B1, B2and B3could be made of other materials than fibers (for example foils). FIG.8shows schematically a splitting process. The first part A comprises a first thermoplastic fiber layer A1and a second thermoplastic fiber layer A2. A splitting device5separates the first thermoplastic fiber layer A1and the second thermoplastic fiber layer A2partially from each other, and a part of the first thermoplastic fiber layer A1and/or the second thermoplastic fiber layer A2is/are removed, preferably by cutting. The same procedure is done for the second part B (not shown inFIG.8) of the nonwoven carrier material1. Whereby the first fiber layer A1(B1not shown inFIG.8) and the second fiber layer A2(B2not shown inFIG.8) of the first part A and the second part B are formed in the disclosed way to create a form-fit connection (likeFIGS.4,6,7). Thereafter, the first part A and the second part B are connected with each other (seeFIGS.3,5). The area, in which the first part A and the second part B are connected with each other, is called the connecting area3(not shown inFIG.8). The splitting device5is part of a splitting machine. For example the firm Fortuna GmbH sold such splitting machines. Other methods than splitting and cutting are included to realize the described form-fit connection (like puzzle parts). FIG.9shows a sideview of a first part A and a second part B of a nonwoven carrier material having inclined layer boundaries with an angle β. FIG.10shows a side view of an embodiment of a connection of a first part A and a second part B of a nonwoven carrier material, wherein the connecting area3is an inclined connecting area with an angle β in view of the main surfaces of the first part A and second part B of the nonwoven carrier material. FIG.11shows a side view of a connection of a first part A and a second part B of a nonwoven carrier material, wherein the first part A and the second part B having inclined layer boundaries with an angle β and are connected at the connecting area3on the main surfaces of the first part A and second part B. The first part A and second part B are connected in such a way, that the thickness of the connected layers in the connecting area is equal to the thickness of the entire nonwoven carrier material. FIG.12shows a sideview of a first part A and a first part B, wherein the first part A and the second part B comprise four fiber layers each (A1-A4and B1-B4). The first fiber layer A1(B1) has a different length to the second fiber layer A2(B2). Subsequently, the second fiber layer A2(B2) has a different length to the third layer A3(B3) and also the third fiber layer A3(B3) to the fourth fiber layer A4(B4). The differences in length between the layers are alternating, so that a zipper like form is obtained. Thereby, the even numbered layers A2(B2) and A4(B4) and/or the uneven numbered layers A1(B1) and A3(B3) do not need necessarily need the same lengths. The sum of the lengths of the fiber layers of all fiber layers are equal. FIG.13shows a sideview of a first part A and a first part B, wherein the first part A and the second part B comprise three fiber layers each (A1-A3and B1-B3). The first fiber layer A1(B1) has a different length to the second fiber layer A2(B2). Subsequently, the second fiber layer A2(B2) has a different length to the third layer A3(B3). The differences in length between the layers are alternating, so that a zipper like form is obtained. Thereby, the even numbered layers A2(B2) do not need necessarily need the same lengths. The sum of the lengths of the fiber layers of all fiber layers are equal. FIG.14schematically shows a first part and a second part of the nonwoven carrier material wherein a scrim is arranged in the first thermoplastic fiber layer of the first part, and a scrim is arranged in the second thermoplastic fiber layer of the second part of the nonwoven carrier material. InFIG.14Aa scrim (dashed line) is arranged in the first thermoplastic fiber layer A1of the first part close to the interface between the first thermoplastic fiber layer A1and the second thermoplastic fiber layer A2of the first part. A scrim (dashed line) is also arranged in the second thermoplastic fiber layer B2of the second part close to the interface between the second thermoplastic fiber layer B2and the first thermoplastic fiber layer B1of the second part. When a form-fit connecting is formed in the connecting interface inFIG.14B, the scrims are arranged closely together which improved the load transfer between both scrims in the nonwoven carrier material. | 9,277 |
11858248 | DETAILED DESCRIPTION In an embodiment of the invention, the multilayer thermoplastic sheet comprises a first colored thermoplastic layer, a second colored thermoplastic layer, and a third colored thermoplastic layer, wherein at one of the colored layers is a different color than at least one of the other colored layers. A first colored layer will be towards the front or exposed side of the sheet and the third colored layer will be toward the back of the sheet. A colored thermoplastic layer comprises one or more colorants, i.e. pigments and/or dyes. A colored thermoplastic layer has a visible color to an average person and is substantially non-transparent. In some embodiments, the multilayer thermoplastic sheet may comprise four or more or five or more thermoplastic layers. The multilayer sheets are not limited in total layers, for instance they may comprise 6, 7, 8 or more thermoplastic layers. The multilayer sheets may comprise 3, 4, 5, 6, 7, 8 or more colored thermoplastic layers. The multilayer sheets may also comprise one or more clear or tinted thermoplastic layers. The term “tinted” meaning colored while still being transparent. In some embodiments, the multilayer sheet may comprise a thermoplastic cap layer, which cap layer will be towards the front or exposed side of the sheet. In some embodiments, the multilayer sheet may comprise a thermoplastic base layer, which base layer will be towards the back of the sheet. In the absence of a cap layer, the first colored layer will be the first exposed layer upon installation of a sheet to a wall. In some embodiments, a thermoplastic cap layer is clear, and may comprise essentially no colorants (pigments or dyes). The cap layer may serve to protect the under-layers. In some embodiments, the cap layer may provide a high gloss finish. In other embodiments, the cap layer may provide a matte finish. In other embodiments, a cap layer may comprise a small amount of colorant, for instance it may be tinted with a colorant. In other embodiments, a cap layer may be colored. In some embodiments, the multilayer sheet may comprise a visible decorative design or pattern, for instance resembling a natural stone or wood grain look. In certain embodiments, a pattern may be printed on a thermoplastic film. The printed film may be laminated or extruded onto another layer. For example, a cap layer may have a pattern printed onto it, and the printed side laminated onto a multilayer sheet, thus providing a visible pattern. The pattern may be a random irregular pattern or may be a regular pattern. A base thermoplastic layer will be in adherence to a wall upon installation of the sheet. In some embodiments, a base layer is clear and may comprise essentially no colorants. In other embodiments, a base layer may be tinted or may be colored. In some embodiments, a base layer aids adhesion of the sheet to a surface and provides resistance to chemical attack. In the absence of a base layer, the next bottom layer will be in adherence to a wall upon installation. In some embodiments, the first, second and third colored layers may have a color chosen from white, grey and black. In some embodiments, the first colored layer has a different color than the second colored layer. In some embodiments, the second colored layer has a different color than the third colored layer. In other embodiments, the first colored layer may have a substantially identical color to that of the second colored layer. In other embodiments, the second colored layer may have a substantially identical color to the third colored layer. Any color combinations are possible for the colored layers. In some embodiments, the first colored layer is white and the second and third colored layers are grey. In other embodiments, the first colored layer is white, the second colored layer is grey and the third colored layer is black. Additionally, any colored layer or combination of colored layers may comprise an “ombre” or gradient effect, wherein within a layer or series of layers, color gradually shifts from light to dark or from dark to light. An ombre effect will allow for a variety of color effects provided by different grout cut depths. Color may be defined according to CIE L*a*b* color space values. In some embodiments, the multilayer thermoplastic sheet may be prepared by one or more co-extrusion or co-lamination processes. Thermoplastics may comprise one or more of polyolefins, styrenic polymers, acrylic polymers, polyesters and polyamides. In some embodiments, the thermoplastics comprise acrylic polymers and styrenic polymers. Acrylic polymers include polymethylmethacrylate (PMMA) and polybutylacrylate. Styrenic polymers include acrylonitrile-butadiene-styrene (ABS) terpolymer. In embodiments wherein one or more layers comprises a different thermoplastic than one or more other layers, the multilayer sheet may be considered a composite sheet. In some embodiments, a total thickness of the thermoplastic multilayer sheet may be from any of about 0.080 inches, about 0.115 inches, about 0.120 inches, about 0.125 inches, about 0.130 inches, about 0.135 inches, or about 0.140 inches, to any of about 0.145 inches, about 0.150 inches, about 0.155 inches, about 0.160 inches, about 0.165 inches, about 0.170 inches, about 0.175 inches, about 0.180 inches, about 0.185 inches, about 0.190 inches, about 0.195 inches, about 0.210 inches, about 0.225 inches, about 0.250 inches, about 0.300 inches, about 0.350 inches, about 0.400 inches, about 0.450 inches, about 0.500 inches, or more. In some embodiments, a cap layer thickness may be from any of about 2%, about 3% or about 4% to any of about 5%, about 6%, about 7% or about 8% or more of a multilayer sheet total thickness. In some embodiments, a first colored layer thickness is from any of about 6%, about 7%, about 8% or about 9% to any of about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18% or more of a multilayer sheet total thickness. In some embodiments, a second colored layer thickness is from any of about 7%, about 8%, about 9%, about 10%, about 11% or about 12% to any of about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, or more of a multilayer sheet total thickness. In some embodiments, a third colored layer thickness is from any of about 50% about 52%, about 54%, about 56%, about 58%, about 60%, about 62%, about 64%, about 66% or about 68% to any of about 70%, about 72%, about 74%, about 76%, about 78%, about 80%, about 82%, about 84% or about 86% or more of a multilayer sheet total thickness. In some embodiments, a base layer thickness is from any of about 0.5%, about 1.0%, about 1.5% or about 2.0% to any of about 2.5%, about 3.0%, about 3.5% or about 4.0% or more of a multilayer sheet total thickness. Layer thicknesses in total add up to 100% of the multilayer sheet total thickness. In some embodiments, a width of the thermoplastic sheet is from any of about 12 inches, about 18 inches, about 24 inches, about 30 inches or about 36 inches to any of about 42 inches, about 48 inches, about 54 inches, about 60 inches, about 64 inches, about 68 inches, about 72 inches or more; and wherein a length of the sheet is from any of about 32 inches, about 38 inches, about 44 inches, about 50 inches or about 56 inches to any of about 62 inches, about 68 inches, about 74 inches, about 80 inches, about 86 inches, about 92 inches, about 96 inches, about 98 inches, or more. Grout lines may be cut into or applied onto a multilayer thermoplastic sheet surface (front) via heat embossing or controlled routing, thus providing a plurality of lines to provide simulated ceramic tile. In other embodiments, grout lines may be cut with water or light (e.g. laser etching). In some embodiments, grout lines may be cut into a multilayer sheet with a CNC (computer numerical control) router. In some embodiments, grout lines may be cut into the sheet through the first colored layer and partially into the second colored layer. A part of the second colored layer may remain between the bottom of a grout line and the third colored layer. The cut lines may be intersecting lines. In other embodiments, cut lines may not intersect. In some embodiments, a thickness of the second colored layer remaining in a grout line may be from any of about 0.002 inches, about 0.003 inches, about 0.004 inches, about 0.005 inches, about 0.006 inches, about 0.007 inches or about 0.008 inches to any of about 0.009 inches, about 0.010 inches, about 0.011 inches, about 0.012 inches, about 0.013 inches, about 0.014 inches, about 0.015 inches, about 0.016 inches, about 0.017 inches or about 0.018 inches or more. This represents a distance from the bottom of a grout line to the beginning of the next layer. In some embodiments, grout lines may be cut into the sheet surface at a depth of from any of about 0.010 inches, about 0.013 inches, about 0.016 inches, about 0.020 inches, about 0.025 inches, about 0.030 inches, about 0.035 inches, about 0.040 inches or about 0.045 inches to any of about 0.050 inches, about 0.055 inches, about 0.060 inches, about 0.065 inches, about 0.070 inches, about 0.075 inches or about 0.080 inches or more. In some embodiments, cut grout lines may have a width of from any of about 0.062 inches, about 0.070 inches, about 0.090 inches, about 0.100 inches, about 0.120 inches about 0.140 inches, about 0.160 inches, about 0.190 inches or about 0.210 inches to any of about 0.220 inches, about 0.240 inches, about 0.260 inches, about 0.280 inches, about 0.300 inches, about 0.310 inches, about 0.330 inches, about 0.350 inches, about 0.360 inches, about 0.375 inches or higher. A width of a cut grout line may be a measurement of a grout line width at a surface of a multilayer sheet. An average width of a cut grout line may be an average width of a random sampling of grout line widths at a surface of a multilayer sheet. A random sampling may include for instance 2 or more, 3 or more, 4 or more, or 5 or more measurements. In some embodiments, a cut grout line may have an essentially symmetrical “rectangle” shape as displayed inFIG.1. In other embodiments, the cut grout lines may have a “V shape” or a “U shape”. Cut grout line shapes may be essentially symmetrical and regular, or alternatively, may have irregular shapes. Cut grout lines may have angled walls—as in a V shape. Cut grout line walls may be substantially parallel—or may not be parallel. In some embodiments, cut grout lines may have parallel walls and may have an essentially symmetrical “parallelogram” shape. In other embodiments, one wall may be angled and the opposing wall may be straight (perpendicular to the surface). In some embodiments, all layers of a multilayer sheet exposed in a cut grout line may be visible to a viewer when observed “straight on”—either both walls of a grout line or one wall. Simulated grout lines may be embossed into, machined into or cut into a multilayer sheet to provide an appearance of ceramic tiles. A present arrangement of layers and colored layers provide for a more aesthetic appearance and a more “real” look of ceramic tile. FIG.1depicts a section of multilayer composite sheet100according to one embodiment of the invention. In this embodiment, multilayer sheet100total thickness is about 0.150 inches. Grout line106is about 0.030 inches deep, extending through cap layer101, through first colored layer102and partially into second colored layer103. In this embodiment, cap layer101is about 0.0075 inches thick, first colored layer102is about 0.0150 inches thick, second colored layer103is about 0.0225 inches thick, third colored layer104is about 0.1020 inches thick, and base layer105is about 0.0030 inches thick. Also in this embodiment, third colored layer104comprises acrylonitrile-butadiene-styrene copolymer (ABS) while the remaining layers comprise polymethylmethacrylate (PMMA). Cap layer101and base layer105are clear and non-colored. First colored layer102is white and second103and third104colored layers are a substantially identical shade of grey. Portion107of second colored layer103remains after grout line106is cut, portion107being about 0.015 inches. In an alternative embodiment, a total sheet thickness may be about 0.180 inches. A cap layer may be about 0.009 inches thick, a first colored white layer may be about 0.018 inches thick, a second colored grey layer may be about 0.027 inches thick, a third colored grey ABS layer may be about 0.122 inches thick, and a clear base layer may be about 0.004 inches thick. Grout lines may be cut at a depth of about 0.040 inches thick, through the first colored layer and partially into the second colored layer. In yet another embodiment, a total sheet thickness may be about 0.165 inches. A cap layer may be about 0.008 inches thick, a first colored white layer may be about 0.017 inches thick, a second colored grey layer may be about 0.025 inches thick, a third colored grey ABS layer may be about 0.112 inches thick, and a clear base layer may be about 0.003 inches thick. Grout lines may be cut at a depth of about 0.033 inches thick, through the first colored layer and partially into the second colored layer. In other aspects of the invention, disclosed is a multilayer thermoplastic sheet, wherein the sheet has a total thickness of from about 0.125 inches to about 0.500 inches, and a plurality of lines cut into the surface at depth of from about 0.010 inches to about 0.080 inches. In some embodiments, multilayer sheets may comprise one or more colored layers, wherein the color of any two layers may be the substantially the same or different. Such multilayer sheets provide a realistic ceramic tile look. Such multilayer sheets may provide the appearance of variable color effects within a grout line, even without having different color layers. In some embodiments, these multilayer thermoplastic composite sheets may comprise a first colored thermoplastic layer and a second colored thermoplastic layer, wherein the plurality of cut lines extend partially into the first colored layer and a thickness of the first colored layer remaining in the lines is from about 0.002 inches to about 0.018 inches. A color of the first colored layer may be substantially the same or may be different than the color of the second colored layer. In some embodiments, colored layers comprise one or more colors chosen from white, grey and black. In other embodiments, one or both of these layers may be clear and/or tinted. In some embodiments, these multilayer sheets may comprise three, or more thermoplastic layers, four or more thermoplastic layers, or five or more thermoplastic layers. In some embodiments, these multilayer sheets may comprise a thermoplastic cap layer and/or a thermoplastic base layer. In some embodiments, these multilayer sheets may comprise one or more layers comprising an acrylic polymer and/or one or more layers comprising a styrenic polymer. In some embodiments, these multilayer sheets may have a first colored layer having a thickness of from about 7% to about 26% of the sheet total thickness; and a second colored layer has a thickness of from about 74% to about 93% of the sheet total thickness. Thicknesses of other possible layers are as defined above. Other measures likewise may be as above. The multilayer thermoplastic sheets are suitable for use in bathrooms, for instance in bath tub or shower enclosures and provide the appearance of ceramic tile. In some embodiments, one or more of the thermoplastic layers may comprise glass fibers or one or more other fillers. Following are some embodiments of the disclosure. In a first embodiment, disclosed is a multilayer thermoplastic sheet, comprising a first colored thermoplastic layer; a second colored thermoplastic layer; and a third colored thermoplastic layer; wherein at least one of the colored layers is a different color than at least one of the other two colored layers. In a second embodiment, disclosed is the multilayer thermoplastic sheet according to embodiment 1, comprising four or more thermoplastic layers. In a third embodiment, disclosed is the multilayer thermoplastic sheet according to embodiment 1, comprising five or more thermoplastic layers. In a fourth embodiment, disclosed is a multilayer thermoplastic sheet according to any of the preceding embodiments, comprising a cap layer. In a fifth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, comprising a base layer. In a sixth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein the color of the first colored layer is different than the color of the second colored layer; and/or the color of the second colored layer is different than the color of the third colored layer. In a seventh embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein the color of the first colored layer is substantially identical to the color of the second colored layer; or the color of the second colored layer is substantially identical to the color of the third colored layer. In an eighth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein two or more layers comprise an acrylic polymer. In a ninth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein one or more layers comprises a styrenic polymer. In a tenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein the total thickness of the multilayer sheet is from about 0.080 inches to about 0.500 inches. In an eleventh embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein the first colored layer has a thickness of from about 7% to about 18% of the sheet total thickness; the second colored layer has a thickness of from about 7% to about 26% of the sheet total thickness; and the third colored layer has a thickness of from about 56% to about 86% of the sheet total thickness. In a twelfth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein one or more colored layers are white. In a thirteenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein one or more colored layers are grey. In a fourteenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein one or more colored layers are black. In a fifteenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein the sheet comprises grout lines cut into the sheet extending through the first colored layer and partially into the second colored layer. In a sixteenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein the sheet comprises grout lines cut into the sheet at a depth from about 0.010 inches to about 0.080 inches. In a seventeenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein the sheet comprises grout lines cut into the sheet extending through the first colored layer and partially into the second colored layer, wherein a thickness of the second colored layer remaining in the grout lines is from about 0.002 inches to about 0.018 inches. In an eighteenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein the sheet comprises grout lines cut into the sheet, wherein a width of the grout lines is from about 0.070 inches to about 0.375 inches. In a nineteenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein a width of the sheet is from about 12 inches to about 72 inches; and a length of the sheet is from about 32 inches to about 98 inches. In a twentieth embodiment, disclosed is a method of preparing a multilayer thermoplastic sheet according to any of the preceding embodiments, the method comprising one or more co-extrusion or co-lamination processes. In a twenty-first embodiment, disclosed is a method of cutting grout lines into a multilayer thermoplastic sheet according to any of the preceding embodiments, the method comprising computer numerical control (CNC) routing. Following are another set of embodiments. In a first embodiment, disclosed is a multilayer thermoplastic sheet, wherein the sheet has a total thickness of from about 0.125 inches to about 0.500 inches, and a plurality of lines cut into the surface at depth of from about 0.010 inches to about 0.080 inches. In a second embodiment, disclosed is the multilayer thermoplastic composite sheet according to embodiment 1, comprising a first colored thermoplastic layer; and a second colored thermoplastic layer; wherein the plurality of cut lines extend partially into the first colored layer and a thickness of the first colored layer remaining in the lines is from about 0.002 inches to about 0.018 inches. In a third embodiment, a multilayer thermoplastic sheet according to embodiments 1 or 2, comprising four or more thermoplastic layers. In a fourth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, comprising five or more thermoplastic layers. In a fifth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, comprising a cap layer. In a sixth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, comprising a base layer. In a seventh embodiment, the multilayer thermoplastic sheet according to any of embodiments 1 to 6, wherein the color of the first colored layer is substantially the same as the color of the second colored layer. In an eighth embodiment, the multilayer thermoplastic sheet according to any of embodiments 1 to 6, wherein the color of the first colored layer is different the color of the second colored layer. In a ninth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein one or more layers comprise an acrylic polymer. In a tenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein one or more layers comprises a styrenic polymer. In an eleventh embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein the first colored layer has a thickness of from about 7% to about 26% of the sheet total thickness; and the second colored layer has a thickness of from about 74% to about 93% of the sheet total thickness. In a twelfth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein one or more colored layers are white. In a thirteenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein one or more colored layers are grey. In a fourteenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein one or more colored layers are black. In a fifteenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein a width of the cut lines is from about 0.070 inches to about 0.375 inches. In a sixteenth embodiment, the multilayer thermoplastic sheet according to any of the preceding embodiments, wherein a width of the sheet is from about 12 inches to about 72 inches; and a length of the sheet is from about 32 inches to about 98 inches. In a seventeenth embodiment, disclosed is a method of preparing a multilayer thermoplastic sheet according to any of the preceding embodiments, the method comprising one or more co-extrusion or co-lamination processes. In an eighteenth embodiment, disclosed is a method of cutting grout lines into a multilayer thermoplastic sheet according to any of the preceding embodiments, the method comprising computer numerical control (CNC) routing. The articles “a” and “an” herein refer to one or to more than one (e.g. at least one) of the grammatical object. Any ranges cited herein are inclusive. Measurements described herein, for instance thicknesses or widths, may be a measure at any one point or may represent an average measurement over a series of points. A series of points may be a random sampling of 2, 3, 4, 5 or more at any points. The term “about” used throughout is used to describe and account for small fluctuations. For instance, “about” may mean the numeric value may be modified by ±0.05%, ±0.1%, ±0.2%, ±0.3%, ±0.4%, ±0.5%, ±1%, ±2%, ±3%, ±4%, ±5%, ±6%, ±7%, ±8%, ±9%, ±10% or more. All numeric values are modified by the term “about” whether or not explicitly indicated. Numeric values modified by the term “about” include the specific identified value. For example “about 5.0” includes 5.0. The terms “substantially” or “essentially” are similar to “about” in that the defined term may vary from for example by ±0.05%, ±0.1%, ±0.2%, ±0.3%, ±0.4%, ±0.5%, ±1%, ±2%, ±3%, ±4%, ±5%, ±6%, ±7%, ±8%, ±9%, ±10% or more of the definition; for example the term “substantially the same color” may mean the L*a*b* color space values may be “about” the same. The term “generally” may be equivalent to “substantially”. Embodiments of the disclosure include any and all parts and/or portions of the embodiments, claims, description and FIGURES. Embodiments of the disclosure also include any and all combinations of embodiments. All U.S. patent applications, published patent applications and patents referred to herein are hereby incorporated by reference. | 25,837 |
11858249 | Additional details regarding various features illustrated within the figures are described in further detail below. DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. Conventional Laminate Characteristics As mentioned previously herein, conventional legacy quad laminates were made of collections of [0], [±45] and [90] ply configurations. These laminates were discrete and not possible to interpolate due to a variety of self-inflicted constraints (e.g., fixed angles, symmetry, etc.). To have more directional properties, plies had to be added to their sub-laminates, which in turn increased weight and decreased design flexibility of laminate structures due to thickness. Nevertheless, to achieve somewhat desirable material characteristics of legacy laminates, necessarily at least 6-, 8- and 10-ply thick (and oftentimes thicker) sub-laminates were utilized. When laminates with mid-plane symmetry are required and met, their thicknesses with 6- to 10-ply sub-laminates would be doubled, tripled or more. Such thick sub-laminates were, in addition to being undesirably heavy in weight, delamination prone, which also made blending, ply drop, and ply layup difficult; still further material characteristics could oftentimes not be optimized (to, for example, desired characteristics) due to limitations imposed by the discrete number of ply configurations available in the field (see field1illustrated inFIG.1A). As a result, there are gaps between laminate stiffness and strength that cannot be bridged using conventional legacy quad laminates. Multiple failure modes and complexity in manufacturing thus existed. These various considerations involved with conventional legacy quad laminates may be understood with reference again toFIG.1A, wherein the legacy quad field1for a 10-ply thick sub-laminate2is illustrated. Once more, conventional nomenclature is utilized as [0p/90q/±45r] to identify the sub-laminate, wherein p represents the number of 0° ply layers, q represents the number of 90° ply layers, and r represents the number of ±45° ply layers. In the specific example illustrated 10 total plies are provided. In example discrete sub-laminate3A, the sub-laminate is formed with 80% 0° ply layers, 20%±45° ply layers and no 90° ply layers (i.e., for the 10-ply configuration illustrated, eight 0° ply layers, two ±45° ply layers and no 90° ply layers). Another discrete sub-laminate3B is also highlighted, wherein the sub-laminate is formed with 70% 0° ply layers, 20%±45° ply layers and thus 10% 90° ply layers (i.e., for the 10-ply configuration illustrated, seven 0° ply layers, two ±45° ply layers and one 90° ply layers). As another non-limiting example, if stiffness with 80% 0°, 10% 90° ply and 10%±45° ply is desired, the sub-laminate will have to be 20 ply thick. Remaining characteristics for the other discrete twenty-four (24) sub-laminates available (i.e., each dot or anchor inFIG.1A) may be extrapolated from these examples. With reference now toFIG.1B, relative to the 10-ply legacy quad field1illustrated inFIG.1A, populated therein also are the discrete sub-laminates achievable (indicated by the discrete dots or anchors shown) with not only a 10-ply sub-laminate, but also with associated 6-ply and 8-ply configurations (i.e., a combined 10-, 8-, and 6-ply configuration5). Thus, it may be understood that—even with the 6-, 8-, and 10-ply conventional legacy quad sub-laminate structures—a total field of only forty-seven (47) laminates was achievable (see again,FIG.1B). Notably, though, holes remain visible between the respective discrete sub-laminate structures (i.e., although some of the dots or anchors6may partially overlap one another, not all of the dots or anchors6fully overlap with each other and thus fill all of the visible space in the field); as a result, achieving certain desirable material characteristics remains challenging and many times simply unachievable (again, due to the various self-inflicted constraints on conventional legacy quad field sub-laminates having different thicknesses in 6 to 10-plies that make blending and ply drop so complicated). FIG.1Cdepicts a set of three charts, namely illustrating a sub-set of the values of one stiffness component A11* with respect to the 10-ply sub-laminate7ofFIG.1A, the 8-ply sub-laminate8ofFIG.1B, and the 6-ply sub-laminate9ofFIG.1B. As may be understood from these respective charts, the sub-laminates exhibit the greatest stiffness (i.e., the highest stiffness values) where the highest percentage of 0° ply layers are used. For example, in the subset illustrated inFIG.1C, the stiffness value (0.763) is highest for the 10-ply sub-laminate where 80% 0° ply layers are used, accompanied by 20%±45° ply layers. Another notable example, which will be returned to during discussion ofFIG.4Delsewhere herein is the stiffness value (0.321) of a “square symmetric” sub-laminate having 10-ply layers, with the “square symmetric” nomenclature—accompanying 10% 0° ply layers are used, accompanied by 80%±45° ply layers—representing that equal stiffness exists along both the x- and the y-axes of any so defined sub-laminate module or structure. This class of sub-laminates is particular useful, due to its having exact replacement of a legacy quad by double-double. For non-square symmetric laminate structures, the replacement is nevertheless still an approximate match. The collection15ofFIG.1Cis also informative in terms of guidance of the laminate design without use of sub-laminates, as mentioned previously herein. As a non-limiting example, the entire laminate may be designed to satisfy the percentages of the quad ranges in 0°, ±45° and 90°. Beyond the requirements of symmetry and ply grouping to larger than three (again, as mentioned previously herein), every ply stacking selection is subjective, meaning there is no scientific or mathematical analysis involved, but for having well dispersed plies that would facilitate ply drop and blending. Unfortunately, this approach often leads to multiple internal fiber discontinuities, ply wrinkling, and other defects that can be sources of multiple damage initiation sites. Double-double laminates and sub-laminate structures, in contrast, achieve structures having no internal defects, due in part to the continuous field of options provided (seeFIGS.2A-C, as previously discussed herein). In this context, having thin sub-laminates with constant thickness makes blending, ply drop, and manufacturing much simpler than the quad laminates in one piece or in thick sub-laminates; however, constraints and challenges have remained. Notably, throughout the above discussion and illustrations it should be understood that the core problem of the legacy quad laminate design is that all sub-laminates are discrete. As a result, even with utilization of 6-, 8-, and 10-ply configurations, there are no comprehensive connections among all 47 members in the sub-laminate. Thus, beyond the remaining “holes” where certain material characteristics may remain unachievable, blending between different laminates (i.e., from adjoining elements) has no standard solution. This is because there is no continuous connection between the two different laminates, for example where each laminate is a different discrete configuration. There will be thousands of fiber discontinuities inside each laminate. They are the sources of multiple failures under static and fatigue loading. Tapering is also difficult due to the lack of continuity. As a result, laminated structures using legacy quad oftentimes cannot be optimized with respect to material characteristics, and ply stacking (including tapering and blending) is extremely complicated, making automated layup procedures not only costly, but also necessarily involving compromises in material characteristics and thus structural integrity, possibly leading to multiple material failure modes that are not possible to predict (at least in part due the complexities and uncertainties involved between the discrete dots or anchors). Double-Double Laminate Characteristics The continuous field of double-double sub-laminate structures described herein (see, as previously developed, with reference toFIGS.2A-Cdescribed herein-above) achieves sub-laminates with at most 4-ply thick structures; even thinner 2- and 1-ply thick configurations are obtainable. Throughout various embodiments, the ply angles are also continuous, making blending of different laminates and their optimization achievable. Sub-laminate thickness remains constant. For directional property, the angles of each double helix can change continuously to the desired values. Plies are not added like the case of legacy quad family. As a result, far fewer failure modes (and virtually no unpredictable failure modes) are encountered, and automated layup procedures may be conducted in relative simplistic fashions. All of these and still other advantages lead to much simpler and lighter structures that are also better optimized for purposes of efficiency and accuracy, notably improvements given that the further above-detailed degree of uncertainty with conventional legacy quad laminate structures is becoming ever-increasingly unacceptable across multiple industries. Having thinner sub-laminates (4 of less versus 12 to 20) the minimum gage requirement is lowered. Many electronic and medical devices can now use composite laminate. This is not possible if laminates must be multiples of 12 to 20 plies. 1. Originally Utilized Stacking Sequence FIG.2Cfurther illustrates the manner in which the degree of granularity involved in forming each collection of continuous double-double sub-laminates is potentially indefinite, whereby here there is illustrated a continuous field40(see right-hand chart), produced with angle increments of 1°. This field results, as illustrated in the right-hand chart ofFIG.2C, in a double-double laminate field40that contains 8,281 sub-laminate structures from which to choose, each having distinctive material characteristics associated therewith. It should be understood that the illustrated angle increments in these figures (e.g., 10°, 2°, 1°) are non-limiting examples; in view of the derivative nature of the double-double sub-laminate field (as detailed elsewhere herein), any angle increment can be selected, depending upon the degree of granularity that may be necessary to obtain a viable stiffness or strength match (as also detailed elsewhere herein) to a conventional laminate structure and/or sub-laminate structure. In this manner, the double-double sub-laminate fields30,35,40should be understood as indicative of a continuous field of selectable ply angle and ply layer configurations, so as to best match conventional laminate structures having much greater thicknesses and/or to fill gaps of strength or stiffness values in such conventional structures due to the limited set of 47 discrete values under legacy quad-type configurations, as described previously herein. Returning now toFIG.2B, a continuous field of laminates [±Φ/±Ψ] (seeFIG.2Cas well, illustrating the discrete and independent [±Φ]42and [Ψ] 41 ply angle sets) is provided for selection therefrom, as contrasted with the discrete legacy quad collections (i.e., 47 options versus double-double's 8,281+ potential options). Zooming to achieve higher resolution (i.e., granularity) is conceptually easy via various embodiments of the double-double sub-laminate described herein and is shown on the right side ofFIG.2B. Equally important with granularity and this continuous field is the advantage that the sub-laminate thickness remains constant, at most being 4-ply; 2- or 1-ply configurations are, however, also possible if folding is incorporated. Stiffness values may thus be also changed in a continuous fashion (i.e., no holes or gaps), simply by changing the angles within the continuous field, as may be understood with reference toFIG.4A. Notwithstanding this flexibility and opportunities for optimization associated therewith, a remaining constraint for purposes of homogenization and achieving specifically desired material characteristics of formed laminates remained the discrete stacking sequence, whereby specific ply angle sets were required. These ply angle sets, referenced generally as [±Φ]42and [Ψ]41resulted in laminate and sub-laminate structures having limitations as to the sequence of the discrete plies when stacked relative to one another. 2. Improved Stacking Sequences and Applications Therefor Via the various embodiments described herein, multiple and improved stacking sequence configurations have been discovered for double-double laminate and sub-laminate structures, beyond the discrete (i.e., paired) [±Φ] and [Ψ] sequence previously utilized. To understand the implications of eliminating this discrete sequence, it is informative to revisit homogenization and the advantages associated therewith. For purposes of context and understanding, consider firstlyFIG.3containing table300, which shows a stress-strain relation of laminates in thickness-normalized and absolute values according to various embodiments described herein. As mentioned, the double-double family of laminates and sub-laminate structures is a balanced and orthotropic replacement of conventional legacy quad configurations. The double-double replacement is advantageous for multiple reasons, among them the ability to achieve homogenization with less material (i.e., fewer layers, better ply drops for tapering, etc.). Homogenization of a laminate is defined by two conditions set forth in Equation 1 below: [A*]=[D*];[B*]=0 where: [A*]=[A]/h; [D*]=12[D]/h3; [B*]=2[B]/h2; and h=laminate thickness. According to various embodiments, with reference now also toFIG.4, the constant [B] may be normalized using thickness or master ply stiffness values. Notably, when master ply stiffness values are used, the resulting constants are fractions of Tsai's modulus; this can be compared to thickness-based normalization calculated in table401on the left side ofFIG.4. In table402on the right side ofFIG.4, where [B] is normalized to [B*] based upon master ply stiffness, the resulting constant may be, in certain circumstances, sufficiently small to ignore. Relative to stacking sequence determination and/or optimization, as described herein-below, two criteria will be used: one when [B*]≤1 percent; the other, [B*]≤2 percent. The reason for these limits is based on the coefficient of variations of master ply that is normally between these two values. Referencing alsoFIG.5, it may be understood from chart501that according to various embodiments there may be thousands of stacking sequences502in conventional legacy quad configurations, due largely to the strict requirements thereof for symmetry and balance—greatly increasing the required independent number of plies503. For example, in one legacy quad embodiment having sixteen (16) independent laminate plies, a corresponding set of 166,080 independent stacking sequences are possible. This provided great uncertainty as to material characteristics, as but one non-limiting examples of challenges with legacy quad (see discussion previously herein). By way of contrast, remaining withFIG.5, it may be understood from chart511that according to various embodiments there were conventionally, at most, two (i.e., paired) stacking sequences512(DD1) and513(DD2) for double-double laminate structures. The implications of this may be understood by considering the data required for sufficient accuracy of simulation models for laminate structures with characteristics predictably desirable. As an example, to distinguish between 10,000 members of a population, the accuracy of an exemplary simulation model and its associated data would require at least five (5) significant figures. For laminate composites, however, available data is generally no better than three (3) significant figures, promoting possibility for inaccuracy and inefficiency. With the above-noted three (3) significant figure limitation, conventionally there was no impetus to consider any legacy quad laminate structures having more than six (6) ply sub-laminates (600 total members in a family, as illustrated in chart501). As a result, there are only four laminates in this legacy quad sub-family ([0/±45/903]; [02/±45/902]; [03/±45/90]; [0/±452/90])—but subject to uncertainty due to a near-infinite number of stacking sequences502. By way of contrast, double-double laminates and sub-laminate structures will always have a choice of at least 91 family members (see DD1512stacking sequence in chart511); with only one other alternative conventionally with DD2513stacking sequence. According to various embodiments, though, a significant advantage of double-double laminates and sub-laminate structures lies in available permutations of the paired stacking sequences (DD1512, DD2513). Specifically, six stacking sequence permutations display advantageous results related to material characteristics for laminates and sub-laminate structures. These include: a first paired sequence601(seeFIG.6A) of [Φ/−Φ/Ψ/−Ψ]; a second paired sequence602(seeFIG.6A) of [Φ/−Φ/−Ψ/Ψ]; a first staggered sequence603(seeFIG.6B) of [Φ/−Ψ/−Φ/Ψ]; a second staggered sequence604(seeFIG.6D) of [Φ/Ψ/−Φ/−Ψ]; a third staggered sequence605(seeFIG.6F) of [Φ/−Ψ/Ψ/−Φ]; and a fourth staggered sequence606(seeFIG.6H) of [Φ/Ψ/−Ψ/−Φ]. To determine how many repeats of each of these stacking sequences is required for homogenization, the definition thereof is set by the value of the largest absolute component of [B*] and [A]*-[D]*, as previously defined herein. As one example, conditions to reach homogenization may be [B*]=0 and [A]*=[D]*. The homogenization results according to various embodiments of the six sequences may be understood in each ofFIGS.6A,6B,6D,6F, and6H, respectively. Of note, as would be expected for pairing-based sequences, the results of the first and second paired sequences601/602are duplicative of one another, resulting in a total of five independent stacking sequences601/602,603,604,605,606, respectively. Those sequences requiring the fewest number of repeats (i.e., ply layers) to achieve homogenization are the first staggered sequence603and the third staggered sequence605. Details surrounding this are described herein-below. ReferencingFIG.6Afirst, illustrated therein in table610is the first paired [±Φ/±Ψ] stacking sequence or configuration of double-double sub-laminates, with the second paired [Φ/−Φ/−Ψ/−Ψ] stacking sequence or configuration illustrated in table611according to various embodiments. Considered together, these graphs illustrate that the minimum number of repeats (i.e., ply layers) to reach homogenization ranges from 1 to 8, dependent on respective values of [Φ/Ψ]. While angular orientations in the 40- to 50-degree range align with the average values, as expected the extremes are associated with opposing or aligned angles at either 0- or 90-degrees. Further, both paired configuration stacking sequences illustrated inFIG.6Areturn the same results, representative of the ordering—provided it is in a paired structure—is not an independent variable for purposes of homogenization (and material characteristics derived therefrom). In other words, the first and second paired stacking sequences [±Φ/±Ψ] and [Φ/−Φ/−Ψ/Ψ] are duplicates; neither providing differing repeat values relative to the other purposes of optimization of thickness and/or other material characteristics of formed laminates and sub-laminate structures. Reference is next made toFIG.6B, illustrating a comparison between the first staggered configuration603[Φ/−Ψ/−Φ/Ψ] and the second paired configuration602[Φ/−Φ/+Ψ/−Ψ] according to various embodiments. By way of comparison of table620and table621, the second paired stacking sequence602or configuration needs more repeats for homogenization than the first staggered stacking sequence603, across a large number of the angular options illustrated. As a non-limiting example, compared to the 8 repeats or layers required for homogenization of a paired configuration of [80/−80/20/−20], that same set of angles staggered in a sequence of [80/−20/−80/20] requires only 4 repeats or layers for homogenization. In this embodiment alone, homogenization (and desirable material characteristics of laminate structures related thereto) is achieved with half the ply layers and thus material/thickness/weight/and the like. The enhancement factor680of the first staggered configuration603relative to the second paired configured602may be further appreciated, according to various embodiments, with reference to table622ofFIG.6C. In this figure, the repeat values for respective sequences or configurations under comparison are overlaid and divided relative to one another. For the sequence of [80/−20/−80/20], an enhancement factor680of 2.0 is visible, representative of the repeat values for the second paired stacking sequence602divided by the repeat values for the first staggered stacking sequence603. Enhancement factor680values greater than one indicate a faster achievement of homogenization, which in turn may realize other advantageous characteristics of a formed laminate structure, including reduced thickness and/or weight, or the like. As other illustrated and non-limiting examples ofFIG.6C, the sequences of [60/−20/−60/20] and [70/−30/−70/30] achieve homogenization with less than half the repeats, indicated by an enhancement factor680of 2.3. Generally, where the angle between [±Φ/±Ψ] for the first staggered sequence603greater than 20 degrees, improvements are realized as compared to the paired sequence or configurations. Reference is next made toFIG.6D, illustrating a comparison between the first staggered configuration603[Φ/−Ψ/−Φ/Ψ/] and the second staggered configuration604[Φ/Ψ/−Φ/−Ψ] according to various embodiments. By way of comparison of table630and table631, the second staggered stacking sequence604or configuration needs, in certain angular orientations, more repeats for homogenization than the first staggered stacking sequence603. As a non-limiting example, compared to the three (3) repeats or layers required for homogenization of the first staggered stacking sequence603of [60/−40/−60/40], that same set of angles staggered in a sequence of [60/40/−60/−40] requires six (6) repeats or layers for homogenization. In this embodiment of the first staggered stacking sequence603alone, homogenization (and desirable material characteristics of laminate structures related thereto) is achieved with half the ply layers and thus material/thickness/weight/and the like. Of course, in certain embodiments where the second staggered sequence has values largely aligned with that of the first staggered sequence, for example with the sequence604of [70/20/−70/−20] ofFIG.6D, a repeat of four (4) remains an improvement of the same angular combination applied to either paired sequence601/602(seeFIG.6A) of [70/−70/20/−20], requiring eight (8) repeats. The enhancement factor680of the first staggered configuration603relative to the second staggered stacking sequence604may be further appreciated, according to various embodiments, with reference to table632ofFIG.6E. In this figure, the repeat values for respective sequences or configurations under comparison are overlaid and divided relative to one another. For the sequences of [50/30/−50/−30]; [50/40/−50/−40]; [50/50/−50/−50]; [40/40/−40/−40]; [60/40/−60/−40] all have enhancement factors680of 2.0 or greater. Once again, these enhancement factor680values greater than one indicate a faster achievement of homogenization, which in turn may realize other advantageous characteristics of a formed laminate structure, including reduced thickness and/or weight, or the like. As a general observation, for many of the selectable angular option as between [±Φ/±Ψ], the second staggered sequence604requires more repeats (and thus greater thickness, weight, and the like), as compared to the first staggered sequence603. In other angular options, though, as mentioned, the second staggered sequence604achieves homogenization with a lesser number of repeats than that required via the paired stacking sequences601/602, thus providing remaining advantages as well. Reference is next made toFIG.6F, illustrating a comparison between the first staggered configuration603[Φ/−Ψ/−Φ/Ψ/] and the third staggered configuration605[Φ/−Ψ/Ψ/−Φ] according to various embodiments. By way of comparison of table640and table641, the third staggered stacking sequence605or configuration needs, in certain angular orientations, more repeats for homogenization than the first staggered stacking sequence603. As a non-limiting example, compared to the three (3) repeats or layers required for homogenization of the first staggered stacking sequence603of [60/−30/−60/30], that same set of angles staggered in a sequence of [60/−30/30/−60] requires six (5) repeats or layers for homogenization. In this embodiment of the first staggered stacking sequence603alone, homogenization (and desirable material characteristics of laminate structures related thereto) is achieved with nearly half the ply layers and thus material/thickness/weight/and the like. Of course, in certain embodiments where the second staggered sequence has values largely aligned with that of the first staggered sequence, for example with the sequence605of [70/−20/−20/−70] ofFIG.6F, a repeat of four (4) remains an improvement of the same angular combination applied to either paired sequence601/602(seeFIG.6A) of [70/−70/20/−20], requiring eight (8) repeats. The enhancement factor680of the first staggered configuration603relative to the third staggered stacking sequence605may be further appreciated, according to various embodiments, with reference to table642ofFIG.6G. In this figure, the repeat values for respective sequences or configurations under comparison are overlaid and divided relative to one another. For the sequences with angular pairs of 60/20, 60/30, 70/30, and 50/40—all have enhancement factors680of 1.7 or greater. Notably, beyond the central portion of table642, angular pairs of 10/0, 20/0, 20/10, 80/70, 90/70, and 90/80 have enhancement factors680of 1.5 of greater. In the remaining areas, the third staggered stacking sequence605performs equally with the first staggered sequence603or configuration. As a further observation, even where the third staggered sequence605performs less optimally than the first staggered stacking sequence603(e.g., angular pairs of 70/0, 80/0, 90/0, 90/10, 90/20), the third staggered sequence605continues to achieve homogenization with a lesser number of repeats than that required via the paired stacking sequences601/602, thus providing remaining advantages as well. Stated otherwise, the third staggered sequence605controls the area close to (Φ=90, Ψ=0) and the first staggered sequence603controls the area close to the diagonal [Φ=Ψ]. As a non-limiting example, this paired and largely non-overlapping set of advantageous angular pairings indicates useful applications for combinations of the first/third staggered sequences in laminate structures formed from more than one sub-laminate module. Reference is next made toFIG.6H, illustrating a comparison between the first staggered configuration603[Φ/−Ψ/−Φ/Ψ/] and the fourth staggered configuration606[Φ/Ψ/−Ψ/−Φ] according to various embodiments. By way of comparison of table650and table651, the fourth staggered stacking sequence606or configuration needs, in certain angular orientations, more repeats for homogenization than the first staggered stacking sequence603. As a non-limiting example, compared to the three (3) repeats or layers required for homogenization of the first staggered stacking sequence603of [60/−40/−60/40], that same set of angles staggered in a sequence of [60/40/−40/−60] requires five (5) repeats or layers for homogenization. In this embodiment of the first staggered stacking sequence603alone, homogenization (and desirable material characteristics of laminate structures related thereto) is achieved with nearly half the ply layers and thus material/thickness/weight/and the like. Other angular pairings (e.g., 40/40 and 50/50) do achieve homogenization with half the number of layers or repeats. Of course, in certain embodiments where the fourth staggered sequence has values largely aligned with that of the first staggered sequence, for example with the sequence606of [80/10/−10/−80] ofFIG.6H, a repeat of four (4) remains an improvement of the same angular combination applied to either paired sequence601/602(seeFIG.6A) of [80/−80/10/−10], requiring eight (8) repeats. The enhancement factor680of the first staggered configuration603relative to the fourth staggered stacking sequence606may be further appreciated, according to various embodiments, with reference to table652ofFIG.6I. In this figure, the repeat values for respective sequences or configurations under comparison are overlaid and divided relative to one another. For the sequences having angular pairs of 40/40, 50/40, 50/50, and 60/30—all have enhancement factors680of 2.0 or greater. Notably, beyond the central portion of table652, the lower-left quadrant of angular pairs has enhancement factors680of 1.0, indicating comparable performance and homogenization as the first staggered sequence603. As a further observation, even where the fourth staggered sequence606performs comparable with the first staggered stacking sequence603, both continue to achieve homogenization with a lesser number of repeats than that required via the paired stacking sequences601/602, thus providing remaining advantages as well. Turning now toFIG.7, shown is a further comparison of the first staggered configuration [Φ/−Ψ/−Φ/Ψ/] and the third staggered configuration [Φ/−Ψ/Ψ/−Φ], illustrating a combination thereof for optimizing repeats for homogenization across an angular spectrum according to various embodiments. In other words,FIG.7illustrates, by way of non-limiting example, a configuration across all angular pairs, combining both the first and third staggered sequences602/605in different areas of table700, so as to minimize the number of repeats across the entire field. As evident fromFIG.7, the first staggered configuration [Φ/−Ψ/−Φ/Ψ/] require fewer repeats (i.e., ply layers) for double-double homogenization where a first absolute difference701between |Φ−Ψ| is less than 45 degrees. By way of comparison, the third staggered configuration [Φ/−Ψ/Ψ/−Φ] requires fewer repeats (i.e., ply layers) for double-double homogenization where a second absolute difference702between |Φ−Ψ| is greater than 45 degrees. As a result, for a laminate or sub-laminate structure having a variety of ply orientations (i.e., with both [Φ−Ψ] greater than and less than 45 degrees), a combination of staggered stacking sequences or configurations may be utilized within a single structure. Remaining withFIG.7, considering the lower repeat of the two fields (i.e., the first staggered and the third staggered configurations) it may be understood that a sharp demarcation line exists at [π/4] (i.e., 45 degrees) of the absolute difference between |Φ−Ψ|. Those values where the first staggered sequence603is optimal are shaded more lightly (e.g., tan) as compared to those values where the third staggered sequence605is optimal. Starting from the tan or yellow area, a distinct example of the first staggered sequence [45/−45/−45/45]rTis symmetric, which reveals why this area is optimal for the first staggered sequence as compared to the third. Similarly in the aqua or darker shaded area, the third staggered sequence of [0/90/90/0]rTis symmetric, indicating the basis for this area being optimal and controlled by the third staggered sequence as compared to the first. In these examples, where double-double laminates are constructed, if thin plies are utilized (0.0625 mm in thickness), the highest thickness at For DD with thin plies (0.0625 mm), the highest thickness at eight (8) repeats would be 0.3125 mm for 2 percent. By comparison, a conventional legacy laminate would take 72 regular plies or 9 mm to reach homogenization; 18 times thicker. Skipping next toFIGS.9A-B, shown therein in tables901/902, respectively, are exemplary number of repeats to reach homogenization relative to an absolute difference between [Φ−Ψ] for the first and third staggered configurations (see alsoFIG.7) according to various embodiments described herein. As mentioned previously herein, certain laminates or sub-laminate structures may be constructed using a combination of the staggered stacking sequences603-606, depending on desired material characteristics, homogenization, and the like. Consider as examples a construction wherein the layers have the same stacking except for the outer two sets of ply layers. So constructed, the convergence rate of the five sequences (toward homogenization) varies, with the first staggered sequence603and the third staggered sequence605(those extensively described herein) being the fastest to converge due to their being the most disperse, as compared to the second and fourth staggered sequences604/606. This may be understood with reference firstly toFIGS.9A-B. InFIG.9A, symmetry lines903/904indicate the symmetry that exists with respect to the axes [Φ=Ψ] and [Φ+Ψ=90], respectively. Along line904, for example, the five angular options (90/0; 80/10; 70/20; 60/30; 50/40) converge to the same [ABBD]* with [B]*=0 and [A]*=[D]*, as defined previously herein. The only difference is the convergence rate, whereby, as a non-limiting example, the angular orientation 50/40 converges to homogenization with three (3) repeats or layers, as compared to the four (4) repeats required at 90/0. A key factor is, as also previously detailed herein, the absolute difference between |Φ−Ψ|, whereby the [π/4] (i.e., 45 degrees) demarcation line905of the absolute difference is defined, as evident inFIG.9B. Turning toFIG.9C, mapped therein in table910is another exemplary set of five distinct sequences, utilizing the first and third staggered configurations603/605, for determination of a convergence rate911thereof according to various embodiments described herein. In conjunction with followingFIGS.10A-E, the results are understood for the following distinct angular differences: [Φ=80;Ψ=0];[Φ=70;Ψ=10];[Φ=60;Ψ=20];[Φ=50;Ψ=30];[Φ=40;Ψ=40] To determine the convergence rate911, the variation with respect to [A*=D*] and [B*=0] is defined as: Maximumvalueof{Maximumvalueof❘"\[LeftBracketingBar]"Bij*_❘"\[RightBracketingBar]"/A11*fori_=1,2,3,j=1,2,3Maximumvalueof❘"\[LeftBracketingBar]"Bij*_❘"\[RightBracketingBar]"/D11*fori_=1,2,3,j=1,2,3Maximumvalueof❘"\[LeftBracketingBar]"Aij*_-Dij*_❘"\[RightBracketingBar]"/A11*fori_=1,2,3,j=1,2,3Maximumvalueof❘"\[LeftBracketingBar]"Aij*_-Dij*_❘"\[RightBracketingBar]"/D11*fori_=1,2,3,j=1,2,3 Referencing firstFIG.10Aand the chart1010illustrated therein, it may be seen and understood that, as defined, the third and fourth staggered stacking sequences or configurations605/606, respectively, provide the fastest convergence rates along plot line1011. This is at least because the angular difference1015for [Φ=80; Ψ=0] is very close to [Φ=90; Ψ=0], where the third/fourth sequences are symmetric [0/90/90/0]rT. The first and second staggered sequences or configurations603/604are not symmetric at [Φ=90; Ψ=0], thus providing a slower convergence with plot line1012. The paired stacking sequences or configurations601/602have still further repeats and a slower convergence with plot line1013. It may thus be understood that for [Φ=90; Ψ=0], convergence is quicker (i.e., with fewer repeats) for the third and fourth staggered sequences, although all of the described staggered sequences outperform and/or are optimal as compared to the paired stacking sequences or configurations. Turning toFIG.10B, chart1020illustrates the [Φ=70; Ψ=10] angular difference configuration1025. In this configuration the third staggered sequence605slightly outperforms even the fourth staggered sequence606. Still further, the first and second staggered sequences603/604are very near (but not quite equal to) the performance of the third and fourth sequences or configurations. This is at least because the [Φ=70; Ψ=10] angular difference is not that close to the 90/0 configuration. Performance again is not comparable to that achievable with a paired stacking sequence601/602(see plot line1021). For example, more than double the percentage variation remains in a paired stacking sequence, even with 20 repeats or ply layers (compare plot line1021with those grouped as lines1022). InFIG.10C, the [Φ=60; Ψ=20] angular difference1035is illustrated in chart1030, whereby all four of the staggered stacking sequences603-606perform slightly differently, largely due to the departure from the [Φ=90; Ψ=00] angular difference, where symmetry exists. More importantly, as we transition across the [π/4] (i.e., 45 degrees) demarcation line905(seeFIG.9B), the first staggered sequence603(line1031) presents the fastest convergence rate, followed by the second staggered sequence604(line1032), the third staggered sequence605(line1033), and the fourth staggered sequence606(line1034). Once again, all staggered sequences or configurations603-606outperform the paired stacking configurations601-602(line1036). Progressing further beyond the [π/4] (i.e., 45 degrees) demarcation line905(seeFIG.9B), the [Φ=50; Ψ=30] angular difference1045is illustrated in chart1040ofFIG.10D, whereby the first staggered sequence603is further optimized (line1041), as compared to the convergence rate observed for the third staggered sequence605(line1042)—both trailed further by second and fourth and paired sequences or configurations (line1043). With movement further from the [Φ=90; Ψ=00] angular difference, where symmetry exists, the second and fourth sequences fail to perform significantly better than the paired configuration or sequence (line1044). This may be seen even more evidently inFIG.10Efor the [Φ=40; Ψ=40] angular difference1055and chart1050thereof, whereby the first staggered sequence605(line1051) converges below 1% variation with as few as eight (8) repeats or layers. By way of comparison, the third staggered sequence605and the paired sequences601/602converge (line1052) to the same degree only after 18 repeats or layers; more than twice. Even at 20 repeats or layers, the convergence and variation percentage for the second and fourth staggered sequences604/606remain near 2% (line1053). The first staggered sequence603shows the fastest convergence rate at least because the [Φ=40; Ψ=40] angular difference is very close to sequence [45/−45/−45/45]rTwhich is symmetric (see againFIG.9B). Comparing and consideringFIGS.10A-Ecollectively, it may be understood that the staggered sequences requiring the fewest repeats (i.e., layers) to reach homogenization are those whose couples are composed of different angles and different signs, as illustrated below: Considering the above, it also follows that the sequence requiring the fewest repeats, across multiple angular differences is a combination of the two sequences illustrated above, namely the first and third staggered sequences or configurations603/605, respectively. Of particular preference, the first staggered sequence is optimal where the absolute difference in angles is less than 45 degrees, coupled with utilization of the third staggered sequence where the absolute difference in angles is greater than 45 degrees, as detailed elsewhere herein. These staggered sequences (the “staggered” term to be contrasted with a pairing of equal/opposite angles in any coupling) are thus favorable and/or desirable for achieving homogenization with the fewest number of repeats or ply layers for a laminate or sub-laminate structure. Exemplary Non-Limiting Applications and Methods of Stacking Various embodiments utilizing the staggered stacking sequences603-606described herein may be utilized in manufacturing and/or otherwise forming multi-ply layer laminate structures and/or one or more sub-laminate modules and structures having multi-ply layers, whereby one or more of the distinct modules may operate as a building block, with two or more thereof being combined to define any distinct laminate structure. Exemplary types of structures include: cylinders, fuselages, wings, pressure vessels, wind turbine components, rockets, and the like. Structures may be grid, skin-based, a combination of grid/skin as detailed in PCT/US2018/025600 (as published), with tapering techniques described therein also applicable. Lay-up methods and techniques may also be understood from PCT/US2018/025600 and related publications by the named inventor(s), whereby the layup of tape or fabric (or even grid/skin combinations) can go from one end of a structure to the opposite end without stopping, cutting, or experience local tape buckling. Conventional legacy quad sub-laminates simply cannot achieve such smooth paths, due at least in part to the internal constraints placed thereon, including maintaining of certain plies at particular angles throughout. Flexibility and simplicity, with improved convergency upon homogenization with fewer repeats (i.e., layers) is achieved only via the staggered stacking sequences and configurations detailed herein, when utilized alone or in combination with paired sequences also applicable to double-double laminate structures. An exemplary part801is illustrated with reference toFIGS.8A-B, with a tapered and staggered configuration applied thereto according to various embodiments. As shown, the omega part801may realize an over 40% weight reduction by using the double-double configurations described herein. With a maximum thickness805at eight (8) repeats and tapered applied to opposing and either sides thereof, down to a single (1) repeat802at outer edges of the part, a streamlined, light-weight part can be provided while retaining certain desirable material characteristics. For example, using the first staggered sequence603or configuration and a maximum thickness of 1.4 millimeters (for homogenization), no warpage is observed under testing, as illustrated in imaging810, left side ofFIG.8B. This can be contrasted with imaging820on the right side ofFIG.8B, whereby a much thicker part is required that nevertheless exhibits some degree of warpage under testing. Thus, beyond reduced thickness capabilities, the convergence upon homogenization realizes additional advantages and material characteristic benefits, even as compared to the paired stacking sequence configurations601/602. Considering alsoFIG.8C, when the first staggered sequence603was used in a 70/20 angular difference configuration831(see chart830), the part showed minimal (if any) noticeable twist or warpage, even when the average number of repeats was reduced to 4.5; and a minimum of four (4) repeats or ply layers. This may be contrasted once more with the paired sequence602used with the same 70/20 angular difference841configuration (see chart840). In the latter, the part801showed visible twist deformation, even when the same (4.5) average number of repeats were used. This is, at least in part, due to the required minimum number of 8 repeats for homogenization utilizing the paired configurations. Homogenization is thus another practical way to limit, minimize, and/or eliminate warpage with high repeats. In certain embodiments, for example within the first staggered sequence603, a bending-torsion coupling is also achieved, improving the structural integrity of parts such as that illustrated with even as few as four (4) repeats or ply layers. Turning toFIG.11, a particular test case is illustrated, namely the single-double (Φ=Ψ) configuration1100. In this embodiment, a paired stacking sequence (see configurations601/602described elsewhere herein) maintains single-thickness plies while a first staggered sequence603is provided with plies having a double thickness, which is an advantage for paired stacking sequence. Because the first staggered sequence603or configuration is symmetric and therefore after cure there will be no warping, this unique sequence exhibits the bending-torsion coupling mentioned herein-above. This may be distinctly contrasted with a paired sequence, which will typically generate some warping after cure, due at least in part to the in plane-bending coupling and no bending-torsion coupling achieved thereby. As a result, it is observed that the first staggered sequence603is preference for tapered structures (e.g., part801); this, amongst various advantages can suppress undesirable warping at part edges and/or any delamination associated therewith. For additional or alternative parts (not illustrated specifically) that may be subjected to in-plane loads, since no bending will be generated, the first staggered sequence603is also considered optimal. By way of contrast, though, so as to not minimize the remaining usefulness thereof, the paired sequences601/602and/or configurations thereof are advantageous in closed parts with no free edges, including for structures such as cylinders—where bending but not torsion may be encountered and/or externally applied. By maintaining single-thickness plies for paired sequence stacking in such applications, thickness while maintaining homogenization can be mitigated. To reiterate, homogenization is very important to composite laminates in general, and for double-double laminate configurations particularly. In general, when a laminate is homogenized by having many repeats, tapering can be used to reduce weight, say, from 10, to 9, to 8, to 7, and the like. If the laminate or sub-laminate structure is not homogenized, tapering can still be done to reduce weight, but the laminate properties will change as plies are dropped. It is no longer a simple way to achieve an optimum laminate with constantly varying thickness and properties. Indeed, for many complex technological applications, uncertainty and/or variation of material properties is undesirable and/or unsafe. Exemplary Advantages Realized Exemplary and non-limiting advantages of various embodiments of the staggered stacking sequences described herein thus include, as mere non-limiting examples, at least the following:(1) Homogenization across the thickness of the laminate is more easily achieved with thinner sub-laminates and higher number of repeats. Legacy quad is the worst family when it comes to homogenization because its member laminates are stacks of discrete plies with 0, ±45, and 90.(2) When a laminate is homogenized, it is naturally symmetric. Mid-plane symmetry no longer needs be enforced. This means that layup process is more error free and can be done faster. We refer to this as continuous or nonstop stacking. It reduces cost of stacking either in terms of time required to complete a layup process thus freeing ATL for other components or increase production rate with the same machine.(3) A homogenized laminate is easier to analyze and design. The in- and out-of-plane properties are easier to determine and use for simulation. Laminate is stronger and has higher resistance to delamination. It is stronger because each thin ply failure is a smaller percentage of the total. It is tougher because interlaminar stresses are uniform across the thickness and is smaller in magnitude because of thin plies. There is no longer any stacking sequence effect.(4) Ply drop can be done one at a time, without need to drop two with mid-plane symmetry. Ply drop can be done by sub-laminates if they are thin. Then, material property will not change as ply drop takes place. This is not so with the legacy quad laminates because as individual plies are dropped, the property of the laminate changes.(5) With homogenized laminates like members from the double-double family layup fabrication is easier, and the tapering of laminated skin can more easily match what optimum design calls for. Thus, the structure can be expected to perform accordingly.(6) Patches for hard points and repair can use the same sub-laminate and would be most effective because there are no stress raisers due to mismatch of stiffness.(7) Tapering of laminates can reduce weight and put materials where it is needed. Composites are unique because it is the original additive process. Thin-ply sub-laminates such as those from the double-double family can be fully deployed to offer the drastic taper that is not possible with thick sub-laminates from the legacy family.(8) The mismatch in stacking sequence between adjacent panels of legacy heterogeneous laminates is a critical issue and lead to designs with stress concentrations, prone to delamination, and a nightmare for manufacturing. Blending and ply drop become major issues for design and manufacturing. In use of double-double, one sub-laminate may be considered for the entire component eliminating the need for blending. The structure with one sub-laminates that is homogenized can be tapered to reach optimum weight and layup. CONCLUSION Of course, many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | 50,313 |
11858250 | FORMS FOR CARRYING OUT THE PRESENT INVENTION Summary of Layered Body A layered body according the present invention will be explained in detail first. The layered body according to the present invention is a layered body that includes (L1) a high dielectric sheet that includes a single layer or multiple layers of a polymer cured material that has a dielectric functional group, and (L2) at least one pressure-sensitive adhesive layer, and may also have (L3) an electrode layer, and (L4) one or more selections from non-silicone thermoplastic resin layers, where another protective layer, a non-silicone adhesive layer, an optical functional layer such as a reflective layer, or the like, may be provided between any of the layers, or as outside layers, as desired. The layered body that has these functional layers can, itself, be used as a member for an electronic device, and can function as a dielectric layer and as a functional layer structural unit that includes a dielectric layer, through disposition thereof within the device. Moreover, electrode or protective layers may further be provided on these layered bodies, depending on the type of device. The layered body is particularly useful as a member for an electrical or electronic component, a transducer, or a display device, or, in particular, as a member that includes a dielectric member, and can improve the production efficiency and yields of various types of devices, with superior ease of handling in the industrial production processes. On the other hand, the layered body according the present invention may instead be a releasable layered body that further includes a (L5) separator that is provided with a release surface that faces the (L2) pressure-sensitive adhesive layer of the layered body described above. This type of releasable layered body can be manufactured, shipped, and stored in a form that includes the separator, so has the benefit of superior productivity and ease of handling. Moreover, by peeling the separator to expose the pressure-sensitive adhesive layer, the layered body, with the separator removed, can be used as a member for an electronic device, the same as described above. Moreover, the releasable layered body, after the separator is separated, has a pressure-sensitive adhesive layer on at least one surface of an outer layer, and thus has the benefit of the ability to place the layered body on a desired device through the use of the pressure-sensitive adhesive layer. Note that the (L5) separator substrate may be a thermoplastic resin film that is identical to the (L4) non-silicon thermoplastic resin layer, where ultimately this layer is peeled off, and the meaning of the functional layer will differ depending on whether or not the layer is ultimately removed for placement onto a device. [(L1) High Dielectric Sheet] A high dielectric sheet that includes a polymer cured material that has a dielectric functional group is one essential feature of the layered body according to the present invention, and is the layer that functions as a dielectric layer when disposed on the device. The layer may be a single-layer high dielectric sheet structured from a polymer cured material that is molded in the form of a single sheet, but may instead be a multilayer high dielectric sheet formed from multiple sheets of polymer cured materials that may be either mutually identical or mutually different. The multilayer high dielectric sheet can more easily be made into a thick film when compared to a high dielectric sheet of a single layer, and layering high dielectric polymer cured materials having different physical properties, such as hardnesses, dielectric constants, or thicknesses (for example, a polymer cured material in the form of a gel and a polymer cured material in the form of an elastomer, or polymer cured materials of different dielectric constants, etc.) makes it possible to adjust the physical properties of the high dielectric sheet as a whole. Moreover, layering polymer cured material sheets that are anisotropic, such as stretched sheets, in either identical directions or perpendicular directions, enables adjustment of the physical properties of the high dielectric sheets as a whole. There is no particular limitation on the type of polymer cured material that has the dielectric functional group, and a single type, or combinations of two or more types of polymers, may be selected from identical or different publicly known dielectric polymers. Specific examples include acrylic polymers, urethane polymers, siloxane polymers, and mixtures thereof (including hybrid polymer mixtures). As described above, the high dielectric sheet according the present invention may be of multiple layers, and thus it may be a high dielectric sheet of layers of polymer cured materials having different types of dielectric functional groups with different physical properties, and may be a high dielectric sheet wherein layers of different types of polymer cured materials are layered (for example, a layered body of a urethane polymer layer and a siloxane polymer layer). Note that, from the perspective of electrical insulation performance, thermal durability, and ability to withstand cold (in particular, in suppressing a change in physical properties at low temperatures in particular), preferably the high dielectric sheet according the present invention uses a siloxane-based polymer layer. The dielectric functional group is a functional group that applies dielectric properties to the polymer cured material and to the high dielectric sheet made therefrom, and while there is no particular limitation thereon, it may be, for example: a) a halogen atom or a group that includes a halogen atom, such as a fluoroalkyl group, including fluoromethyl groups, 3-fluoropropyl groups, and 3,3,3-trifluoropropyl groups, or a fluoroalkyl group; b) a group that includes a nitrogen atom, such as a cyano group (for example, a cyanopropyl group or a cyanoethyl group); c) a group that includes oxygen atom, such as an ester group, or the like; d) a complex cyclic group such as an imidazole group, a pyridine group, a phthalocyanine group, or the like; e) a boronated group such as a borate ester group, a borate group, or the like; f) a group that includes phosphorus such as, for example, a phosphine group, a phosphine oxide group, a phosphonic acid ester group, a phosphorus acid ester group, a phosphoric acid ester group, or the like; g) a group that includes sulfur, such as a thiol group, a sulfone group, a thioketone group, a sulfonic acid ester group, or a sulfonamide group, or the like. The polymer cured material that structures the high dielectric sheet may include one or more types of these dielectric functional groups, and there is no particular limitation on the inclusion proportions thereof. Moreover, there is no particular limitation on the means for introducing the dielectric functional group into the polymer cured materials described above, where the polymer of a curing reaction polymer that is modified with a dielectric functional group may be cured, a compound that has the dielectric functional group may be added and dispersed into the polymer matrix, a compound having a dielectric functional group and a reactive functional group may be introduced into a polymer matrix that is curable through a curing reaction polymer, a compound that has a dielectric functional group that is compatible with a curing reaction polymer may cause a polymer cured material to swell, or an arbitrary filler treatment using a compound that has a dielectric functional group may be performed to add the compound, together with the filler, to the curing reaction polymer, to cure the material as a whole. The curing reaction that is applied to the polymer curing material that has the dielectric functional group is arbitrary, where there is no particular limitation on the curing system that can be used with the acrylic polymer cured material, urethane polymer cured material, or siloxane polymer cured material, and a single type or a combination of two or more types may be used. Preferably a condensation curable, addition curable, peroxide curable, radical reaction curable, or light or energy beam curable polymer cured material is used. Other arbitrary additives, such as fillers, may be included in the polymer cured material having the dielectric functional group in a range that does not negatively affect the technological effects and function of the dielectric layer of the present invention. Specifically, they may include one or more inorganic particles selected from a group comprising dielectric inorganic particles and reinforcing inorganic particles that can be used for surface treatments, mold releasing agents, insulation modifiers, adhesive improving agents, and the like. Note that these components, and similar materials, are similar to the components disclosed in Patent Documents 3 through 6, listed above, and may be added with no particular limitations to siloxane polymer cured materials and polymer cured materials that have other dielectric functional groups. Preferably the high dielectric sheet that includes a polymer cured material having a dielectric functional group, listed above, is substantially flat, and suitably the difference in thicknesses between the end of the sheet and the thickness at the center of the sheet is no more than 5.0%, and the thickness at the center of the sheet is in a range of between 5 and 1000 μm. Moreover, as described above, the high dielectric sheet may be a single layer or may be multiple layers, and may be used for the purpose of forming a dielectric sheet in excess of 1000 μm through layering a plurality of sheets together to form a dielectric layer with high capacity that can be used in a device such as any of a variety of transducers. The high dielectric sheet according the present invention may be transparent or opaque, depending on the application. On the other hand, when the polymer cured material is a polymer matrix with superior transparency, such as an organopolysiloxane cured material that includes fluoroalkyl groups, it will be substantially transparent unless a coloring agent, a filler with a large particle diameter, or the like, is mixed in. Here “substantially transparent” means transparent visually when a film-type cured material with a thickness of between 50 and 1000 μm is formed, wherein, in general, the transparency to light with a wavelength of 450 nm is no less than 80%, indexed to the value for air being 100%. The high dielectric sheet of the present invention, from the perspective of dielectric performance, has a relative dielectric constant, at 1 kHz and 25° C., of no less than 4, and preferably no less than 5, and more preferably no less than 6. Note that the polymer cured material is an organopolysiloxane cured material that includes fluoroalkyl groups, where the use of a cured material of a curable organopolysiloxane composition that includes at least an organopolysiloxane that includes fluoroalkyl groups wherein at least 10 mol % of all substituents for silicon atoms are specific fluoroalkyl groups, such as trifluoropropyl groups, enables a high dielectric sheet with a relative dielectric constant of 6 or 7 to be designed relatively easily. When the high dielectric sheet according to the present invention is used in an application as an electronic material for a touch panel, or the like, or an electronic member for a display device, or, in particular, as a transducer material for a sensor, or the like, preferably the shear storage modulus at 23° C. is in a range of between 103and 105Pa, and more preferably in a range of between 1.0×103through 5.0×104Pa. Moreover, through arbitrary selections, preferably the compression residual strain (%) of the high dielectric sheet of the present invention is less than 10%, where less than 5% is more preferable, and no more than 4% is particularly preferable. Similarly, preferably the compressibility (%) is no less than 15%, more preferably no less than 18%, and particularly preferably no less than 20%. The means for measuring these are the same as in Patent Document 6 (International Patent Application Publication WO 2017/183541), referenced above. There are no particular limitations on the nature of the high dielectric sheet according to the present invention, and while it may be in the form of a flexible gel, an elastomer with superior viscoelasticity, or a hard resin, from the perspective of the technological effect of the present invention, the high dielectric sheet as a whole being in the form of a gel or an elastomer is particularly preferred. In particular, the layered body according to the present invention may be used for the purpose of placing onto a device, with good efficiency, a high dielectric sheet of a gel type, which, by itself, would be poor in ease of handling. An organopolysiloxane cured material that includes fluoroalkyl groups proposed in Patent Documents 3 through 6, above, is particularly well-suited as the high dielectric sheet according to the present invention, and preferably is a material wherein a curable organopolysiloxane composition that includes at least an organopolysiloxane where at least 10 mol % of all substituents on silicon atoms include fluoroalkyl groups that are fluoroalkyl groups represented by (CpF2p+1)—R— (where R is an alkylene group with a carbon number between 1 and 10, and p is a number in the range of between 1 and 8) has been cured. In particular, a high dielectric sheet that is a single sheet or a multilayer sheet that combines a plurality of sheets, of a flat gel sheet made from an organopolysiloxane cured material that includes a fluoroalkyl group that includes a 3,3,3-trifluoropropyl group, and which is substantially transparent, is particularly preferred. A high dielectric sheet that is formed through inclusion of an organopolysiloxane cured material that includes fluoroalkyl groups exhibits characteristics of having a low adhesive strength, a high compression ratio, and good recovery characteristics. Moreover, even at low temperatures of, for example, less than 0° C., there is little change in the physical properties listed above, making it possible to achieve sensor sensitivity that is highly stabilized over a broad temperature range, with superior pressure responsiveness even under low pressures, when applied as a dielectric layer for a display device such as a touch panel. The high dielectric sheet according to the present invention may be produced through forming a coating film through coating onto another functional layer, suitably onto a silicone pressure-sensitive adhesive layer or non-silicone thermoplastic resin layer, in a structure wherein the curable polymer composition described above (suitably a curable organopolysiloxane composition that includes at least an organopolysiloxane that includes fluoroalkyl groups), and curing, under desired conditions, to produce a cured material, or may be produced through coating the curable silicone composition, described above, onto another releasable substrate and curing, and peeling the cured material from the releasable substrate and applying to another functional layer or to a layered structural unit that includes the other functional layer. The coating method may be, for example, gravure coating, offset coating, offset gravure, roller coating, reverse-roller coating, air knife coating, curtain coating, or comma coating. Note that with the high dielectric sheet according to the present invention, a rolling process may be carried out either prior to the curing reaction or following the curing reaction for the curable polymer composition. The rolling process may also be carried out on the polymer cured material in a cured through semi-cured state, or on a polymer semi-cured material, but curing through heating or the like after performing the rolling process on an uncured curable polymer composition to produce a polymer cured material that is flat and uniform is preferred. Moreover, when carrying out the rolling process, a flat and uniform layer structure may be obtained through curing, through heating, or the like, after a rolling process on the entire layered body wherein an uncured pressure-sensitive adhesive layer and curable polymer composition are coated, with a separator that has a release layer, described below, therebetween, and is preferred. [(L2) Pressure-Sensitive Adhesive Layer] The pressure-sensitive adhesive layer may be a pressure-sensitive adhesive layer (outermost layer) that enables placement, through contact bonding to a device, of the high dielectric sheet described above, or a layered structural unit that includes the high dielectric sheet, described above, and is a layer that is different from the polymer cured layer that has the dielectric functional groups, described above, or may be an intermediate layer for improving inter-layer adhesion between the other functional layers that structure the layered body. The provision of the pressure-sensitive adhesive layer improves the utility as a member, depending on the placement, in addition to enabling an improvement in the ease of handling, when handling the layered body itself as a member for an electronic device, through physically reinforcing and integrating the entirety of the layered body, including the high dielectric sheet. The type, physical nature, and adhesive characteristics of the pressure-sensitive adhesive layer according to the present invention can be selected as appropriate depending on the types of layer structural units and of the device, the use conditions, and the manufacturing process, and there is no particular limitation on the thickness or method for forming the pressure-sensitive adhesive layer according to the present invention. The pressure-sensitive adhesive layer that can be used in the present invention may be, for example, a rubber pressure-sensitive adhesive agent, an acrylic pressure-sensitive adhesive agent, a silicone pressure-sensitive adhesive agent, a vinyl alkyl ether pressure-sensitive adhesive agent, a polyester pressure-sensitive adhesive agent, a polyimide pressure-sensitive adhesive agent, a urethane pressure-sensitive adhesive agent, a fluorine pressure-sensitive adhesive agent, a polyvinyl pyrrolidone pressure-sensitive adhesive agent, a polyacrylamide pressure-sensitive adhesive agent, a cellulose pressure-sensitive adhesive agent, or the like, and, depending on the purpose, these may further include well-known heat resistance additives, tackifying agents, plasticizing agents, filling agents, oxide inhibitors, antiaging (anti-degradation) agents, optical stabilizing agents, flame retardants, antistatic agents, dyes, pigments, and the like. Suitably, the pressure-sensitive adhesive agent according to the present invention may be structured from one or more types of pressure-sensitive adhesive agents selected from rubber pressure-sensitive adhesive agents, acrylic pressure-sensitive adhesive agents, and silicone pressure-sensitive adhesive agents, or may be a pressure-sensitive adhesive agent of a compound type wherein two types are mixed, layered, or grafted, such as acryl-silicone systems. For the pressure-sensitive adhesive agent according to the present invention, silicone pressure-sensitive adhesive agent layers, acrylic pressure-sensitive adhesive layers, and combinations thereof are particularly preferred. These pressure-sensitive adhesive agent layers can be provided, as necessary, with thermal durability, resistance to cold, and durability and, if desired, a substantially transparent pressure-sensitive adhesive agent can be provided easily, and, additionally, the adhesive strength can be adjusted easily, enabling suppression of paste transfer or residual adhesive within the device, and thus has the benefit of superior reworkability accompanying re-adhesion, or the like. Depending on the application, the pressure-sensitive adhesive agent layer according to the present invention may be a substantially transparent pressure-sensitive adhesive agent layer. Here, as described above, “substantially transparent” means transparent visually when a film-type cured material with a thickness of between 50 and 1000 μm is formed, wherein, in general, the transparency to light with a wavelength of 450 nm is no less than 80%, indexed to the value for air being 100%. While there is no particular limitation on the adhesive strength of the pressure-sensitive adhesive agent layer in the present invention, preferably the adhesive strength is no less than 5 N/m in the case of peeling at an angle of 180° at a speed of 300 mm/m in a 23° C., 50% humidity environment for a test piece wherein a polyethylene terephthalate (PET) substrate (with a thickness of 50 μm) is adhered to both faces of a pressure-sensitive adhesive layer that has a thickness of 100 μm, where 10 N/m is more preferred. The rubber pressure-sensitive adhesive agent may be a rubber pressure-sensitive adhesive agent that has, as the base polymer, a natural rubber or any of a variety of synthetic rubbers such as, for example, a polyisoprene rubber, a styrene/butadiene block copolymer (SB) rubber, a styrene/isoprene block copolymer (SI) rubber, a styrene/isoprene/styrene block copolymer (SIS) rubber, a styrene/butadiene/styrene block copolymer (SBS) rubber, a styrene/isoprene/butadiene/styrene block copolymer (SIBS) rubber, a styrene/ethylene/butylene/styrene block copolymer (SEBS) rubber, a styrene/ethylene/propylene/styrene block copolymer (SEPS) rubber, a styrene-ethylene-propylene block copolymer (SEP) rubber, recycled rubber, a butyl rubber, polyisobutylene, or modified products thereof. The acrylic pressure-sensitive adhesive agent may be an acrylic pressure-sensitive adhesive agent that has, as the base polymer, an acrylic polymer (homopolymer or copolymer) that uses, as a monomer component, one or more types of (meth) acrylic acid alkyl esters. The (meth) acrylic acid alkyl ester in the acrylic pressure-sensitive adhesive agent may be a C1 through 20 alkyl ester (meth) acrylate such as methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, isopropyl (meth) acrylate, butyl (meth) acrylate, isobutyl (meth) acrylate, s-butyl (meth) acrylate, t-butyl (meth) acrylate, pentyl (meth) acrylate, hexyl (meth) acrylate, heptyl (meth) acrylate, octyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, (meth) isooctyl acrylate, nonyl (meth) acrylate, isononyl (meth) acrylate, decyl (meth) acrylate, isodecyl (meth) acrylate, undecyl (meth) acrylate, dodecyl (meth) acrylatetridecyl (meth) acrylate, tetradecyl (meth) acrylate, pentadecyl (meth) acrylate, hexadecyl (meth) acrylate, heptadecyl (meth) acrylate, octadecyl (meth) acrylate, nonadecyl (meth) acrylate, eicosyl (meth) acrylate (and preferably a C4 through 18 alkyl (straight-chain or branched alkyl) ester (meth) acrylate), or the like. Note that the acrylic polymer may include a unit corresponding to another monomer component that can copolymerize with the (meth) acrylic acid alkyl ester, if necessary, for the purpose of modifying the cohesive force, thermal durability, cross-linking performance, or the like. The reactive (meth) acrylic acid alkyl ester, in the presence of a polymerization initiator, is cured through exposure to a high energy beam such as ultraviolet radiation, to form an acrylic pressure-sensitive adhesive layer. For the silicone pressure-sensitive adhesive agent layer according the present invention, a cured material of a curable silicone composition that includes: (A) a straight-chain or branched organopolysiloxane wherein the average number of curing reaction functional groups in a molecule is greater than 1; (B) an organopolysiloxane resin; and (C) a curing agent is particularly preferred. Here the silicone pressure-sensitive adhesive agent layer according the present invention has a function as a pressure-sensitive adhesive agent layer, where, insofar as it is a layer that is independent of the aforementioned (L1) high dielectric sheet layer, a high dielectric functional group, typified by a fluoroalkyl group that includes a 3,3,3-trifluoropropyl group, may be included, and is preferred. There is no limitation on the system for curing the curable silicone composition, and that which is publicly known may be used. For example, it may be that which is peroxide curable that is cured with peroxide, that which is hydrosilylation reaction curable that is cured through a platinum catalyst, that which is energy beam curable/optically curable that is cured through exposure to an energy beam such as ultraviolet radiation, or that which is condensation reaction curable. Normally peroxide curable silicone compositions include diorganopolysiloxanes that include alkyl groups, and are cured through the effects of peroxide at a high temperature. The hydrosilylation reaction curable silicone compositions normally are cured through the hydrosilylation reaction between the vinyl group in a diorganopolysiloxane and an SiH group (a hydrogen atom bonded to a silicon atom) in an organohydrodiene polysiloxane, through the effect of a platinum catalyst. In energy beam curable/optically curable silicone compositions that are cured through a radical reaction in the presence of an optical polymerization initiator, that which is well known as a compound that produces radicals through exposure to an energy beam, such as ultraviolet radiation, or the like is, for example, organic peroxides, carbonyl compounds, organic sulfur compounds, azo compounds, and the like. Normally a condensation reaction curable silicone composition is cured through a condensation reaction between a silanol group, such as diorganopolysiloxane, and a hydrolyzable group, through the effect of a condensation reaction catalyst. The use of a hydrosilylation reaction curable silicone composition that is cured through a hydrosilylation reaction is preferred, in particular, due to the ability to cure in a short time at a relatively low temperature. When a hydrosilylation reaction curable material is used for the curable silicone composition, the (A) curing reaction functional group of the organopolysiloxane is an alkynyl group, and, in particular, an alkynyl group with a carbon number between 2 and 10. The alkynyl group with a carbon number between 2 and 10 may be, for example, a vinyl group, an allyl group, a butenyl group, or a hexenyl group. Preferably the alkynyl group with a carbon number between 2 and 10 is a vinyl group. The (A) organopolysiloxane may include only a single component, or may be a mixture of two or more different components. A functional group other than an alkynyl group in the (A) component may be, for example, an alkyl group with a carbon number between 1 and 10 or an aryl group with a carbon number between 6 and 10, that has been modified with a halogen atom, such as a fluorine atom, or the like, and preferably is an alkyl group or a phenyl group with a carbon number between 1 and 6. Moreover, a fluoroalkyl group, such as a 3,3,3-trifluoropropyl group, may be included in the (A) component, and is preferred. Preferably the (A) organopolysiloxane is of a straight-chain type. The room temperature characteristics of the (A) component may be oily or of a raw rubber type, and preferably the viscosity of the (A) component at 25° C. is no less than 50 mPa·s, and, in particular, preferably is no less than 100 mPa·s. In particular, when the curable silicone composition is of a solvent type, the (A) has a viscosity at 25° C. of no less than 100,000 mPa·s, or has a plasticity, measured based on the method stipulated in JIS K6249 (the value when a 1-kgf load is applied for three minutes to a 4.2-g spherical sample at 25° C.) is in a range between 50 and 200, and, more preferably, is an organopolysiloxane that includes an alkynyl group of a raw rubber type with a pliability in a range of between 80 and 180. However, an (A) component with a lower viscosity may also be used. The (B) organopolysiloxane resin is a component that applies adhesive strength to the hard layer, and there is no particular limitation thereon insofar as it is an organopolysiloxane that has a three-dimensional network structure. For example, it may be a resin that is made from R2SiO2/2units (D units) and RSiO3/2units (T units) (where, in this formula, R indicates mutually independent monovalent organic groups and may or may not include a hydroxyl group or a hydrolyzable group), or a resin made from T units alone that have hydroxyl groups or hydrolyzable groups, or may be a resin made from R3SiO1/2units (M units) and SiO4/2units (Q units), and may or may not have hydroxyl groups or hydrolyzable groups. In particular, the use of a resin (known as an MQ resin) made from R3SiO1/2units (M units) and SiO4/2units (Q units) that may or may not have hydroxyl groups or hydrolyzable groups, is preferred. Note that hydroxyl groups and hydrolyzable groups are groups that are produced as the result of a derivative of silane, as a raw material, or hydrolysis of silane, through direct bonding of T units or Q units within the resin directly to silicon. The monovalent organic group of R is preferably a monofunctional hydrocarbon group with a carbon number between 1 and 10, and may be, for example, an alkynyl group with a carbon number between 2 and 10, an aryl group with a carbon number between 6 and 10, a cycloalkyl group with a carbon number between 6 and 10, a benzyl group, a phenylethyl group, a phenylpropyl group, or an alkyl group with a carbon number between 1 and 10, which may be modified with a halogen atom, such as a fluorine atom. In particular, preferably at least 90 mol % of R is an alkyl group or a phenyl group with a carbon number between 1 and 6, and, particularly preferably, between 95 and 100 mol % of R is methyl groups. Moreover, a portion of R may include fluoroalkyl groups, such as 3,3,3-trifluoropropyl ethyl groups, or the like, and this is preferred. Preferably the (B) organopolysiloxane resin has a mole ratio of M units to Q units of between 0.5 and 2.0 when it is a resin structured from R3SiO1/2units (M units) and RSiO3/2units (T units) and SiO4/2units (Q units). This is because if the mole ratio were less than 0.5, the adhesive strength to a hard layer would be reduced, and if greater than 2.0, the cohesive strength of the substance that structures an intermediate layer would be reduced. Moreover, D units and QT units may also be included in the (B) component in a range wherein there is no adverse effect on the characteristics of the present invention, and two or more types of organopolysiloxanes may be used in parallel in the (B) component. The organic polysiloxane may have a prescribed amount of hydroxyl groups or hydrolyzable groups, and may be a resin with hydroxyl groups or hydrolyzable groups, a resin without hydroxyl groups or hydrolyzable groups, or a mixture thereof, without any particular limitation. The organopolysiloxane resin, if it has hydroxyl groups or hydrolyzable groups, normally includes hydroxyl groups or hydrolyzable groups at between 0.1 and 5.0 mass %. When a hydrosilylation reaction curable material is used for the curable silicone composition, preferably the (C) is an organohydrodiene polysiloxane having at least two Si—H bonds in the molecule. In this case, the alkynyl groups of the organopolysiloxane undergo hydrosilylation with the hydrogen atoms that are bonded to the silicon atoms in the organohydrodiene polysiloxane, to form the cured material of the curable silicone composition. The (C) curing agent may include only a single component, or may be a mixture of two or more different components. When that which is hydrosilylation reaction curable is used for the curable silicone composition, the inclusion proportion of the (C) curing agent preferably is in a mole ratio in a range of between 0.1 and 100, and more preferably between 0.2 and 50, for the silicon atom-bonded hydrogen atom (SiH) group in the (C) component in respect to the alkyl groups in the composition. This is because if the mole ratio were in excess of 100, then the amount of curing agent that would remain without reacting would be too great, and if the mole ratio were less than 0.1, then the curing would be inadequate. Moreover, if that which is hydrosilylation reaction curable is used for the curable silicone composition, a (D) hydrosilylation reaction catalyst may be included as another component. The hydrosilylation reaction catalyst may be, for example, a platinum catalyst, a rhodium catalyst, or a palladium catalyst, where a platinum catalyst is preferred due to its ability to promote curing of the composition remarkably. The platinum catalyst may be a platinum ultra-powder, chloroplatanic acid, an alcohol solution of chloroplatanic acid, a platinum-alkenyl siloxane complex, a platinum-olefin complex, or a platinum-carbonyl complex, where a platinum-alkenyl siloxane complex is particularly preferred. The alkenyl siloxane may be selected from 1,3-di-vinyl-1,1,3,3-tetramethyl disiloxane, 1,3,5,7-tetramethyl-1,3,5,7-tetravinyl chloro tetrasiloxane, alkynyl siloxanes wherein a portion of the methyl groups of these alkenyl siloxanes have been replaced with ethyl groups, phenyl groups, or the like, or groups selected from a set comprising nitriles, amides, dioxylanes, and sulfolanes, or alkenyl siloxanes wherein the vinyl groups in the alkynyl siloxanes have been replaced with allyl groups, hexenyl groups, or the like. In particular, given the good stability of platinum-alkenyl siloxane complexes, 1,3-divinyl-1,1,3,3-tetramethyl disiloxane is preferred. Note that non-platinum metal catalysts, such as iron, ruthenium, iron/cobalt, and the like, may be used instead as the catalyst for promoting the hydrosilylation reaction. The inclusion proportion of the (D) hydrosilylation relation reaction catalyst is with the amount of platinum metal in the range of between 1 and 5000 ppm, in respect to the total amount of components (A) through (C), where a range of 1 through 1000 ppm is preferred, and a range of 1 through 200 ppm is more preferred. This is because if the inclusion proportion of the (D) hydrosilylation relation reaction catalyst were less than 1 ppm, the curing rate would be slow, or the curing would be inadequate, and if in excess of 5000 ppm, this would produce problems with discoloration, and the like. Components other than the components listed above may be included in the curable silicone composition in a range wherein the characteristics thereof are not lost. For example, curing retardation agents; adhesion promoting agents; non-reaction organopolysiloxanes, such as polydimethyl siloxane or polydimethyldiphenyl siloxane; oxide inhibitors such as those that are phenol-based, quinone-based, amine-based, phosphor-based, phosphide-based, sulfur-based, thioether-based, and the like; optical stabilizing agents such as those that are triazole-based, benzophenone-based, and the like; flame retarding agents such as those that are phosphoric acid ester-based, halogen-based, phosphor-based, antimony-based, and the like; one or more types of antistatic agents made from cationic surface activating agents, anionic surface activating agents, non-ionic surface activating agents, and the like; dyes; pigments; and so forth may be included. The silicone-based pressure-sensitive adhesive agent layer according to the present invention may be obtained through forming a coating film, through coating onto a high dielectric sheet, or onto a layered structural unit including the same, and then forming into a cured material under desired conditions, or the curable silicone composition described above may be coated onto another releasable substrate and then cured, and the cured material may be peeled from the releasable substrate and applied to the high dielectric sheet or onto the layered structural unit including the same. The method for coating may be gravure coating, offset coating, offset gravure, roller coating, reverse-roller coating, air knife coating, curtain coating, and comma coating. While the curing reaction will differ depending on the curing system, in the case of that which is hydrosilylation relation reaction curable, curing is achieved through heating the composition or exposing it to an activation energy beam. While there is no particular limitation on the temperature for the curing reaction through heating, between 50° C. and 200° C. is preferred, and between 60° C. and 200° C. is more preferred, and between 80° C. and 180° C. is even more preferred. Moreover, while the time for the curing reaction is dependent on the structures of the (A), (B) and (C) components, described above, normally it is between one second and three hours. Generally the cured material can be produced through holding for between 10 seconds and 30 minutes in a range of between 90 and 180° C. [(L3) Electrode Layer] The electrode layer is an electrode layer or electrically conductive layer that is provided on the high dielectric sheet, or the layered structural unit including the high dielectric sheet, described above, for the purpose of applying power. Specifically, the electrode layer is that which forms a single electrode, or a plurality thereof, on the dielectric sheet, described above, the pressure-sensitive adhesive agent layer, the thermoplastic resin layer, or the like, where the electrode is an electrically conductive film or a conductor. This electrode layer may be a transparent electrode layer or may be opaque. The methods for forming these electrode layers are publicly known, where a conductor may be formed through a method of coating an ink into which has been dispersed conductive particles selected from a group comprising Au, Ag, Cu, C, ZnO, and In2O3, and the like. In this case, preferably a paste wherein these conductive particles, a binder resin, and an organic solvent are mixed and dispersed (termed also a “conductive pace”) is coated and printed. This enables the binder resin to satisfy the function of a binding agent for binding together the conductive particles, improving the final durability of the electrode layer. The binder resin may be, for example, an ethyl cellulose-based resin, an acrylic resin, or the like. The organic solvent may be, for example, terpineol, butyl carbitol acetate, or the like. , depending on the application of this layered body, the electrode layer may be a transparent electrode layer, which is preferred. The transparent electrically conductive film may be structured from, for example, ITO (indium oxide+tin oxide), CNT (carbon nanotubes), IZO (indium oxide+zinc oxide), AZO (Al-doped zinc oxide), a conductive polymer (PEDOT or PSS), or the like. The conductor may be, for example, a photosensitive silver cup, silver nanoink, silver nanowires, vapor-deposited copper, rolled copper, copper nanoink, or the like. In particular, when the layered body is used as a member for an electronic device that is to be used in a display device application, such as for a touch panel, the use of a transparent electrically conductive film, such as ITO, enables the layered body as a whole to be designed to be substantially transparent. There is no particular limitation on the shape or placement of the electrode layer, and, as illustrated inFIG.5of the present invention, a plurality of electrodes may be provided in the same electrode layer plane. Rather, as illustrated inFIG.6of the present invention, electrode layers may be disposed at mutually differing angles. [(L4) Non-Silicone-Based Thermoplastic Resin Layer] The non-silicone-based thermoplastic resin layer is a sheet-shaped layer made from a thermoplastic resin other than silicone, and may be a supporting layer or reinforcing layer for increasing the physical strength of the various layers described above. While the use of such a thermoplastic resin layer in the present invention is arbitrary, it is possible to improve the ease of handling, when handling the layered body itself as an electronic device member, through physical reinforcement of the entirety of the layered body that includes the high dielectric sheet, through the use of, for example, a structure wherein the high dielectric sheet, or a layered structural unit including the high dielectric sheet, has a supporting layer on one face thereof, or is held between supporting layers on both faces thereof. The substrate used for the thermoplastic resin layer may be, for example, polyimide, polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyvinylidene chloride, polycarbonate, polyethylene terephthalate (PET), nylon, a cycloolefin polymer, or polymethyl methacrylate. In particular, when thermal durability is required in the layered body as a whole, a thermally durable synthetic resin film such as of polyimide, polyether ether ketone, polyethylene naphthalate (PEN), liquid crystal polyarylate, polyamide imide, polyether sulfone, and the like, are suitable. On the other hand, when the layered body is to be used in a device that requires visual clarity, such as in a display device, a transparent substrate, specifically a transparent material such as polypropylene, polystyrene, polyvinylidene chloride, polycarbonate, polyethylene terephthalate (PET), PEN, or the like, is suitable. Preferably the thermoplastic resin layer is in the form of a film or a sheet. While there is no particular limitation on the thickness thereof, normally it is between about 5 and 300 μm. Moreover, a thermoplastic resin film or thermoplastic resin sheet that has been treated with a primer process, corona process, etching process, or plasma process may be used in order to improve the adhesion between the thermoplastic resin layer and another functional layer in the layered body. Additionally, a protective layer may be formed or a surface treatment may be performed on the thermoplastic resin, such as a process to prevent scratches, to prevent soiling, to prevent adherence of fingerprints, to prevent glare, to prevent reflections, to prevent static, or the like. [Other Functional Layers] The layered body according to the present invention may have other functional layers in addition to the various layers described above, and there is no limitation on the thickness or type of these functional layers insofar as they technically do not interfere with curing in the present invention. Specifically, the other functional layers may be protective layers, non-silicone adhesive layers, optical functional layers such as reflecting layers, and the like, and these layers, as desired, may be placed between layers (that is, as intermediate layers), or as outer layers. [Placement of Each Layer in the Layered Body] The placement of the various layers, described above, in the layered body according to the present invention is arbitrary, and can be designed depending on the durability and strength, and ease of handling as an electronic device member, required for the layered body. On the other hand, the high dielectric sheet described above may be used as an electrical or electronic component, or as a dielectric layer in a transducer or display device, and can be placed through adhesion of the layered body as a whole to the device, and from the perspective of use as an intermediate layer for improving interlayer adhesion with other functional layers that structure the layered body, a structure is preferred wherein the (L1) single layer or multiple layers of the high dielectric sheet that includes the polymer cured material that has the dielectric functional group, or the layered structural unit that includes the polymer cured material, is held between at least two (L2) pressure-sensitive adhesive layers. Moreover, the layered body according to the present invention preferably has an (L3) electrode layer and/or a (L4) non-silicone thermoplastic resin layer on at least one face of the (L1) single-layer or multilayer high dielectric sheet that includes the polymer cured material that includes the dielectric functional group, and may further have a (L2) pressure-sensitive adhesive layer, (L3) electrode layer, or (L4) non-silicone thermoplastic resin layer as a layer that is further on the outside than these functional layers, when viewed from the high dielectric sheet. Similarly, the layered body according to the present invention may have at least (L1) a single-layer or multilayer high dielectric sheet that has a polymer cured material that has a dielectric functional group, and at least one layer selected from (L3) electrode layers and (L4) non-silicone thermoplastic resin layers on at least one face of a (L2) pressure-sensitive adhesive layer. Note that in the layered body according to the present invention, a functional layer of a given category may be a single layer or multiple layers, and, as explained for the high dielectric sheet, may be a single sheet or a compound sheet. For example, in the (L4) non-silicone thermoplastic resin sheet, single synthetic resin sheets and compound sheets wherein two different types of synthetic resin sheets are adhered together are included in the scope of the present invention. When used as an electronic device member, the structure of this type of layered body made be a combination such as described below. Note that the combinations below are examples, and, of course, the combinations are not limited thereto, and need not be layered bodies that have symmetry, as depicted in some of the examples. Moreover, in the examples, the examples of the individual functional layers are as below, where “I” means that the individual layers are facing in the layering direction of the layered body (typically the direction of thickness that is perpendicular to the surface of each of the functional layers): (L1) a single-layer or a multilayer high dielectric sheet including a polymer cured material having a dielectric functional group: (EAP) (L2) Pressure-sensitive adhesive layer: (PSA) (L3) Electrode layer: (EL) (L4) Non-silicone thermoplastic resin layer (PF) Example 1: PSA/EAP/PSA Example 2: PSA/EL/EAP/EL/PSA Example 3: PSA/PF/EAP/PF/PSA Example 4: PSA/EL/PF/EAP/PF/EL/PSA Example 5: PSA/PF/EL/EAP/EL/PF/PSA Example 6: PF/PSA/EL/EAP/EL/PSA/PF Example 7: EL/PSA/EAP/PSA/EL Example 8: PF/PSA/EL/EAP/PF/PSA/EL Example 9: EL/PSA/EAP/EL Example 10: EL/PSA/EAP/EL/PSA Example 11: PF/PSA/EAP/PF Example 12: PF/PSA/EAP/PF/PSA Example 13: EL/PSA/PF/EAP/PF/PSA/EL Example 14: PSA/EL/PF/EAP/PF/EL/PF Note that for the layered bodies wherein electrode layers are formed on the PSA, such as Example 7, Example 13, and the like, the electrode layer may be provided on the PSA through shipping in a state wherein a releasable layered body that includes the separator on the PSA, as described below, followed by peeling the separator and applying the electrode layer to the PSA. Note that when mounting in a layered display device, such as a touch panel, the display surface, such as a glass substrate, and the transparent electrode substrate, such as ITO, or the like, and the display module may be joined together through a PSA layer. [Releasable Layered Body] The layered body according to the present invention may be a releasable layered body that further includes a (L5) separator that is provided with a releasable surface opposite the (L2) pressure-sensitive adhesive layer. The use of a separator having a release surface that faces the pressure-sensitive adhesive layer enables the layered structure according to the present invention, which includes the dielectric sheet, to be handled through easy removal from the separator that structures the layered body, and enables the layered structure to be bonded to the device using the pressure-sensitive adhesive layer that is exposed when the separator is removed. This layered body has the (L5) separator that is provided with the release surface that faces the pressure-sensitive adhesive layer, and, as appropriate, may be provided with another (L5) separator as well, where the structure of the layered body may be as follows. Note that, in the examples below, “/” means that the individual layers are facing in the layering direction of the layered body (typically the direction of thickness that is perpendicular to the surface of each of the functional layers). Moreover, in the separator, the substrate and the release surface may be integrated together, or may be the same layer (where the substrate is given releaseability through the provision of a material or through physical texturing). Example 1: Separator/release surface/(L2) pressure-sensitive adhesive layer/(L1) dielectric sheet or layered structure that includes a dielectric sheet Example 2: Separator/release surface/(L2) pressure-sensitive adhesive layer/(L1) dielectric sheet or layered structure including dielectric sheet/(L2) pressure-sensitive adhesive layer/release surface/separator. In particular, when there is a configuration wherein, as in Example 2, the dielectric sheet or layered structure including a dielectric sheet according to the present invention is layered between two release surfaces, a layered body that includes a dielectric sheet, according to the present invention, can be transported (even exporting to a foreign country) in a state wherein it is protected by a separator, where the separators that are provided with the release surfaces are removed from both faces of the layered body at a desired location at a desired time, enabling the layered body that includes the dielectric sheet, according to the present invention, to be placed and layered on a desired device using the pressure-sensitive adhesive layer. Moreover, as desired, the entire layered body, including the dielectric sheet according to the present invention, may be subjected to a rolling process through rolling with rollers, or the like, in a state wherein it is held between separators, followed by curing, through heating or the like, the various flattened functional layers, or a curable composition for forming the (L1) dielectric sheet or (L2) pressure-sensitive adhesive layer, to produce a layered body that includes a dielectric sheet according to the present invention. There is no particular limitation on the substrate of the separator described above, and it may be, for example, cardboard, corrugated paper, clay-coated paper, or polyolefin laminated paper, and, in particular, may be polyethylene-laminated paper, a synthetic resin film or sheet, a natural fiber fabric, a synthetic fiber fabric, an artificial leather fabric, or a metal film. In particular, a synthetic resin film or sheet is preferred, where the synthetic resin may be, for example, polyimide, polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyvinylidene chloride, polycarbonate, polyethylene terephthalate, polycycloolefin, or nylon. Preferably the substrate is in the form of a film or a sheet. There is no particular limitation on the thickness thereof, which may be designed at a desired thickness depending on the application. Note that, as described below, the substrate itself may be a material so as to function as the release layer, or may be a structure that is given releaseability through the formation of fine texturing physically on the substrate of the surface. The release surface may also be termed a “release liner,” a “release layer,” or a “release coating layer,” and suitably may be a release layer that has a release coating such as a silicon release coating, a fluorine release coating, an alkyd release coating, a fluorosilicone release coating, or the like, or fine texturing may be formed physically on the substrate surface, or it may be the substrate itself that is resistant to adhesion to the pressure-sensitive adhesive layer described above. [Application of the Layered Body] The layered body that includes the dielectric sheet according to the present invention may be used independently as a dielectric layer in a film capacitor, or the like, but is particularly well-suited as an electrical or electronic component, or as an electronic device member used in a transducer or a display device. Specifically, the layered body according the present invention is useful as an electronic material or as a member for a display device or a member for a transducer (including use for sensors, speakers, actuators, and generators), and, in particular, a layered body that is, overall, transparent is suitable as a member for a display panel or a display, and is beneficial in devices, and particularly in so-called touch panel applications that can operate electronic devices through contacting a screen with a fingertip, or the like, and in various types of transducer applications. [Method for Manufacturing an Electronic Device] The layered body that includes a dielectric sheet according the present invention can be used as an electronic device member, and, specifically, provides a method for manufacturing an electrical or electronic component, or a transducer or display device, having a step for placing the layered body within the device. Similarly, it can provide a method for manufacturing an electrical or electronic component, or a transducer or display device, having, for a releasable layered body that has a separator: (I) a step for removing a (L5) separator from the releasable layered body, and (II) a step for disposing a layered body that has, on its outer layer, the pressure-sensitive adhesive layer, obtained in Step (I), above, into the device. The layered body set forth above may be placed as a single unit into the device, or a plurality of identical or different layered bodies may be placed into the device. When a plurality of layered bodies are placed into the device, they may be placed at functional portion positions that are different in the plane of the device or that are horizontal, or essentially horizontal, thereto, or, in order to secure the thickness of the layered body, a plurality may be disposed stacked in the direction that is perpendicular to the surface of the functional layer. In particular, the latter layering method is a method for placement that is beneficial in a transducer device that requires a large electrostatic capacitance. Moreover, the layered body may be placed through a slot-in method at placement positions for members that are provided in a direction that is perpendicular in respect to the device surface, depending on the type of device and the placement of the dielectric layer. INDUSTRIAL APPLICABILITY There are no constraints whatsoever, other than those described above, in regard to the application of the layered body that includes the dielectric sheet according the present invention, and it may be used in various types of transducers for speakers, actuators, generators, and the like, in television receivers, computer monitors, mobile information terminal monitors, monitors for monitoring, in displays for a variety of instruments such as video cameras, digital cameras, mobile telephones, mobile information terminals, automobiles, and the like, in displays for instruments of a variety of equipment, apparatuses, and devices, and in a variety of flat-panel displays (FPDs) for displaying text, symbols, and images, such as in automatic ticket vending machines, automatic teller machines, and the like. As devices, the application may be in CRT displays, liquid crystal displays, plasma displays, organic EL displays, inorganic EL displays, LED displays, surface electrolytic displays (SEDs), electric field emission-type displays (FEDs), and other display devices, and it may be applied to touch panels used therein. EMBODIMENTS While the present invention will be explained using examples of configurations thereof and raw materials, and the like, for forming the individual functional layers, the present invention is not limited thereby. [Raw Material Components for a Curable Organopolysiloxane Composition for Forming a Dielectric Sheet] Component (a1): 3,3,3-trifluoropropyl methyl siloxane-dimethyl siloxane copolymer with vinyl dimethyl siloxane groups blocked at both ends (3,3,3-trifluoropropyl methyl siloxane units: 182, dimethyl siloxane units: 46, proportion of inclusion of fluoroalkyl groups: 39 mol %). Viscosity, measured with an E-type viscometer at 25°, is approximately 10,000 mPa·s.Component (a2): 3,3,3-trifluoropropyl methyl-dimethyl siloxane copolymer with vinyl dimethyl siloxane groups blocked at both ends (siloxane polymerization: 273, 3,3,3-trifluoropropyl methyl siloxane units: 216, dimethyl siloxane units: 57, proportion of inclusion of fluoroalkyl groups: 40 mol %). Viscosity, measured with an E-type viscometer at 25°, is approximately 17,500 mPa·s.Component (B1): MH1.3TF3Pr(Mw=1.11×103) structured from dimethyl hydrosiloxy units and T units that have 3,3,3-trifluoropropyl groups. Note that the weight-average molecular weight of the component (B1) is a weight-average molecular weight of the calculated equivalent of polystyrene, measured through GPC (gel permeation chromatography) using a tetrahydrofuran (THF) solvent.Component (C1): Platinum-3,3,3-trifluoromethyl siloxane complex, blocked with dimethylvinyl siloxane groups at both ends (siloxane polymerization: 3, about 0.5% by weight by platinum density). <Hydrosilylation Reaction Suppressing Agent> Component (D1): 3-methyl-1-butyne-3-ol The relative dielectric constants and dynamic viscoelasticity (=shear storage modulus) of the dielectric sheets of Composition Example 1 and Composition Example 2 were measured through the method described below. <Measurement of Relative Dielectric Constant> The relative dielectric constant was measured using an LCR6530P, manufactured by Wayne Kerr. The measurement was performed using a sample wherein a film with a thickness of between about 1.5 and 2.0 mm was cured on a substrate film PET. <Measurement of Dynamic Viscoelasticity> An MCR302, manufactured by Anton Paar, was used in measuring the dynamic viscoelasticity. Disk-shaped samples with a thickness of approximately 1.5 mm and a diameter of 8 mm were manufactured, and a parallel plate method was used to measure through heating at a rate of 3°/min from −80° C. through 150° C. At this time the shear storage modulus at 23° C. was used, under conditions of a frequency of 1 Hz and deformation of 0.2%. Composition Example 1: Curable Organopolysiloxane Composition 1 for Providing a Dielectric Sheet A curable organopolysiloxane composition including 99.08 parts by weight of Component (a1), 0.77 parts by weight of Component (B1), 0.07 parts by weight of Component (C1), and 0.08 parts by weight of Component (D1), described above, was prepared. The silicon atom-bonded hydrogen atoms (Si—H) were in an amount of about 0.7 mole per mole of vinyl groups in the composition. This composition was coated in the form of a film, and was cured through heating for 15 minutes at 80° C., followed by heating another 15 minutes at 150° C., to produce a gel-type dielectric sheet (organopolysiloxane cured material). The shear storage modulus measured through the method described above was 4.2×103Pa. Note that the value for the relative dielectric constant of the dielectric sheet, at room temperature and the frequency of 1 kHz, was 6. Composition Example 2: Curable Organopolysiloxane Composition 2 for Providing a Dielectric Sheet A curable organopolysiloxane composition including 99.37 parts by weight of Component (a2), 0.56 parts by weight of Component (B1), and 0.08 parts by weight of Component (C1), described above, was prepared. The silicon atom-bonded hydrogen atoms (Si—H) were in an amount of about 0.6 mole per mole of vinyl groups in the composition. This composition was coated in the form of a film, and was cured through heating for 10 minutes at 110° C. to produce a gel-type dielectric sheet (organopolysiloxane cured material). The shear storage modulus measured through the method described above was 1.6×104Pa. Note that the value for the relative dielectric constant of the cured material, at room temperature and the frequency of 1 kHz, was 6. Component A1 Through A10: MTQ Resin Including 3,3,3-Trifluoropropyl Groups Table 1 shows the inclusion proportions in the structures of the siloxane units of the MTQ-type silicone resins that include 3,3,3-trifluoropropyl groups in composition examples 3 through 19 (component proportions of (CH3)3SiO1/2units: M units, trifluoropropyl-SiO3/2units: TTfPunits, and SiO4/2units: Q units), weight average molecular weights, and inclusion proportions of trifluoropropyl groups (equal=fluoroalkyl groups): TABLE 1ComponentAlA2A3A4A5M Units0.130.050.140.130.10TTfpUnits0.780.730.550.660.69Q Units0.090.220.310.210.21Weight-Average1.85 × l031.09 × 1031.09 × 1031.88 × 1031.52 × 103Molecular WeightProportion of Trifluoropropyl67%83%57%63%70%groups* (mol %)ComponentA6A7A8A9A10M Units0.130.350.210.140.13TTfpUnits0.540.190.680.740.66Q Units0.330.460.110.120.21Weight-Average3.82 × 1033.60 × 1036.90 × 1022.17 × 1033.09 × 103Molecular WeightProportion of Trifluoropropyl58%15%52%64%63%groups* (mol %) [Raw Material Components of the Curable Organopolysiloxane Composition that is a Dielectric Sheet that Functions Also as a Transparent Silicone Pressure-Sensitive Adhesive Agent Layer (OCA Layer)] Along with the components A1 through A10, above, the following components were used as raw material components of the curable organopolysiloxane composition that is a dielectric sheet and that provides the transparent silicone pressure-sensitive adhesive agent layer (OCA layer): Component (a3): 3,3,3-trifluoropropyl methyl siloxane polymer with vinyl dimethyl siloxane groups blocked at both ends (siloxane polymerization: 250, proportion of inclusion of fluoroalkyl groups: 49 mol %) Component (a4): 3,3,3-trifluoropropyl methyl-dimethyl siloxane copolymer with vinyl dimethyl siloxane groups blocked at both ends (siloxane polymerization: 390, proportion of inclusion of fluoroalkyl groups: 20 mol %) Component (B2): MH1.7Q (Mw=1.00×103) Component (B3): MHDTfp13MH(silicon atom-bound hydrogen atom 0.092% by weight) In this formula, MHrepresents a (CH3)2(H)SiO1/2group, DTfPrepresents a (3,3,3-trifloropropyl) methyl SiO2/2group, and Q represents a SiO4/2group. Component (C2): platinum-divinyl tetramethyl disiloxane complex (0.6% by weight, in terms of platinum concentration) Component (D2): 1,3,5,7-tetramethyl-1,3,5,7 tetravinyl cyclotetrasiloxane Component (E): 1,3-bis (trifluoromethyl) benzene Composition Example 3: Curable Organopolysiloxane Composition 3 for Providing a Dielectric Sheet 40.94 parts by weight of component (Al) (with 58.49 parts by weight of a 70 mass % solution of (E) 1,3-bis (trifluoromethyl) benzene), 17.54 parts by weight of component (E), 40.88 parts by weight of component (a3), 0.53 parts by weight of component (B1), 0.06 parts by weight of component (C2), and 0.06 parts by weight of component (D2) were mixed in a glass vial, to manufacture the curable organopolysiloxane composition of Composition Example 3. Composition Examples 4 Through 19: Curable Organopolysiloxane Compositions 4 Through 19 The curable organopolysiloxane compositions that are Composition Examples 4 through 19 were manufactured with the components in compositions shown in Table 2 and Table 3, in the same manner as with Composition Example 3. The relative dielectric constant, dynamic viscoelasticity (=shear storage modulus), optical transparency, and adhesive strength were measured, using the methods described below, for the organopolysiloxane cured materials (=silicone pressure-sensitive adhesive agent layers that are dielectric) of Composition Examples 3 through 19. That is, the organopolysiloxane cured materials of Composition Examples 3 through 19 can be used as the dielectric sheet according to the present invention, while also being components that can function also as transparent silicone pressure-sensitive adhesive agent layers. <Measurement of the Relative Dielectric Constant> For the organopolysiloxane cured materials of Composition Examples 3 through 19, the relative dielectric constants were measured using an LCR6530P, manufactured by Wayne Kerr. The measurements were performed on film-shaped samples of approximately 1.0 mm that were allowed to rest overnight at room temperature followed by curing for 15 minutes at 150° C. <Measurement of Dynamic Viscoelasticity> For the organopolysiloxane cured materials of Composition Examples 3, 6, 8, 10 through 14, 18, and 19, an MCR301, manufactured by Anton Paar, was used for measuring the dynamic viscoelasticity. The curable organopolysiloxane composition for each composition example was allowed to rest overnight at room temperature, followed by curing for 15 minutes at 150° C. Thereafter, a disk-shaped sample with a thickness of approximately 1 mm and a diameter of 8 mm was manufactured, and a parallel plate method was used to perform the measurement at a deformation of 0.1% and frequency of 1 Hz, with a speed of 3° C./min from −60° C. to 150° C. <Measurement of Optical Transparency> For the organopolysiloxane cured materials of Composition Examples 3 through 19, a spectrophotometer CM-5, manufactured by Konica Minolta, was used to measure the total optical transparency. The curable organopolysiloxane composition for each composition example was coated onto polyethylene terephthalate (PET, with a thickness of 50 μm) so as to have a thickness of approximately 300 μm after curing. The samples were allowed to rest overnight at room temperature, followed by curing for 15 minutes at 150° C., and the film-shaped samples produced were provided for measurement. The total optical transparencies for the organopolysiloxane cured materials according to the composition examples listed above were 89% (for all), and, in consideration of the total optical transparency of the PET film that was used, the organopolysiloxane cured materials obtained through Composition Examples 3 through 19 were fully usable in cases wherein transparency is required. <Measurement of Adhesive Strength> For the organopolysiloxane cured materials according to Composition Examples 3 through 19, an automatic coating machine (PI-1210, manufactured by Tester Sangyo Co.) was used to coat the curable organopolysiloxane composition according to each composition example onto a PET substrate (thickness of 50 μm) so as to have a thickness of approximately 100 μm after curing. The samples were allowed to rest for 60 minutes at 70° C., followed by curing for 15 minutes at 150° C. PET substrates (thickness of 50 μm) were adhered to the cured material films produced, to manufacture the test pieces. The measurements of the stripping force were performed through peeling at 180° with a speed of 300 mm/m in a 23° C., 50% humidity environment (RTC-1210, manufactured by Orientec Company). TABLE 2CompositionExample3456789101112Component40.9440.9640.96(A1)Component40.96(A2)Component40.9640.94(A3)Component40.9640.94(A4)Component40.9640.94(A5)Component(A6)Component(A7)Component(A8)Component40.8840.7240.5540.7240.7240.7140.7240.8840.8840.88(a3)Component0.530.650.830.650.650.660.650.530.530.53(B1)Component(B2)Component0.060.060.060.060.060.050.060.060.060.06(C2)Component0.060.060.060.060.060.060.060.060.060.06(D2)Component17.5417.5517.5517.5517.5517.5517.5517.5417.5417.54(E)SiH/Vi1.01.31.61.31.31.31.31.01.01.0Ratio25° C.0.009——0.100.09——0.070.030.03StorageModulusG' (MPa)Trans-Trans-Trans-Trans-Trans-Trans-Trans-Trans-Trans-Trans-Trans-parencyparentparentparentparentparentparentparentparentparentparent(Visual)Relative5.75.75.76.25.25.85.95.25.65.6DielectricConstant(1k Hz)Adhesive67128110598539284358529162319Strength(N/m) TABLE 3CompositionExample13141516171819Component(A1)Component(A2)Component(A3)Component(A4)Component(A5)Component40.9640.9440.96(A6)Component40.95(A7)Component44.44(A8)Component42.86(A9)Component42.86(A10)Component41.0240.8840.7243.6440.7340.73(a3)Component41.04(a4)Component0.360.530.650.710.200.20(B1)Component0.37(B2)Component1.811.81(B3)Component0.060.060.060.040.040.060.06(C2)Component0.060.060.060.040.040.050.05(D2)Component17.5517.5417.5517.5511.1214.2914.29(E)SiH/Vi0.71.01.31.31.31.01.0Ratio25° C.0.080.06———0.0160.034StorageModulusG′ (MPa)TransparencyTransparentTransparentTransparentTransparentTransparentTransparentTransparent(Visual)Relative5.25.05.23.75.35.45.6DielectricConstant(1k Hz)Adhesive6776286577133163279Strength(N/m) Preparation Example 1: Silicone-Based Pressure-Sensitive Adhesive Agent Sheet Formed on a Separator A silicone pressure-sensitive adhesive agent composition SD4580 FC (manufactured by Toray Dow Corning Co., Ltd.) was coated to produce a thickness of 50 μm onto a PET film (separator) that was provided with a release layer, and cured through heating under conditions of 120° C. for five minutes, to produce a layered body wherein a silicone-based pressure-sensitive adhesive agent sheet was formed on a PET film (separator) that was provided with a release layer. Note that in the embodiments below, a pressure-sensitive adhesive agent composition other than the SD4580 FC, described below, may be used, and a separator substrate other than a PET film may be used. Embodiment 1: Production of a Layered Body Equipped with a Structure Comprising Separator/Release Surface/(L2) Silicone-Based Pressure-Sensitive Adhesive Layer/(L1) Dielectric Sheet A layered body comprising a silicone-based pressure-sensitive adhesive agent sheet on the separator prepared in Adjustment Example 1 was adhered onto a gel-type high dielectric sheet, made from one organopolysiloxane cured material selected from Composition Example 1 or 2 so that the silicone-based pressure-sensitive adhesive agent sheet side faced the high dielectric sheet, to perform contact bonding. Thereafter, a layered body comprising a silicone-based pressure-sensitive adhesive agent sheet was adhered onto the separator prepared in Adjustment Example 1, for the other side of the high dielectric sheet, to perform contact bonding. Through this, a layered body was produced wherein silicone-based pressure-sensitive adhesive layers and separators were layered symmetrically onto both faces of a single-layer high dielectric sheet. Embodiment 2: Production of a Layered Body Equipped with a Structure Comprising Separator/Release Surface/(L2) Silicone-Based Pressure-Sensitive Adhesive Layer/(L4) Non-Silicone Thermoplastic Resin Layer/(L1) Dielectric Sheet A PET film was adhered onto a gel-type high dielectric sheet, made from one organopolysiloxane cured material selected from Composition Example 1 or 2 so as to face the high dielectric sheet, to perform contact bonding. Thereafter, a layered body comprising a silicone-based pressure-sensitive adhesive agent sheet on the separator prepared in Adjustment Example 1 was adhered onto the PET film such that the silicone-based pressure-sensitive sheet side faced the PET film, to perform contact bonding. Another layered body, wherein a PET film, a silicone-based pressure-sensitive adhesive agent sheet, and a separator were layered onto a dielectric sheet, was also produced, using the same method. The two sets of layered bodies, described above, were adhered so that the high dielectric sheet faces were facing, and contact bonded. Through this, a layered body was formed wherein PET films, silicone-based pressure-sensitive adhesive layers, and separators were layered symmetrically on both faces of the two layers of high dielectric sheets. Embodiment 3: Production of a Layered Body Equipped with a Structure Comprising Separator/Release Surface/(L2) Silicone-Based Pressure-Sensitive Adhesive Layer/(L4) Non-Silicone Thermoplastic Resin Layer/(L1) Dielectric Sheet A gel-type high dielectric sheet that is held between PET films was manufactured through curing, between two layers of PET films, one curable organopolysiloxane composition selected from Composition Examples 1 and 2. Following this, a layered body wherein a silicone-based pressure-sensitive adhesive agent sheet on the separator manufactured in Adjustment Example 1 was adhered onto each of the PET films so that the silicone pressure-sensitive adhesive agent sheet faces face the PET films. Through this, a layered body wherein PET films, silicone-based pressure-sensitive adhesive layers, and separators are layered symmetrically on both faces of a single layer of a high dielectric sheet was produced. Preparation Example 2: Production of a Transparent Silicone-Based Pressure-Sensitive Adhesive Agent Sheet Formed on a Separator One curable organopolysiloxane composition, selected from Composition Examples 3 through 19, was coated onto a PET film (separator) that was provided with a release layer, so as to have a thickness of about 100 μm after curing. A layered body wherein a transparent silicone-based pressure-sensitive adhesive agent sheet that includes a dielectric functional group was formed on a PET film (separator) that was provided with a release layer was produced through resting for approximately 60 minutes at 70° C. followed by curing for 15 minutes at 150° C. Embodiment 4: Production of a Layered Body Equipped with a Structure Comprising Separator/Release Surface/(L2) Silicone-Based Pressure-Sensitive Adhesive Layer/(L4) Non-Silicone Thermoplastic Resin Layer/(L1) Dielectric Sheet A gel-type high dielectric sheet that is held between PET films was manufactured through curing, between two layers of PET films, one curable organopolysiloxane composition selected from Composition Examples 1 and 2. Following this, a layered body wherein a transparent silicone-based pressure-sensitive adhesive agent sheet that includes a dielectric functional group on the separator manufactured in Adjustment Example 2 was adhered onto each of the PET films so that the silicone pressure-sensitive adhesive agent sheet faces face the PET films. Through this, a layered body wherein PET films, transparent silicone-based pressure-sensitive adhesive layers that include dielectric functional groups, and separators are layered symmetrically on both faces of a single layer of a high dielectric sheet was produced. Embodiment 5 A layered body wherein silicone-based pressure-sensitive adhesive layers and separators were layered symmetrically onto both sides of a single-layer high dielectric sheet was produced identically to Embodiment 1, except that the gel-type high dielectric sheet structured from one organopolysiloxane cured material selected from Composition Examples 1 and 2 in Embodiment 1 has been replaced with a high dielectric sheet structured from one organopolysiloxane cured material selected from Composition Examples 3 through 19. Note that the high dielectric sheet is a layer that also functions as a transparent and silicone-based adhesive layer. Embodiment 6 A layered body wherein PET films, silicone-based pressure-sensitive adhesive layers, and separators were layered symmetrically onto both sides of a double-layer high dielectric sheet was produced identically to Embodiment 2, except that the gel-type high dielectric sheet structured from one organopolysiloxane cured material selected from Composition Examples 1 and 2 in Embodiment 2 has been replaced with a high dielectric sheet structured from one organopolysiloxane cured material selected from Composition Examples 3 through 19. Note that the high dielectric sheet is a layer that also functions as a transparent and silicone-based adhesive layer. Embodiment 7 The release layer on one face of the layered body manufactured in Embodiment 3 was peeled, to expose the pressure-sensitive adhesive layer. Following this, a PET film having an ITO electrically conductive layer (electrode layer) on one face thereof was adhered to a pressure-sensitive adhesive layer of the layered body according to Embodiment 3, described above, with the ITO electrically conductive layer facing the pressure-sensitive adhesive layer of the layered body, to form a layered body having a structure wherein an ITO electrically conductive layer and a pressure-sensitive adhesive layer are adhered together. Moreover, the release surface of one face of the layered body (=one of the two release faces of the layered body in Embodiment 3, corresponding to the release face that is not the place that has already been peeled) was peeled to expose a pressure-sensitive adhesive surface, and in the same manner as with the previous adhesion, a PET film having an ITO electrically conductive layer (electrode layer) on one face was adhered so that the ITO electrically conductive layer faced the pressure-sensitive adhesive layer, to manufacture a layered body having the structure described below. Structure of the Layered Body: PET film/ITO electrically conductive layer/pressure-sensitive adhesive layer/PET film/dielectric silicone layer/PET film/pressure-sensitive adhesive layer/ITO electrically conductive layer/PET film Remarks: Of the structure described above, the structure of the “pressure-sensitive adhesive layer/PET film/dielectric silicone layer/PET film/pressure-sensitive adhesive layer” corresponds to the structure of the layered body of Embodiment 3, except for the release layer (separator) of both faces. Embodiment 8 A gel-type high dielectric sheet held between PET films was manufactured through curing one curable organopolysiloxane composition, selected from Composition Examples 1 and 2, between two PET films. A silver electrically conductive paste was screen-printed onto one face of the PET film, and thermally cured, to manufacture a layered body equipped with a silver electrically conductive film (electrode layer) on the PET film (hereinafter termed a “layered body that includes a high dielectric sheet”). Following this, a silver electrically conductive paste was screen-printed onto a PET film, separate from the layered body described above, to manufacture a PET film with an electrode layer formed with a silver electrically conductive film (electrode layer) of a semi-cured state (hereinafter termed a “PET film with an electrode layer of a semi-cured state”). Finally, the PET film with the electrode layer in the semi-cured state was adhered, so that the silver electrically conductive film was facing, to the surface of the PET film that did not have the electrode layer of the layered body of the high dielectric sheet, and then the silver electrically conductive film was cured completely so as to secure the two faces, to manufacture a layered body with the structure set forth below. A pressure-sensitive adhesive layer was further provided on both faces of the layered body, to enable use as an embodiment according to the present invention (referencing the measurement in Application Example 2). Structure: PET film/electrode layer/PET film/high dielectric silicone layer/PET film/electrode layer Application Example 1 In the structure of the layered body described in Embodiment 7, a layered body with an area of 5 cm×5 cm was manufactured using a gel-type high dielectric silicone sheet (150 μm thick), a PET film (50 μm thick), a silicone-based pressure-sensitive adhesive agent (50 μm thick), and a PET film with an ITO electrically conductive film (135 μm thick). Moreover, 1 cm×1 cm squares of ITO electrically conductive films were patterned into a 3×3 matrix, and leads were connected to each column. Electrodes were disposed so as to overlap the top and bottom leads, crossing at 90°. The matrix pattern of the electrode layer (the ITO electrically conductive film) is depicted inFIG.5. Measurement Example 1 An LCR meter U1732C (manufactured by KEYSIGHT) was connected to the vertically middle lead of the layered body obtained in Application Example 1, and the other leads were connected to the guard of the device. A silicone pressure-sensitive adhesive layer (50 μm thick) and a 0.2-mm glass sheet were adhered to one face of the layered body, and the electrostatic capacitance was measured for 30 seconds each with weights of different masses placed on the center electrode from above. The applied loads and the changes in the electrostatic capacitance are given in Table 4. Application Example 2 In the structure of the layered body described in Embodiment 8, a layered body with an area of 5 cm×5 cm was manufactured using a gel-type high dielectric silicone sheet (150 μm thick), a PET film (50 μm thick), and a PET film (75 μm thick) on which is formed an electrode layer made from a silver conductive film (35 μm thick) and a silver conductive film in a semi-cured state (35 μm thick at the time of curing). The silver conductive film was formed by screen-printing a silver conductive paste (manufactured by Ajanomoto FineTechno) onto the PET film on one side that is holding a gel-type high dielectric sheet, and thermally curing at 100° C. for one hour. On the other hand, the silver conductive film in the semi-cured state (35 μm thick at the time of curing) was formed by screen-printing a silver conductive paste (manufactured by Ajanomoto FineTechno) onto 75-μm-thick PET film. Note that the silver conductor layer of the semi-cured state, after bonding together, was thermally cured, to secure both surfaces. On this layered body, in the same manner as with Application Example 1, 1 cm×1 cm squares of silver conductive films were patterned into a 3×3 matrix, and leads were connected to each column. Electrodes were disposed so as to overlap the top and bottom leads, crossing at 90°.FIG.7shows a cross-sectional view (side view) of the layered body.FIG.6shows a top view of the layered body. Note that this layered body is used through further providing a pressure-sensitive adhesive layer, as shown in the “measurement example 2,” in the next section. Measurement Example 2 An LCR meter U1732C (manufactured by KEYSIGHT) was connected to the vertically middle lead of the layered body obtained in Application Example 2, and the other leads were connected to the guard of the device. In the same manner as with Adjustment Example 1, a silicone pressure-sensitive adhesive layer (50 μm thick) and a 0.2-mm glass sheet were adhered to the surface of the silver conductive film of the layered body, and the electrostatic capacitance was measured for 30 seconds each with weights of different masses placed on the center electrode from above. The applied loads and the changes in the electrostatic capacitance are given in Table 4. As can be changed from the results in Table 4, it can be understood that, through the use of the layered body according to the present invention, the electrostatic capacitance will change linearly in a form corresponding with the load. Use as a sensor, for example, is envisioned. An optically transparent sensor can also be manufactured through using ITO, or the like, in the electrode. TABLE 4Ratio of Change ofRatio of Change ofCapacitance inCapacitance inLoad (g/mm2)Measurement Example 1 (%)Measurement Example 20.071.40.30.092.01.30.113.22.30.166.04.80.218.67.1 The layered body ofFIG.1has a structure wherein electrode layers are provided on both faces of a high dielectric sheet, and silicone-based pressure-sensitive adhesive layers are provided on both sides thereof. The layered body ofFIG.2has a structure wherein PET films are provided on both faces of a high dielectric sheet, and silicone-based pressure-sensitive adhesive layers are provided on both sides thereof. The layered body ofFIG.3has separators, equipped with release surfaces facing the silicone-based pressure-sensitive adhesive layers, on the outsides of the silicone-based pressure-sensitive adhesive layers of the layered body inFIG.1. The layered body ofFIG.4has a structure wherein PET films are provided on both sides of a high dielectric layer, pressure-sensitive adhesive layers are provided on both sides thereof, and a PET film having an electrode layer is further provided. FIG.5is a top view of electrodes wherein 1 cm×1 cm squares are patterned into a 3×3 matrix on a PET film. FIG.6is a layered body top view wherein a high dielectric sheet and a PET film are disposed between layered bodies (3+4) that include electrode layers and PET films, with the electrodes ofFIG.5shifted by 90° vertically. The layered body ofFIG.7is a cross-sectional drawing of the layered body ofFIG.6. EXPLANATION OF REFERENCE SYMBOLS 1: Single Layer or Multiple Layers of a High Dielectric Sheet that Includes a Polymer Cured Body Having a Dielectric Functional Group: (EAP)2: Silicone-Based Pressure-Sensitive Adhesive Layer: (PSA)3: Electrode Layer: (EL)3a: Electrode13b: Electrode23c: Electrode34: Polyethylene Terephthalate (PET) Film5: Separators Comprising a Release Surface Facing a Layer Surface2 | 85,025 |
11858251 | EMBODIMENTS FOR CARRYING OUT THE INVENTION In the following paragraphs, some embodiments of the invention will be described by way of example and not limitation. It should be understood based on this disclosure that various other modifications can be made by those in the art based on these illustrated embodiments. [Laminated Armoring Material] FIGS.1A and1Bshow a laminated armoring material1according to an embodiment of the present invention. The laminated armoring material1is used as a battery case for lithium ion secondary batteries, etc., or a packaging material for food products or pharmaceutical products. In the laminated armoring material1, a heat-resistant resin layer2as an outer layer is laminated on a first surface of a metal foil layer4via a first adhesive agent layer5, a heat-sealable resin layer3as an inner layer is laminated on a second surface of the metal foil layer4via a second adhesive agent layer6, and the resin layers2and3are laminated on both surfaces of the metal foil layer4. Further, on the heat-resistant resin layer2side, a metal exposed section7in which the metal foil layer4is exposed in a plane shape is formed. At the metal exposed section7, the first adhesive agent layer5and the heat-resistant resin layer2do not exist. [Method of Manufacturing Laminated Armoring Material] The laminated armoring material1is manufactured by pasting or adhering (hereinafter referred to as “adhering”) the heat-resistant resin layer2and the heat-sealable resin layer3on the surfaces of the metal foil layer4, then removing a portion of the heat-resistant resin layer2to expose the metal foil layer4. In these processes, as a method of adhering the heat-resistant resin layer2on the first surface side of the metal foil layer4, an adhesive agent unapplied section forming and adhering process prescribed by the present invention is employed, and as a method of adhering the heat-sealable resin layer3on the second surface side of the metal foil layer4, a known adhering process is employed to manufacture a laminated body10of a laminated armoring material as shown inFIG.2, and a resin layer removal process is executed to the laminated body10for a laminated armoring material. Hereinafter, each process will be detailed. [Adhering Metal Foil Layer and Heat-Resistant Resin Layer (Adhesive Agent Unapplied Section Forming and Adhering Process)] The heat-resistant resin layer2is adhered to a first surface of the metal foil layer4. At this time, an adhesive agent constituting a first adhesive agent layer5is applied to a region excluding a portion corresponding to the metal exposed section7, and the adhesive agent is not applied to a region corresponding to the metal exposed section7. That is, in a state in which an adhesive agent unapplied section8in which an adhesive agent is not applied is formed, the metal foil layer4and the heat-resistant resin layer2are adhered together. The adhesive agent5can be applied to either the joining surface of the metal foil layer4or the heat-resistant resin layer2. As a method of forming the adhesive agent unapplied section8on a portion of the joining surface, in a roll application as shown inFIG.3, a method of using a roll31having concave and convex portions on a peripheral surface can be recommended. The entire outer peripheral surface of the roll31is a latticed minute concave and convex region35in which minute convex portions35aand minute concave portions35bare alternately repeated, and metal exposed section forming convex portions31acorresponding to a shape of the metal exposed section7are formed in the minute concave and convex region35. The minute convex portion35aand the metal exposed section forming convex portion31aare the same in height and when their top surfaces are considered as a base surface of the roll31, the minute concave portions35bare retracted from the base surface. An adhesive agent is applied to the entire outer peripheral surface of the roll31, and the adhesive agent is scraped off from the top surface of the metal exposed section forming convex portions31aand the top surfaces of the minute convex portions35aof the minute concave and convex regions35using a doctor blade to remain the adhesive agent only in the minute concave portions35b.By applying the adhesive agent on the application surface of the metal foil layer4or the heat-resistant resin layer2using the roll31to which the adhesive agent is adhered in the aforementioned manner, the adhesive agent adheres to the corresponding portions of the minute concave and convex region35in a dot shape or a lattice shape corresponding to the shapes of the minute concave portions35b.Thus, adhesive agent unapplied sections8in which no adhesive agent is applied are formed at the portions corresponding to the metal exposed section forming convex portions31a.At the corresponding portions of the minute concave and convex regions35, although the adhesive agent is not adhered to the corresponding portions of the minute convex portions35a,the adhesive agent adhered to the corresponding portions of the minute concave portions35bwetly spreads to the corresponding portions of the minute convex portions35a.Then, when pressure-joining the metal foil layer4and the heat-resistant resin layer2, the adhesive agent spreads further, resulting in a state in which the adhesive agent is evenly applied to the corresponding sections of the minute concave and convex regions35. In the aforementioned manner, at the joining surface of the metal foil layer4and the heat-resistant resin layer2, the adhesive agent unapplied sections8are formed on the corresponding positions of the convex portions31aof the roll31and the first adhesive agent layer5is formed on a region excluding the adhesive agent unapplied section8. Further, a case in which the adhesive agent is applied to both the metal foil layer4and the heat-resistant resin layer2is included in the technical scope of the present invention. In the case of applying the adhesive agent to both layers4and2, it is required that the positions of the adhesive agent unapplied sections match after adhering both the layers. The adhering conditions after applying the adhesive agent are arbitrarily set according to the characteristics of the adhesive agent to be used. As shown inFIG.3, when employing a dry laminating method, after applying an adhesive agent composition5awhose density is adjusted by a solvent to one layer4, the solvent is evaporated and dried with a drying machine32to form a first adhesive agent layer5to thereby obtain a two-layer body40. Afterward, the other layer2is stacked, pressure-joined, and adhered on the surface of the first adhesive agent layer5of the two-layered body40to obtain an intermediate laminated body41. The intermediate laminated body41is hardened under the conditions according to the adhesive agent. Further, althoughFIG.3exemplifies a process in which an adhesive agent composition5ais applied to the metal foil layer4and the heat-resistant resin layer2is adhered after drying, a similar operation is performed in a case of applying the adhesive agent composition5ato the heat-resistant resin layer2. The application of the adhesive agent composition5ais performed using the roll31having convex portions31ato form the adhesive agent unapplied sections8at positions corresponding to the convex portions31aof the two-layered body40. Further, in the intermediate laminated body41, since there exist adhesive agent unapplied sections8in the joining interface of the metal foil layer4and the heat-resistant resin layer2, the metal foil layer4and the heat-resistant resin layer2will not be joined even when they come in contact with each other by pressure-joining. In the aforementioned process, the metal foil layer4and the heat-resistant resin layer2are adhered together while forming un-adhered sections (adhesive agent unapplied sections). Further, the method of applying the adhesive agent in the adhesive agent unapplied section forming and adhering process is not limited, and a gravure roll coating method, a reverse roll coating method, a lip roll coating method, etc., can be exemplified. Since adhesive agent unapplied sections8are formed in the adhesive agent unapplied section forming and adhering process, a gravure roll coating method which is advantageous for forming convex portions on a roll can be recommended. Further, the application of an adhesive agent in the present invention refers to the act of thinly adhering an adhesive agent, and as an application method other than the aforementioned roll coating methods, spreading by a spray or a doctor blade can be exemplified. <Adhering Metal Foil Layer and Heat-Sealable Resin Layer> A heat-sealable resin layer3is adhered to a second surface of the metal foil layer4. Since a metal exposed section7is not formed on the heat-sealable resin layer3side, an adhesive agent is applied to the entire area of the joining surface of at least one of the metal foil layer4and the heat-sealable resin layer3for adhering together. The adhering method is not limited, and so a known method such as a dry laminating method, etc., for adhering after applying and drying an adhesive agent composition constituting a second adhesive agent layer6can be arbitrarily employed. The order of adhering the heat-resistant resin layer2and the heat-sealable resin layer3to the metal foil layer4is not limited. For example, by simultaneously executing the adhesive agent application to the heat-resistant resin layer2and the adhesive agent application to the heat-sealable resin layer3and successively adhering them to the metal foil layer4, a laminated body10for a laminated armoring material having the structure as shown inFIG.2can be manufactured. Further, as shown inFIG.3, by winding up the intermediate laminated body41in which the metal foil layer4and the heat-resistant resin layer2are adhered on a wind-up roll33and then adhering a heat-sealable resin layer3to the intermediate laminated body41by a different line, the laminated body10for a laminated armoring material having the layer structure as shown inFIG.2can be manufactured. Further, the method of applying the adhesive agent in the heat-resistant resin layer adhering process and the heat-sealable resin layer adhering process is not limited, and a gravure roll coating method, a reverse roll coating method, a lip roll coating method, etc., can be exemplified. (Resin Layer Removal Process) From the laminated body10for a laminated armoring material, the heat-resistant resin layer corresponding to the adhesive agent unapplied sections8is removed. Although the removal method is not limited, a method of irradiating a laser on the heat-resistant resin layer2to cut the layer and remove the cut portion can be recommended. In the adhesive agent unapplied sections8, the heat-resistant resin layer2and the metal foil layer4are not joined and there is no first adhesive agent layer5. Therefore, as shown inFIG.4, by irradiating a laser L on the peripheral edge of the adhesive agent unapplied section8to cut the heat-resistant resin layer2, the heat-resistant resin layer2aexisting at the adhesive agent unapplied section8can be removed. An advantage of the laser cutting is that, with an appropriate output, only the targeted layer can be cut and occurrence of burrs can be controlled. Also, by removing the heat-resistant resin layer2a,the metal foil layer4is exposed, forming the metal exposed section7. As a result, a laminated armoring material1having the structure as shown inFIG.1AandFIG.1Bis formed. In the adhesive agent unapplied section8, since the heat-resistant resin layer2is not joined to the metal foil layer4, it is easy to partially cut the heat-resistant resin layer2, thereby making it possible to form a planar metal exposed section7with an easy operation of cutting the heat-resistant resin layer2at the peripheral edge of the adhesive agent unapplied section8. Since the adhesive agent is not adhered to the adhesive agent unapplied section8, nothing remains on the surface of the metal foil layer4after removing the heat-resistant resin layer2, allowing an assured exposure of the metal foil layer4. The type of the laser is not limited, and either of a solid-state lasers represented by a YAG laser and a gas laser represented by a carbon dioxide laser may be used. Generally, in a case of using a laminated material in which a metal foil layer and a resin layer is laminated as a packaging material, a flat sheet obtained by a laminating process is processed into a case having a form capable of charging a packaging object, and after charging a packaging object in the case, the opening is heat-sealed to seal the packaged object. The laminated armoring material1manufactured by the method of the present invention is also processed into a case having a form capable of charging a packaging object, and after charging the packaging object, the opening of the case is heat-sealed to be used. The aforementioned resin layer removal process can be performed at any time after obtaining the laminated body10for a laminated armoring material by adhering the heat-resistant resin layer2and the heat-sealable resin layer3to the metal foil layer4. Therefore, the time at which the removal process of the heat-resistant resin layer as an outer layer is performed will be one of (a) to (d).(a) Before processing into a case having a form capable of charging a packaging object(b) Before charging a packaging object in the case(c) Before charging a packaging object in the case and heat-sealing(d) After heat-sealing the case in which the packaging object is charged A process into a case having a form capable of charging a packaging object is exemplified by, for example, a process for plastically deforming a flat sheet into a three-dimensional shape by press-forming such as bulging, drawing, etc., or a bag-making process for processing into a bag shape by, e.g., heat-sealing a portion of the flat sheet. Therefore, the laminated body for a laminated armoring material subjected to the resin layer removal process in the aforementioned (a) is a flat sheet, and the laminated body for a laminated armoring material subjected to the resin layer removal process in the aforementioned (b) to (d) is a case. In the abovementioned (b) to (d), a flat sheet-like laminated body10for a laminated armoring material is subjected to a plastic deformation process or a bag-making process before performing a resin layer removal process. As explained above, the method of manufacturing the laminated armoring material of the present invention includes not only a case in which it is completed in a flat sheet state, but a case in which a step of a plastic deformation process or a bag-making process, a step of charging a packaging object, or a step for heat-sealing is additionally performed before the resin layer removal step. In the method of manufacturing a laminated armoring material of the present invention, at the stage of adhering the heat-resistant resin layer2and the metal foil layer4together, an adhesive agent is not applied to the section forming the metal exposed section7. Therefore, there is no risk that an adhesive agent remains on the metal exposed section7, and thus the metal foil layer4can be assuredly exposed. The number of the metal exposed sections7is not limited, and an arbitrary number of metal exposed sections7can be formed according to the intended purpose of the case. Further, in a laminated armoring material manufactured from a laminated body for a laminated armoring material having a plurality of adhesive agent unapplied sections, adhesive agent unapplied sections in which the heat-resistant resin layer is not removed may remain. The position of the metal exposed section is also not limited, but it is preferable to avoid a position where the process into a case is obstructed or a position where the strength decreases due to the process. For example, as shown inFIG.5, in a case in which side walls21aare vertically formed from a flat sheet by bulging or drawing to process into a case in which a concave portion21for charging a packaging object is formed, it is preferable to avoid forming a metal exposed section on the side walls21aand the corner sections21bhaving a large deformation amount. In the case20, it is preferable to form the metal exposed sections on a bottom wall21cof the concave portion21or the flange22. Further, the intended purpose of the metal exposed section is not limited, and differs depending on the application of the laminated armoring material. In a battery case manufactured by a laminated armoring material having a metal exposed section on the surface side of the heat-resistant resin layer, the metal exposed section can be used as a soldering section to be soldered to a substrate or a housing, or can be used as an electrode. Further, in applications other than a battery case, a metal exposed section can be formed on an aluminum foil processed container for accommodating jams or processed food products, and a heat generating element is brought into contact with that section to heat food products, or to directly flow electricity to use as a food container in which sterilization is possible by joule heating. [Other Embodiments of Laminated Armoring Material and Manufacturing Method Thereof] In the laminated armoring material of the present invention, it is required that a metal exposed section is formed on at least one of the surface sides of the metal foil layer. Therefore, other than a laminated armoring material1having the metal exposed section7only on the heat-resistant resin layer2side, a laminated armoring material having the metal exposed sections only in the heat-sealable resin layer, and a laminated armoring material having the metal exposed section on both surfaces are also included in the present invention. The method of manufacturing a laminated armoring material of the present invention is performed by forming a laminated body for a laminated armoring material by employing the abovementioned adhesive agent unapplied section forming and adhering process when adhering a metal foil layer and a resin layer on the surface side on which the metal exposed section is formed, and thereafter performing a resin layer removal process for removing a resin layer corresponding to the adhesive agent unapplied section. That is, for a laminated armoring material having metal exposed sections on both surfaces, a laminated body for a laminated armoring material is manufactured by employing an adhesive agent unapplied section forming and adhering process on both surfaces of the metal foil. For a laminated armoring material having metal an exposed section only on one surface, the adhesive agent unapplied section forming and adhering process is applied for the one surface and a known adhering process is applied to the other surface to manufacture a laminated body for a laminated armoring material. Then, the manufactured laminated body for a laminated armoring material is subjected to a resin layer removal process. FIG.6shows a laminated body11for a laminated armoring material in which adhesive agent unapplied sections8are formed on both surfaces of the metal foil layer4, and a process in which metal exposed sections7are formed by performing a resin layer removal process on both surfaces of the laminated body11for an laminated armoring material to remove the heat-resistant resin layer2aand the heat-sealable resin layer3afrom the adhesive agent unapplied sections8. The manufactured laminated armoring material12has metal exposed sections7on both surfaces. Further, since the heat-sealable resin layer3is served inside a case, the time to perform the resin layer removal process is limited to before charging packaging objects in the case, which is the aforementioned (a) before process into a case having a form capable of charging packaging objects, or (b) before charging packaging objects in the case. Depending on the shape of the case, the time for performing the resin layer removal process may be further limited to only (a). The metal exposed section7formed on the heat-sealable resin layer3side as an inner layer side can be used for joining to an electrode inside a laminated battery. In the case of a food container, the metal exposed section7can be used when heating food products by bringing the metal exposed section7into contact with a heat generating element or when directly flowing electricity to the food products. Further, the number of the metal exposed section to be formed on the heat-sealable resin layer side can be set arbitrary and the forming position can also be set arbitrary as long as it does not interfere with the process into a case shape, in the same manner as in the metal exposed section to be formed on the heat-resistant resin layer side. Further, in the case of forming the metal exposed sections on both surfaces, the number and/or the position of the metal exposed sections are not required to coincide with each other, and the metal exposed sections can be set independently depending on the intended use of the metal exposed sections on each surface. [Constituent Materials of Laminated Armoring Material] The materials for each layer constituting the laminated armoring material1are not specifically limited, and any material can be arbitrarily used according to the intended use. The preferred materials for a packaging material for battery cases, electronic components, food products, pharmaceutical products, etc., can be exemplified as follows. (Heat-Resistant Resin Layer) As a heat-resistant resin constituting the heat- resistant resin layer2which is an outer layer, a heat-resistant resin that does not melt at a heat sealing temperature when heat-sealing the armoring material is used. As a heat-resistant resin, it is preferable to use a heat-resistant resin having a melting point higher than the melting point of the heat-sealable resin by 10° C. or more, and it is especially preferable to use a heat-resistant resin having a melting point higher than the melting point of the heat-sealable resin by 20° C. or more. As the heat-resistant resin layer2, for example, a polyamide film, a polyester film, etc., can be exemplified, and these stretched films are preferably used. Among them, from the viewpoint of formability and strength, a biaxially stretched polyamide film or a biaxially stretched polyester film, or a multi-layer film including the biaxially stretched polyamide film or the biaxially stretched polyester film is especially preferable. Further, it is preferable to use a multi-layer film in which a biaxially stretched polyamide film and a biaxially stretched polyester film are joined together. The polyamide film is not especially limited, but for example, a nylon 6 film, a nylon 6, 6 film, an MXD nylon film, etc., can be exemplified. Further, as a biaxially stretched polyester film, a biaxially stretched polybutylene terephthalate (PBT) film, a biaxially stretched polyethylene terephthalate (PET) film, etc., can be exemplified. Further, it is also preferable to combine a lubricant and/or solid fine particles to improve the slidability of the surface of the heat-resistant resin layer2to thereby improve the slidability with respect to the molding die. It is preferable that the thickness of the heat-resistant resin layer2is 9 μm to 50 μm. By setting it to the suitable lower limit or more, sufficient strength can be secured as a packaging material. By setting it to the suitable upper limit or less, the stress at the time of molding can be made small, which in turn can improve the moldability. (Heat-Sealable Resin Layer) The heat-sealable resin layer3which is an inner layer has excellent chemical resistance against strongly corrosive electrolyte used for lithium ion secondary batteries, etc., and exerts a role of applying heat sealing properties to a packaging material. As the heat-sealable resin layer3, it is preferable to use a thermoplastic resin unstretched film. The thermoplastic resin unstretched film is not specifically limited, but in terms of chemical resistance and heat sealing properties, it is preferably constituted by polyethylene, polypropylene, olefin-series copolymer, and their acid modifications and ionomers. Further, as an olefin-series copolymer, EVA (ethylene-vinyl acetate copolymer), EAA (ethylene-acrylic acid copolymer), and EMMA (ethylene-methacrylic acid copolymer) can be exemplified. Further, a polyamide film (e.g., nylon 12) or a polyimide film can also be used. As to the heat-sealable resin layer3, similarly to the heat-resistant resin layer2, it is preferable to combine a lubricant and/or a solid fine particle to improve the slidability of the surface of the heat-resistant resin layer. It is preferable that the thickness of the heat-sealable resin layer3is set to 20 μm to 80 μm. By setting the thickness to 20 μm or more, generation of pinholes can be sufficiently prevented, and by setting the thickness to 80 μm or less, the amount of resin used can be reduced, thereby making it possible to reduce the cost. Among them, it is especially preferable that the thickness of the heat-sealable resin layer3is set to 30 μm to 50 μm. Further, the heat-sealable resin layer3can be a single layer or a multi-layer. As a multi-layer film, a three-layer film in which a random polypropylene film is laminated on each of both surfaces of a block polypropylene film can be exemplified. (Metal Foil Layer) The metal foil layer4plays a role of giving gas barrier characteristics for preventing invasion of oxygen and/or moisture into the laminated armoring material1. The metal foil layer4is not especially limited, but for example, an aluminum foil, a copper foil, a nickel foil, a stainless foil, a clad foil thereof, an annealed foil thereof, an unannealed foil thereof, etc., can be exemplified. The metal foil layer4is a layer exposed at the metal exposed section7, and is arbitrarily selected according to the purpose for exposure. Further, as to the aluminum foil, in the case of forming a concave portion21by bulging or drawing (seeFIG.5), it is preferable to use an aluminum alloy foil: JIS A8079 or JIS A8021 having good formability. Further, in a case in which formability does not need to be considered, other than the aforementioned aluminum alloy foils, pure aluminum series aluminum foils can also be suitably used. Further, it is also preferable to use a metal foil plated with a conductive metal such as nickel, tin, copper, chrome, etc., such as a plated aluminum foil. The conductive plated film may be formed at a portion corresponding to at least the metal exposed section of the metal foil layer. Further, it is preferable that the metal foil layer4is subjected to the following chemical conversion treatment as a substrate treatment to form a chemical conversion film. (Chemical Conversion Treatment of Metal Foil Layer) The outer layer and the inner layer of the laminated armoring material1are layers made of resin. For these resin layer, although a minute amount, light, oxygen, and liquid may enter from outside the case and the contents (electrolyte of batteries, food products, pharmaceutical products, etc.) may soak from the inside. When reaching the metal foil layer, these intruded objects cause corrosion of the metal foil layer. In the laminated armoring material1of the present invention, by forming a chemical conversion film high in corrosion resistance on the surface of the metal foil layer4, the corrosion resistance of the metal foil layer4can be improved. The chemical conversion film is a film formed by subjecting the metal foil surface to a chemical conversion treatment, and can be formed, for example, by subjecting the metal foil to a chromate treatment or a non-chromium type chemical conversion treatment using a zirconium compound. For example, in the case of a chromate treatment, after applying a solution of any one of the following mixtures 1) to 3) to the surface of the metal foil to which a degreasing treatment was subjected, it is dried.1) A mixture of phosphoric acid, chromic acid and at least one of metal salt of fluoride and non-metal salt of fluoride2) A mixture of phosphoric acid, acrylic resin, either a chitosan derivative resin or a phenol series resin, at least one of chromic acid and chromium (III) salt3) A mixture of phosphoric acid, any one of acrylic resin, chitosan derivative resin or phenol series resin, at least one of chromic acid and chromium (III) salt For the chemical conversion film, it is preferable that the chromium adhesion amount is 0.1 to 50 mg/m2, more preferably 2 to 20 mg/m2. By the chemical conversion film having the thickness or the chromium adhesion amount, a molding packaging material having high resistance to corrosion can be obtained. Further, a laminated armoring material having the chemical conversion film on one of surfaces is included in the present invention. The thickness of the metal foil layer4is preferably 20 μm to 200 μm. By setting the thickness to 20 μm or more, generation of pinholes or breakages at the time of rolling and heat sealing when producing a metal foil can be prevented. By setting the thickness to 200 μm or less, the stress at the time of bulging or drawing can be decreased to thereby improve the formability. Further, by setting the thickness of the metal foil layer 4 to 200 μm or less, the increase in weight and cost of materials can be controlled. (First Adhesive Agent Layer) The first adhesive agent layer5is a layer for joining the metal foil layer4and the heat-resistant resin layer2as an outer layer. For example, an adhesive agent including a two-part curing type polyester-urethane-based resin including a polyester resin as a base resin and a multifunctional isocyanate compound as a curing agent, or a polyether-urethane-based resin is preferably used. (Second Adhesive Agent Layer) The second adhesive agent layer6is a layer for joining the metal foil layer4and the heat-sealable resin layer3as an inner layer. For example, a polyurethane-based adhesive agent, an acrylic-based adhesive agent, an epoxy-based adhesive agent, a polyolefin-based adhesive agent, an elastomer-based adhesive agent, a fluorine-based adhesive agent, etc., can be exemplified. Among them, it is preferable to use an acrylic-based adhesive agent or a polyolefin-based adhesive agent, and in such a case, the resistance to electrolyte and moisture barrier characteristics of the packaging material1can be improved. Further, in the case of using the laminated armoring material as a battery case, it is preferable to use an adhesive agent such as an acid-modified polypropylene, polyethylene, etc. For the adhesive agent unapplied section, since the glossiness is different from the section in which an adhesive agent is applied even through the heat-resistant resin layer or the heat-sealable resin layer, even in a state in which the heat-resistant resin layer or the heat-sealable resin layer is adhered, the position and the shape of the adhesive agent unapplied section can be discriminated. Further, to make it easy to discriminate the adhesive agent unapplied section, a coloring agent such as an organic pigment, an inorganic pigment, a pigment, etc., can be added to the adhesive agent in a range of 0.1 mass parts to 5 mass parts with respect to 100 mass parts of a resin component. The organic pigment is not especially limited, but for example, an azo pigment such as lake red, naphthols, Hansa yellow, Disazo yellow, benzimidazolone, etc.; a polycyclic pigment such as quinophthalone, isoindolin, pyrrolo-pyrrole, dioxazine, phthalocyanine blue, phthalocyanine green, etc.; a lake pigment such as lake red C, Watchung red, etc., can be exemplified. Further, the inorganic pigment is not especially limited, but for example, carbon black, titanium oxide, calcium carbonate, kaolin, iron oxide, zinc oxide, etc., can be exemplified. Further, the pigment is not especially limited, but for example, a yellow pigment such as a trisodium salt (Yellow No.4), a red pigment such as a disodium salt (Red No.3), a blue pigment such as a disodium salt (Blue No.1) can be exemplified. Further, regardless of whether a coloring agent is added, by adhering a transparent heat-resistant resin layer or a heat-sealable resin layer, it becomes easy to discriminate the adhesive agent unapplied section. When a coloring agent is added to the adhesive agent, and a transparent heat-resistant resin layer or a heat-sealable resin layer is adhered, it becomes extremely easy to discriminate the adhesive agent unapplied section. Further, the total thickness of the laminated armoring material is preferably in the range of 50 to 300 μm. The total thickness of the laminated armoring material and the suitable thickness of each of the aforementioned layers differ according to the intended purpose of the laminated armoring material. EXAMPLES The laminated armoring material1shown inFIG.1AandFIG.1Bwas manufactured. The metal exposed section7was a 50 mm×50 mm square. Example 1 The material of each layer constituting the laminated armoring material1was as follows. Metal foil layer4: a tin plated film having a thickness of 1 μm was formed on one surface of a soft aluminum foil (JIS H4160 A8079H) having a thickness of 40 μm Heat-resistant resin layer2: a stretched nylon film having a thickness of 25 μm Heat-sealable resin layer3: unstretched polypropylene film having a thickness of 30 μm First adhesive agent layer5: two-part curing type polyester-urethane-based adhesive agent Second adhesive agent layer6: two-part curing type acid-modified polypropylene-based adhesive agent <Adhering Metal Foil Layer and Heat-Resistant Resin Layer (Adhesive Agent Unapplied Section Forming and Adhering process)> The heat-resistant resin layer2and the metal foil layer4were adhered together using the dry laminating method shown inFIG.3. As an adhesive agent application roll, a gravure roll31having convex portions31ahaving a top surface measurement of 50 mm×50 mm was used. On the tin-plated film side surface of the metal foil layer4, an adhesive agent composition5awhose concentration was adjusted with a solvent was applied using the gravure roll31and dried to thereby form the first adhesive agent layer5having adhesive agent unapplied sections8corresponding to the convex portion31ashape. Subsequently, the heat-resistant resin layer2was stacked on the first adhesive agent layer5side and pressure-joined to obtain an intermediate laminated body41. Further, the intermediate laminated body41was cured for three days at 40° C. in an aging furnace to cure the first adhesive agent layer5. The thickness of the first adhesive agent layer5after curing was 4 μm. <Adhering Metal Foil Layer and Heat-Sealable Resin Layer> On the other surface of the metal foil layer4of the intermediate laminated body41after curing, an adhesive agent composition whose concentration was adjusted by a solvent was applied using the dry laminating method shown inFIG.3and dried to form the second adhesive agent layer6, and a heat-sealable resin layer3was adhered. Further, the second adhesive agent layer6was hardened by being cured for three days at 40° C. in an aging furnace to cure. The thickness of the second adhesive agent layer6after curing was 2 μm. By the abovementioned two processes, the laminated body10for a laminated armoring material as shown inFIG.2was obtained. <Resin Layer Removal Process) As shown inFIG.4, on the laminated body10for a laminated armoring material, YAG laser L was irradiated along the peripheral edge of the adhesive agent unapplied section8of the heat-resistant resin layer2to cut the heat-resistant resin layer2to thereby remove the heat-resistant resin layer2acorresponding to the adhesive agent unapplied section8. With this, the metal foil layer4was exposed, and a laminated armoring material1having a metal exposed section7was obtained. <Process into Case> A flat sheet-like laminated armoring material1was processed into a cubic shape case20as shown inFIG.5. In the process, using a straight mold including a polytetrafluoroethylene punch having length 100 mm×width 100 mm and corners R: 2mm and a die having length 100.5 mm×width 100.5 mm and corners R: 2.25 mm and having a free forming height, bulging one step forming was performed in a manner such that the inner heat-sealant resin layer3was in contact with the punch, to form a concave portion21having a side wall21a4 mm in height (formed depth). In this forming process, the laminated armoring material1was positioned so that the center of the punch matched the center of the metal exposed section7, and the metal exposed section7was formed at the center of the outer surface of the bottom wall21cof the concave portion21. The laminated armoring material1after the bulging process was cut leaving a flange having a width of 10 mm at the opening edge of the concave portion21. Example 2 A laminated armoring material1was manufactured in the same manner as in Embodiment 1 except that a nickel plated film having a thickness of 1 μm was formed on one surface of a soft aluminum foil (JIS H4160 A8079H) having a thickness of 40 μm as the metal foil layer4,1and then processed into a case20. Example 3 A laminated armoring material1was manufactured in the same manner as in Embodiment 1 except that a soft stainless foil (SUS304) having a thickness of 20 μm was used as the metal foil layer4, and then processed into a case20. Example 4 A laminated armoring material1was manufactured in the same manner as in Embodiment 1 except that a soft aluminum foil (JIS H4160 A8079H) having a thickness of 40 μm without plating was used as the metal foil layer4, and then processed into a case20. In the laminated armoring materials of Embodiments 1 to 4, metal exposed sections could be assuredly formed with easy operations and could be processed into cases20without hindrance. The present invention claims priority to Japanese Patent Application No. 2014-78786 filed on Apr. 7, 2014, the entire disclosure of which is incorporated herein by reference in its entirety. It should be understood that the terms and expressions used herein are used for explanation and have no intention to be used to construe in a limited manner, do not eliminate any equivalents of features shown and mentioned herein, and allow various modifications falling within the claimed scope of the present invention. Industrial Applicability The present invention can be suitably used for manufacturing a laminated armoring material used as a packaging material. | 38,740 |
11858252 | DESCRIPTION OF THE PREFERRED EMBODIMENTS Throughout the following detailed description, similar reference characters refer to similar elements in all figures of the drawings. Unless otherwise indicated, the following terms as used herein have the meaning as defined below. “Actinic radiation” refers to radiation capable of initiating reaction or reactions to change the physical or chemical characteristics of a photosensitive composition. “Lines per inch” (LPI) is a measurement of printing resolution in systems which use a halftone screen. It is a measure of how close together lines in a halftone grid are. Higher LPI generally indicates greater detail and sharpness to an image. “Halftone” is used for the reproduction of continuous-tone images, by a screening process that converts the image into dots of various sizes and equal spacing between centers. A halftone screen enables the creation of shaded (or grey) areas in images that are printed by transferring (or non-transferring) of a printing medium, such as ink. “Continuous tone” refers to an image that has a virtually unlimited range of color or shades of grays, that contains unbroken gradient tones having not been screened. “Dots per inch” (DPI) is a frequency of dot structures in a tonal image, and is a measure of spatial printing dot density, and in particular the number of individual dots that can be placed within the span of one linear inch (2.54 cm). The DPI value tends to correlate with image resolution. Typical DPI range for graphics applications: 75 to 150, but can be as high as 300. “Line screen resolution”, which may sometimes be referred to as “screen ruling” is the number of lines or dots per inch on a halftone screen. “Optical Density” or simply “Density” is the degree of darkness (light absorption or opacity) of an image, and can be determined from the following relationship: Density=log10{1/reflectance} where reflectance is {intensity of reflected light/intensity of incident light}. Density is commonly calculated in conformance with ISO 5/3:2009 International Standard for Photography and graphic technology—Density measurements—Part 3: Spectral conditions. “Solid Ink Density” is a measure of the density of a printed area meant to display the maximum amount of print color. “Graininess” refers to the variation in density of print areas. The ISO-13660 International Print Quality Standard defines it as, “Aperiodic fluctuations of density at a spatial frequency greater than 0.4 cycles per millimeter in all directions.” The ISO-13660 metric of graininess is the standard deviation of density of a number of small areas that are 42 um square. “Cell pattern unit” refers to the smallest repeat structure of a microcell pattern. Cell pattern units, some embodiments of which are shown inFIGS.3athrough3j, are bitmap files that are tiled or repeated to provide desired coverage and used by a digital imager unit to form a mask of a digital layer of a printing precursor that will be used to print a pattern of microcells, i.e., “Printed Microcell Pattern”, as a layer of a photosensitive element of the present invention. Each cell pattern unit includes black blocks which represent areas of the digital layer of the printing precursor that will be removed or ablated by infrared laser radiation; and, clear or white blocks which represent areas of the digital layer that will remain on the precursor. Each block is representative of a pixel at 4000 pixels per inch which results in a size of 6.35 microns on a side. “Printed microcell pattern” refers to a composite of features that together form a pattern that is printed for inclusion at some stage of production of the photosensitive element of the present invention. A printed microcell pattern in which a plurality of features is printed with a particular ink for incorporation into a photosensitive element is distinguished from a microcell pattern that is conventionally formed in a digital layer of a photosensitive element with infrared laser radiation by a digital imager device. “Cell pattern layer” refers to the printed microcell pattern that forms a layer integral to the photosensitive element of the present invention, and is oriented between a source of actinic radiation and a surface of the photosensitive layer that will ultimately become the printing surface of the resulting relief printing form. “Microcells” refer to image elements or microcells that alter a print surface, which can appear as dimples and/or very tiny reverses, and that are each smaller in at least one dimension than the spacing between smallest periodic structures on the printing form that results from the photosensitive element of the present invention. The microcells are irregularities on a print surface of the relief printing form that are designed to improve the uniformity and apparent density of ink printed on a substrate by the relief printing form. In some embodiments, microcells of the relief printing form can correspond with features of the printed microcell pattern that is integrated into the present photosensitive element. “Microcell pattern” refers to a composite of image elements or microcells that together form a pattern that alters a print surface of a relief printing form which results from the photosensitive element of the present invention. The term “pattern” is not limited in reference to “cell pattern unit”, “microcell pattern”, “printed microcell pattern”, and “cell pattern layer”; and, refers to placement of the individual features relative to one another, to include as a composite of the individual feature patterns that are random, pseudo-random, or regular, in one or two directions. “Visible radiation or light” refers to a range of electromagnetic radiation that can be detected by the human eye, in which the range of wavelengths of radiation is between about 390 and about 770 nm. “Infrared radiation or light” refers to wavelengths of radiation between about 770 and 106nm. “Ultraviolet radiation or light” refers to wavelengths of radiation between about 10 and 390 nm. Note that the provided ranges of wavelengths for infrared, visible, and ultraviolet are general guides and that there may be some overlap of radiation wavelengths between what is generally considered ultraviolet radiation and visible radiation, and between what is generally considered visible radiation and infrared radiation. “White light” refers to light that contains all the wavelengths of visible light at approximately equal intensities, as in sunlight. “Room light” refers to light that provides general illumination for a room. Room light may or may not contain all the wavelengths of visible light. The term “photosensitive” encompasses any system in which the photosensitive composition is capable of initiating a reaction or reactions, particularly photochemical reactions, upon response to actinic radiation. Upon exposure to actinic radiation, chain propagated polymerization of a monomer and/or oligomer is induced by either a condensation mechanism or by free radical addition polymerization. While all photopolymerizable mechanisms are contemplated, the compositions and processes of this invention will be described in the context of free-radical initiated addition polymerization of monomers and/or oligomers having one or more terminal ethylenically unsaturated groups. In this context, the photoinitiator system when exposed to actinic radiation can act as a source of free radicals needed to initiate polymerization of the monomer and/or oligomer. The monomer may have non-terminal ethylenically unsaturated groups, and/or the composition may contain one or more other components, such as a binder or oligomer, that promote crosslinking. As such, the term “photopolymerizable” is intended to encompass systems that are photopolymerizable, photocrosslinkable, or both. As used herein, photopolymerization may also be referred to as curing. The photosensitive element may also be referred to herein as a photosensitive precursor, photosensitive printing precursor, printing precursor, and precursor. As used herein, the term “solid” refers to the physical state of the photosensitive layer that has a definite volume and shape and resists forces that tend to alter its volume or shape. The layer of the photopolymerizable composition is solid at room temperature, which is a temperature between about 5° C. and about 30° C. A solid layer of the photopolymerizable composition may be polymerized (photohardened), or unpolymerized, or both. The term “digital layer” encompasses a layer that is responsive or alterable by laser radiation, particularly infrared laser radiation, and more particularly is ablatable by infrared laser radiation. The digital layer is also opaque to non-infrared actinic radiation. The digital layer may also be referred to herein as an infrared-sensitive layer, an infrared-sensitive ablation layer, a laser ablatable layer, or an actinic radiation opaque layer. Unless otherwise indicated, the terms “photosensitive element”, “printing form precursor”, “printing precursor”, and “printing form” encompass elements or structures in any form suitable as precursors for printing, including, but not limited to, flat sheets, plates, seamless continuous forms, cylindrical forms, plates-on-sleeves, and plates-on-carriers. The present invention concerns a photosensitive element, particularly a photopolymerizable printing form precursor; a method of preparing the photosensitive element to form a printing form; and, a process of making the photosensitive element. The photosensitive element includes a layer of a composition sensitive to actinic radiation which in most embodiments is a composition that is photopolymerizable. The photosensitive element includes a layer of the photosensitive composition, a digital layer adjacent to the photosensitive layer, and a cell pattern layer. The cell pattern layer includes a plurality of features in which each feature has an area between 5 to 750 square microns and is composed of an ink that is opaque to actinic radiation and transparent to infrared radiation. In most embodiments, the digital layer is ablatable by infrared radiation and opaque to non-infrared actinic radiation. The cell pattern layer is a microcell pattern that is preprinted, i.e., a printed microcell pattern, with the ink and integrated into the photosensitive element at time of manufacture. Advantages of the present photosensitive element having a printed cell pattern layer integral to the photosensitive element include that it saves the end-user time and can increase productivity in the preparation of a printing form from the photosensitive element. The presence of the cell pattern layer avoids the need for end-users to form a microcell pattern in the digital layer with a digital imager device, and can increase productivity in the preparation of the printing form since the mask can be formed in the digital layer by a low resolution digital imager device that is operated at high speed. And since the cell pattern layer is pre-printed at manufacture, cell patterns can be created and printed using high resolution systems, such as gravure printing and high resolution flexographic printing, and thus end-users can avoid the need for a costly high resolution digital imager device with substantially increased imaging time to create the plate cell pattern and the mask from the digital layer. Furthermore, the relief printing form that results from the present photosensitive precursor advantageously meets the increasing demands for print quality to improve the transfer of ink to printed substrate and to print, particularly solid areas, with uniform, dense coverage of ink, and capable of printing a full tonal range including printing of fine print elements and highlight dots. Photosensitive Element The photosensitive element includes a layer of the photosensitive composition, a digital layer adjacent to the photosensitive layer, and a cell pattern layer. The cell pattern layer is integrated in the photosensitive element, or is integrated in a separate element that is combined with a photopolymerizable layer to form the photosensitive element. In one embodiment, the photosensitive element includes a layer of the photosensitive composition, a digital layer that is adjacent to the photosensitive layer, and a cell pattern layer that is disposed between the photosensitive layer and the digital layer. In another embodiment, the photosensitive element includes a support, a layer of the photosensitive composition adjacent to the support, a digital layer that is adjacent to a side of the photosensitive layer that is opposite the support, and a cell pattern layer that is disposed between the photosensitive layer and the digital layer. In yet another embodiment, the photosensitive element includes a layer of the photosensitive composition adjacent to an optional support, a digital layer that is adjacent to a side of the photosensitive layer that is opposite the optional support, and a cell pattern layer that is disposed on or above a side of the digital layer that is opposite the photosensitive layer. Optionally, the photosensitive element can include a support on a side of the photosensitive layer that is opposite the digital layer, and/or a coversheet on a side of the digital layer that is opposite the photosensitive layer. FIG.1depicts one embodiment of a photosensitive element10of the present invention that is a printing form precursor10used for preparing printing forms. The printing form precursor10includes a support12, at least one layer of a photosensitive composition14that is on or adjacent the optional support12, a digital layer16adjacent to a side18of the photosensitive layer14that is opposite the support12, and one embodiment cell pattern layer20that is disposed between the photosensitive layer14and the digital layer16. In most embodiments the photosensitive layer14is a layer of a photopolymerizable composition. The precursor10shown inFIG.1is exploded with the digital layer16separated from photopolymerizable layer14so that a plurality of features22of the cell pattern layer20can be seen disposed between the digital layer16and the photopolymerizable layer14, and integrated as a layer within the printing form precursor10. In most embodiments, the plurality of features22of the cell pattern layer20that is printed with an ink is so thin relative to its adjacent layers, i.e., the digital layer16and the photopolymerizable layer14, that the cell pattern layer would not actually be seen in cross-section, and in this embodiment the digital layer would appear to directly contact the photopolymerizable layer. Optionally the photosensitive element10can include one or more additional layers and/or a coversheet, but for simplicity the additional layers and coversheet is not shown in the embodiment of the precursor10ofFIG.1. A coversheet that is removable can be disposed on or above a side of the digital layer16that is opposite the photopolymerizable layer14. The photosensitive element10can optionally include a barrier layer and/or a wax layer between the digital layer and the cell pattern layer, and a side of the barrier layer that is opposite the digital layer would substantially contact the photopolymerizable layer. The photosensitive element10can optionally include an elastomeric capping layer between the photopolymerizable layer and the cell pattern layer, such that the cell pattern layer is between the elastomeric capping layer and the digital layer. Other additional layers are also possible. In most embodiments, the printing forms are a relief printing forms that encompass flexographic printing forms and letterpress printing forms. The photosensitive element precursor for printing end-use and the printing form can be of any shape or form including plates and cylinders. The embodiment of the photosensitive printing precursor10shown inFIG.1is a plate form. Relief printing is a method of printing in which the printing form prints from an image area, where the image area of the printing form is raised and the non-image area is recessed. Relief printing includes flexographic printing and letterpress printing. In order to render the cell pattern layer20useful for its intended purpose which is to create a pattern of very small image elements, so-called microcells, on a print surface of a relief printing form, the cell pattern layer that is a printed microcell pattern is oriented between a source of actinic radiation and a surface of the photosensitive layer that will ultimately become the printing surface of the resulting relief printing form. In most embodiments of the photosensitive element, the cell pattern layer is a printed microcell pattern that is disposed between the digital layer and the photopolymerizable layer. In some other embodiments of the photosensitive element, the cell pattern layer is a printed microcell pattern that is disposed on a side of the digital layer that is opposite the photopolymerizable layer, i.e., the digital layer is between the photopolymerizable layer and the cell pattern layer. In yet other embodiments of the photosensitive element, the cell pattern layer is a printed microcell pattern is disposed in or on a separate cover element, such as a barrier layer coversheet, The cell pattern layer20includes a plurality of features each having an area of 5 to 750 square microns and separated from adjacent features with spacing on average of 5 to 30 micron as determined by a geometric centroid of each feature. Each feature of the pattern is a two-dimensional shape (based on a planar view) that is not limited, and can have a convex perimeter, or a non-convex perimeter. Non-limiting examples of features with two-dimensional shapes having a convex perimeter include circles, squares, and rectangles. Non-limiting examples of features with two-dimensional shapes having a non-convex perimeter include kidney shapes, and crescent shapes. Each feature can be separate or disconnected from other adjacent features. Alternatively, each feature can overlap with other adjacent features to thereby form larger “super-features” that refers to a union of two-dimensional areas covered by overlapping portions, and as such features may appear larger in shape or have a connected shape. The plurality of features are printed as a pattern to create a layer-like effect (but not a continuous layer of ink) that is integrated and superimposed on the entire or substantially entire surface area of the photosensitive element, thereby forming the cell pattern layer. The plurality of features can be applied directly or indirectly to a layer of the photosensitive element to form the cell pattern layer by printing with the ink that in most embodiments is opaque to actinic radiation and transparent to infrared radiation. The ink that is used to print the features of the cell pattern layer is transparent to, i.e., does not absorb, infrared radiation, particularly at the wavelength/s of infrared laser radiation that is used to form the mask of the digital layer, so that the features of the cell pattern layer are not removed by, or disturbed, or modified by, the impinging laser radiation. The ink that is used to print the features of the cell pattern layer is opaque to, i.e., does absorb, actinic radiation, particularly at the wavelength/s of actinic radiation (such as ultraviolet radiation at 350 to 380 nm), that is used to expose and cure the photosensitive layer, so that the features can sufficiently block the radiation and provide for the formation of corresponding microcells on the print surface of the resulting printing form. It should be understood that “opaque to actinic radiation” with particular reference to the property of the ink that prints the features encompasses “opaque or substantially opaque to actinic radiation”, that is, the feature that is printed with the ink can, but need not, absorb 100% of the incident actinic radiation, and can absorb less than 100% of the incident actinic radiation with the proviso that a microcell can be created in the print surface of the resulting relief printing form. The absorbance of the ink after printing to actinic radiation, particularly to ultraviolet radiation, can be determined by transmission density measurement. One example of a device suitable for measuring transmission density, and used for the present invention, is an X-Rite 361T tabletop transmission densitometer, in UV mode, (X-Rite, Inc., Grand Rapids, MI, U.S.A.) It should also be understood that “transparent to infrared radiation” with particular reference to the property of the ink that prints the features encompasses “transparent or substantially transparent to infrared radiation”, that is, the feature that is printed with the ink can, but need not, transmit 100% of the incident infrared (laser) radiation, and can transmit less than 100% of the incident infrared (laser) radiation with the proviso that a feature is not removed or modified, or not substantially removed or modified, by the infrared laser radiation that is used to create the mask from the digital layer. One method to determine if the ink is suitably transparent to infrared laser radiation is to print the ink as a patch onto a transparent film substrate, such as a polyester film; mount the printed film in a digital imager; and expose the printed film to infrared laser radiation from the imager. If the printed patch after digital exposure is not changed or altered, or not substantially changed or altered, the ink is acceptably transparent to infrared radiation. In other embodiments of the photosensitive element, the plurality of features can be applied directly or indirectly to a layer of the photosensitive element to form the cell pattern layer by printing with an ink that is opaque to actinic radiation, and is not necessarily transparent to infrared radiation. Since absorbance, and transparency, of an ink is directly proportional to the thickness of the ink laid down and the concentration of the absorbing materials in the ink, the determination of the ability of the ink to prevent or substantially prevent transmission of actinic radiation and to transmit or substantially transmit infrared radiation is most appropriately determined after ink is applied or printed onto the surface of the printing precursor by the desired method. In one embodiment, the plurality of features of the cell pattern layer is generated with an ink that is suitable for printing and blocks 80 to 100% of the actinic radiation and transmits 80 to 100% of the infrared radiation, i.e., incident infrared laser radiation, particularly after printing the features. In another embodiment, the plurality of features of the cell pattern layer is generated with a printing ink and blocks 80 to 99% of the actinic radiation and transmits 80 to 99% of the infrared radiation, i.e., incident infrared laser radiation, particularly after printing features. Ink is a fluid or paste used for printing that is composed of a pigment or dye in a liquid vehicle. Inks are formulated to meet various requirements that include color, opacity, fade resistance, pliability, odorlessness, drying, and health and environmental safety. In some embodiments inks can include one or more components that absorb actinic radiation, particularly ultraviolet radiation. Inks can be formulated by those skilled in the art to eliminate or to reduce the absorbance of infrared radiation. Inks suitable for use in the present invention are not limited. It is within the skill of a person in the art to formulate an ink to accommodate the particular printing method, e.g., relief printing, gravure printing, ink-jet printing, letterpress printing, lithographic printing, screen printing with ink jet, thermal transfer printing, and electrophotographic printing, which is used to print the features of the cell pattern layer and to provide the features of the printed microcell pattern to be sufficiently opaque actinic radiation and transparent infrared radiation on a surface of the printing precursor. Although the printing method that is used to print the cell pattern layer should facilitate production purposes, e.g., suitable to print the cell pattern layer on a moving web, the cell pattern layer could also be printed by other methods that are not conventionally printed onto a web, such as, intaglio printing, and stencil printing, as well. The ink laid down or applied or printed on layer of the photosensitive element has a thickness which is dependent upon the particular printing method, the printing conditions, the ink, and the particular surface on which the cell pattern layer is printed. The thickness of the ink printed for the plurality of features is not limited. Acceptable results can occur over a wide range of ink thicknesses. To the extent that the ink is opaque to actinic radiation and transparent to infrared radiation, the color of the ink is not limited. However, the selection of color for the ink may be influenced by the inherent absorbance of the ink relative to the actinic radiation, and transparency of the ink to infrared radiation. In most embodiments, the ink is cyan colored since the absorbance of cyan inks into the ultraviolet region is typically sufficient to block actinic radiation and transparent to infrared radiation. If the ink is not sufficiently absorptive of actinic radiation, particularly ultraviolet radiation, ultraviolet absorbing compound/s could be added to the ink. One exception is that while the addition of certain compound/s, such as carbon black, to an ink would increase its absorbance of ultraviolet radiation, the compound would also increase its absorbance of infrared radiation, particularly near-infrared radiation, which would be problematic for digital imaging with infrared laser radiation. The digital layer16is employed in digital direct-to-plate image technology in which laser radiation, typically infrared laser radiation, is used to form a mask of the image for the photosensitive element (instead of the conventional image transparency or phototool). The digital layer is opaque or substantially opaque to actinic radiation that corresponds with the sensitivity of the photopolymerizable material; and is sensitive to infrared laser radiation. The digital layer can be a single layer that provides both functions of opaque to actinic radiation and sensitive to infrared radiation. Alternatively, the digital layer can be a composite of two or more separate layers in which the each functionality of opaque to actinic radiation and sensitive to infrared radiation is provided in one of the separate layers. In one embodiment, digital methods use the laser radiation to create from the digital layer a mask image that can be formed in situ on or disposed above the photopolymerizable layer of the printing form precursor. In other embodiments, digital methods use the laser radiation to create from the digital layer a mask that is formed on a digital element that is separate from the photopolymerizable layer, and subsequently the digital element with the mask is applied to the photopolymerizable layer forming the printing form precursor. In some embodiments, the photosensitive element initially includes the digital layer disposed above and covers or substantially covers the entire surface of the photopolymerizable layer; and the cell pattern layer is disposed between the digital layer and the photopolymerizable layer. In some embodiments, the infrared laser radiation imagewise removes, i.e., ablates or vaporizes, the digital layer to form the in-situ mask. Suitable materials and structures for this actinic radiation opaque layer are disclosed by Fan in U.S. Pat. No. 5,262,275; Fan in U.S. Pat. No. 5,719,009; Fan in U.S. Pat. No. 6,558,876; Fan in EP 0 741 330 A1; and Van Zoeren in U.S. Pat. Nos. 5,506,086 and 5,705,310. A material capture sheet adjacent the digital layer may be present during laser exposure to capture the material of the digital layer as it is removed from the photosensitive element as disclosed by Van Zoeren in U.S. Pat. No. 5,705,310. Only the portions of the digital layer that were not removed from the photosensitive element will remain on the element forming the in-situ mask. In another embodiment, the photosensitive element will not initially include the digital layer. A separate element bearing the digital layer will form an assemblage with the photosensitive element (that in this embodiment includes primarily the photopolymerizable layer and the optional support) such that the digital layer is adjacent the surface of the photosensitive element opposite the support, which is typically is the photopolymerizable layer. If present, a coversheet associated with the photosensitive element typically is removed prior to forming the assemblage. In one embodiment, the cell pattern layer is printed onto the surface of the photopolymerizable layer that is opposite the support. The separate element includes at least the digital layer on a polymeric film, and may include one or more other layers, such as ejection layers or heating layers, to aid in the digital exposure process. Hereto, the digital layer is also sensitive to infrared radiation. In one embodiment, the assemblage is exposed imagewise with infrared laser radiation to selectively transfer or selectively alter the adhesion balance of the digital layer and form the mask on or disposed above the photopolymerizable layer, so that the cell pattern layer is not covered by the non-transferred portions of the digital layer (and the cell pattern layer is between the photopolymerizable layer and the transferred portions of the digital layer). Materials and structures suitable for this actinic radiation opaque layer are disclosed by Fan et al. in U.S. Pat. No. 5,607,814; and Blanchett in U.S. Pat. Nos. 5,766,819; 5,840,463; and EP 0 891 877 A. As a result of the imagewise transfer process, only the transferred portions of the digital layer will reside on the photosensitive element forming the in-situ mask, and the cell pattern layer will be present in the open portions of the mask. In some other embodiments, the cell pattern layer and the digital layer form a separate element. The digital layer of the separate element is imagewise exposed to infrared laser radiation to form the mask, which then forms an assemblage with the photosensitive element (that in this embodiment includes primarily the photopolymerizable layer and the optional support) such that the mask of the digital layer is adjacent the surface of the photosensitive element opposite the support, which is typically is the photopolymerizable layer. (If present, the coversheet associated with the photosensitive element typically is removed prior to forming the assemblage.) In this embodiment of the separate element, the cell pattern layer is disposed between a film and the digital layer. And after the separate element with a mask of the digital layer forms the assemblage with the photopolymerizable layer, the photosensitive element includes film (of separate element), the cell pattern layer, the digital layer forming a mask, the photopolymerizable layer, and optional support. The film of the separate element may remain with the assemblage, and be present during imagewise exposure of the photosensitive layer. Materials constituting the digital layer and structures incorporating the digital layer are not particularly limited, provided that the digital layer can be imagewise exposed to form the in-situ mask on or adjacent the photopolymerizable layer of the photosensitive element. The digital layer may substantially cover the surface or only cover an imageable portion of the photopolymerizable layer. The digital layer can be used with or without a barrier layer. If used with the barrier layer, the barrier layer is disposed between the photopolymerizable layer and the digital layer to minimize migration of materials between the photopolymerizable layer and the digital layer. Monomers and plasticizers can migrate over time if they are compatible with the materials in an adjacent layer, which can alter the laser radiation sensitivity of the digital layer or can cause smearing and tackifying of the digital layer after imaging. The digital layer is also sensitive to laser radiation that can selectively remove or transfer digital layer. In some embodiments, the digital layer comprises a radiation-opaque material, an infrared-absorbing material, and an optional binder. Dark inorganic pigments, such as carbon black and graphite, mixtures of pigments, metals, and metal alloys generally function as both infrared-sensitive material and radiation-opaque material. The optional binder is a polymeric material which includes, but is not limited to, self-oxidizing polymers, non-self-oxidizing polymers, thermochemically decomposable polymers, polymers and copolymers of butadiene and isoprene with styrene and/or olefins, pyrolyzable polymers, amphoteric interpolymers, polyethylene wax, materials conventionally used as the release layer described above, and combinations thereof. The thickness of the digital layer should be in a range to optimize both sensitivity and opacity, which is generally from about 20 Angstroms to about 50 micrometers. The digital layer should have a transmission optical density of greater than 2.0 in order to effectively block actinic radiation and the polymerization of the underlying photopolymerizable layer. The digital layer includes (i) at least one infrared absorbing material, (ii) a radiation opaque material, wherein (i) and (ii) can be the same or different, and at least one binder. The following materials are suitable as the binder for the digital layer and include, but not limited to, polyamides, polyethylene oxide, polypropylene oxide, ethylcellulose, hydroxyethyl cellulose, cellulose acetate butyrate, ethylene-propylene-diene terpolymers, copolymers of ethylene and vinyl acetate, copolymers of vinyl acetate and vinyl alcohol, copolymers of vinyl acetate and pyrrolidone, polyvinyl acetate, polyethylene wax, polyacetal, polybutyral, polyalkylene, polycarbonates, polyester elastomer, copolymers of vinyl chloride and vinyl acetate, copolymers of styrene and butadiene, copolymers of styrene and isoprene, thermoplastic block copolymers of styrene and butadiene, thermoplastic block copolymers of styrene and isoprene, polyisobutylene, polybutadiene, polycholorprene, butyl rubber, nitrile rubber, thermoplastic polyurethane elastomer, cyclic rubbers, copolymers of vinylacetate and (meth)acrylate, acrylonitrile-butadiene-styrene terpolymer, methacrylate-butadiene-styrene terpolymer, alkyl methacrylate polymer or copolymer, copolymers of styrene and maleic anhydride, copolymers of styrene and maleic anhydride partially esterified with alcohols, and combinations thereof. Preferred binders include polyamides, polyethylene oxide, polypropylene oxide, ethylcellulose, hydroxyethyl cellulose, cellulose acetate butyrate, ethylene-propylene-diene terpolymers, copolymers of ethylene and vinyl acetate, copolymers of vinyl acetate and vinyl alcohol, copolymers of vinyl acetate and pyrrolidone, polyvinyl acetate, polyethylene wax, polyacetal, polybutyral, polyalkylene, polycarbonates, cyclic rubber, copolymer of styrene and maleic anhydride, copolymer of styrene and maleic anhydride partially esterified with alcohol, polyester elastomers, and combinations thereof. Materials suitable for use as the radiation opaque material and the infrared absorbing material include, but is not limited to, metals, metal alloys, pigments, carbon black, graphite and combinations thereof. Mixtures of pigments in which each pigment functions as the infrared absorbing material, or the radiation opaque material (or both) can be used with the binder. Dyes are also suitable as infrared absorbing agents. Examples of suitable dyes include poly(substituted)phthalocyanine compounds; cyanine dyes; squarylium dyes; chalcogenopyrloarylidene dyes; bis(chalcogenopyrylo)-polymethine dyes; oxyindolizine dyes; bis(aminoaryl)-polymethine dyes; merocyanine dyes; croconium dyes; metal thiolate dyes; and quinoid dyes. Preferred is carbon black, graphite, metal, and metal alloys that functions as both the infrared absorbing material and the radiation opaque material. The radiation opaque material and the infrared absorbing material may be in dispersion to facilitate handling and uniform distribution of the material. The photopolymerizable layer14is a solid layer formed of the composition comprising a binder, at least one ethylenically unsaturated compound, and a photoinitiator. The photoinitiator is sensitive to actinic radiation. Throughout this specification actinic radiation will include ultraviolet radiation and/or visible light. The solid layer of the photopolymerizable composition is treated with one or more solutions and/or heat to form a relief suitable for relief printing. As used herein, the term “solid” refers to the physical state of the layer which has a definite volume and shape and resists forces that tend to alter its volume or shape. A solid layer of the photopolymerizable composition may be polymerized (photohardened), or unpolymerized, or both. In some embodiments, the layer of the photopolymerizable composition is elastomeric. In one embodiment, the photosensitive element includes a layer of photopolymerizable composition composed at least of a binder, at least one ethylenically unsaturated compound, and a photoinitiator. In another embodiment, the layer of the photopolymerizable composition includes an elastomeric binder, at least one ethylenically unsaturated compound, and a photoinitiator. In some embodiments, the relief printing form is an elastomeric printing form (i.e., the photopolymerizable layer is an elastomeric layer). The binder can be a single polymer or mixture of polymers. In some embodiments, the binder is an elastomeric binder. In other embodiments, the layer of the photopolymerizable composition is elastomeric. Binders include natural or synthetic polymers of conjugated diolefin hydrocarbons, including polyisoprene, 1,2-polybutadiene, 1,4-polybutadiene, butadiene/acrylonitrile, and diene/styrene thermoplastic-elastomeric block copolymers. Preferably, the elastomeric block copolymer of an A-B-A type block copolymer, where A represents a non-elastomeric block, preferably a vinyl polymer and most preferably polystyrene, and B represents an elastomeric block, preferably polybutadiene or polyisoprene. In some embodiments, the elastomeric A-B-A block copolymer binders can be poly(styrene/isoprene/styrene) block copolymers, poly(styrene/butadiene/styrene) block copolymers, and combinations thereof. The binder is present in an amount of about 10% to 90% by weight of the photosensitive composition. In some embodiments, the binder is present at about 40% to 85% by weight of the photosensitive composition. Other suitable binders include acrylics; polyvinyl alcohol; polyvinyl cinnamate; polyamides; epoxies; polyimides; styrenic block copolymers; nitrile rubbers; nitrile elastomers; non-crosslinked polybutadiene; non-crosslinked polyisoprene; polyisobutylene and other butyl elastomers; polyalkyleneoxides; polyphosphazenes; elastomeric polymers and copolymers of acrylates and methacrylate; elastomeric polyurethanes and polyesters; elastomeric polymers and copolymers of olefins such as ethylene-propylene copolymers and non-crosslinked EPDM; elastomeric copolymers of vinyl acetate and its partially hydrogenated derivatives. The photopolymerizable composition contains at least one compound capable of addition polymerization that is compatible with the binder to the extent that a clear, non-cloudy photosensitive layer is produced. The at least one compound capable of addition polymerization may also be referred to as a monomer and can be a single monomer or mixture of monomers. Monomers that can be used in the photopolymerizable composition are well known in the art and include, but are not limited to, addition-polymerization ethylenically unsaturated compounds with at least one terminal ethylenic group. Monomers can be appropriately selected by one skilled in the art to provide elastomeric property to the photopolymerizable composition. The at least one compound capable of addition polymerization (i.e., monomer) is present in at least an amount of 5%, typically 10 to 20%, by weight of the photopolymerizable composition. The photoinitiator can be any single compound or combination of compounds which is sensitive to actinic radiation, generating free radicals which initiate the polymerization of the monomer or monomers without excessive termination. Any of the known classes of photoinitiators, particularly free radical photoinitiators may be used. Alternatively, the photoinitiator may be a mixture of compounds in which one of the compounds provides the free radicals when caused to do so by a sensitizer activated by radiation. In most embodiments, the photoinitiator for the main exposure (as well as post-exposure and backflash) is sensitive to visible or ultraviolet radiation, between 310 to 400 nm, and preferably 345 to 365 nm. Photoinitiators are generally present in amounts from 0.001% to 10.0% based on the weight of the photopolymerizable composition. The photopolymerizable composition can contain other additives depending on the final properties desired. Additional additives to the photopolymerizable composition include sensitizers, plasticizers, rheology modifiers, thermal polymerization inhibitors, colorants, processing aids, antioxidants, antiozonants, dyes, and fillers. The thickness of the photopolymerizable layer can vary over a wide range depending upon the type of printing plate desired, for example, from about 0.005 inches to about 0.250 inches or greater (about 0.013 cm to about 0.64 cm or greater). In some embodiments, the photopolymerizable layer has a thickness from about 0.005 inch to 0.0450 inch (0.013 cm to 0.114 cm). In some other embodiments, the photopolymerization layer has a thickness from about 0.020 inches to about 0.112 inches (about 0.05 cm to about 0.28 cm). In other embodiments, the photopolymerizable layer has a thickness from about 0.112 inches to about 0.250 inches or greater (0.28 cm to about 0.64 cm or greater). As is conventional in the art, manufacturers typically identify the printing precursors relative to the total thickness of the printing form on press, which includes the thickness of the support and the photopolymerizable layer. The thickness of the photopolymerizable layer for the printing form is typically less than the manufacturer's designated thickness since the thickness of the support is not included. The photosensitive element can include one or more additional layers on or adjacent the photosensitive layer. In most embodiments the one or more additional layers are on a side of the photosensitive layer opposite the support. Examples of additional layers include, but are not limited to, a protective layer, a capping layer, an elastomeric layer, a barrier layer, and combinations thereof. The one or more additional layers can be removable, in whole or in part, during one of the steps to convert the element into a printing form, such as treating. Optionally, the photosensitive element may include an elastomeric capping layer on the at least one photopolymerizable layer. The elastomeric capping layer is typically part of a multilayer cover element that becomes part of the photosensitive printing element during calendering of the photopolymerizable layer. Multilayer cover elements and compositions suitable as the elastomeric capping layer are disclosed in Gruetzmacher et al., U.S. Pat. Nos. 4,427,759 and 4,460,675. In some embodiments, the composition of the elastomeric capping layer includes an elastomeric binder, and optionally a monomer and photoinitiator and other additives, all of which can be the same or different than those used in the bulk photopolymerizable layer. Although the elastomeric capping layer may not necessarily contain photoreactive components, the layer ultimately becomes photosensitive when in contact with the underlying bulk photopolymerizable layer. As such, upon imagewise exposure to actinic radiation, the elastomeric capping layer has cured portions in which polymerization or crosslinking have occurred and uncured portions which remain unpolymerized, i.e., uncrosslinked. Treating causes the unpolymerized portions of the elastomeric capping layer to be removed along with the photopolymerizable layer in order to form the relief surface. The elastomeric capping layer that has been exposed to actinic radiation remains on the surface of the polymerized areas of the photopolymerizable layer and becomes the actual printing surface of the printing plate. In embodiments of the photosensitive element that include the elastomeric capping layer, the cell pattern layer is disposed between the elastomeric capping layer and the digital layer. For some embodiments of photosensitive elements useful as relief printing forms, the surface of the photopolymerizable layer may be tacky and a release layer having a substantially non-tacky surface can be applied to the surface of the photopolymerizable layer. Such release layer can protect the surface of the photopolymerizable layer from being damaged during removal of an optional temporary coversheet or other digital mask element and can ensure that the photopolymerizable layer does not stick to the coversheet or other digital mask element. During image exposure, the release layer can prevent the digital element with the mask from binding with the photopolymerizable layer. The release layer is insensitive to actinic radiation. The release layer is also suitable as a first embodiment of the barrier layer which is optionally interposed between the photopolymerizable layer and the digital layer. The elastomeric capping layer may also function as a second embodiment of the barrier layer. Examples of suitable materials for the release layer are well known in the art, and include polyamides, polyvinyl alcohol, hydroxyalkyl cellulose, copolymers of ethylene and vinyl acetate, amphoteric interpolymers, and combinations thereof. The photosensitive printing element may also include a temporary coversheet on top of an uppermost layer of the element, which may be removed prior to preparation of the printing form. One purpose of the coversheet is to protect the uppermost layer of the photosensitive printing element during storage and handling. Examples of suitable materials for the coversheet include thin films of polystyrene, polyethylene, polypropylene, polycarbonate, fluoropolymers, polyamide or polyesters, which can be subbed with release layers. The coversheet is preferably prepared from polyester, such as Mylar® polyethylene terephthalate film. The optional support12can be any flexible material that is conventionally used with photosensitive elements10used to prepare printing forms. In most embodiments the support is transparent to actinic radiation to accommodate “backflash” exposure through the support. Examples of suitable support materials include polymeric films such those formed by addition polymers and linear condensation polymers, transparent foams and fabrics. Under certain end-use conditions metals, such as aluminum, may also be used as a support, even though a metal support is not transparent to radiation. Supports of a film composed of a synthetic resin and an antihalation agent as disclosed by Swatton et al. in EP 0 504 824 B1 are also suitable for use in the present invention. The support can be planar for use in a printing form that is plate-shaped, and can be cylindrical for use in a printing form that is a cylinder, often referred to as a printing sleeve. In one embodiment, the support is a polyester film; and, particularly a polyethylene terephthalate film. In some embodiments, the support itself can include an ultraviolet absorbent material in the film composition and/or the material can be included in a layer on the support. The support may be in sheet form or in cylindrical form, such as a sleeve. The sleeve may be formed from single layer or multiple layers of flexible material. Flexible sleeves made of polymeric films or composite materials are preferred, as they typically are sufficiently transparent to ultraviolet radiation to accommodate backflash exposure for building a floor in the cylindrical printing element. A preferred sleeve is a multiple layered sleeve as disclosed in EP 2460657 A1. The sleeve may also be made of non-transparent, actinic radiation blocking materials, such as nickel or glass epoxy. The support has a thickness that can be from 0.002 to 0.250 inch (0.0051 to 0.635 cm). The support typically has a thickness from 0.002 to 0.050 inch (0.0051 to 0.127 cm). In some embodiments, the thickness for the sheet form is 0.003 to 0.016 inch (0.0076 to 0.040 cm). In some embodiments, the sleeve has a wall thickness from 4 to 80 mils (0.010 to 0.203 cm) or more. In other embodiments, the sleeve has a wall thickness of 10 to 40 mils (0.025 to 0.10 cm). Optionally, the element includes an adhesive layer between the support12and the photopolymerizable layer14, or a surface of the support that is adjacent the photopolymerizable layer has an adhesion promoting surface. The adhesive layer on the surface of the support can be a subbing layer of an adhesive material or primer or an anchor layer as disclosed in U.S. Pat. Nos. 2,760,863 and 3,036,913 to give suitable adhesion between the support and the photopolymerizable layer. Alternatively, the surface of the support on which the photopolymerizable layer resides can be treated to promote adhesion between the support and the photopolymerizable layer, with flame-treatment or electron-treatment, e.g., corona-treated. Process to Make Photosensitive Element The process of making the photosensitive element includes a step in which the cell pattern layer is created by printing a microcell pattern with an ink onto a layer of the photosensitive element; or, onto a layer of a separate element or film that forms an assemblage with the photopolymerizable layer to form the photosensitive element. The cell pattern layer is a microcell pattern that is preprinted, i.e., printed microcell pattern, and integrated into the photosensitive element at time of manufacture. In most embodiments, the cell pattern layer is created and incorporated as an integral layer between the digital layer and the photopolymerizable layer of the photosensitive element. In some embodiments, the cell pattern layer is printed onto a surface of the digital layer that will be adjacent to and substantially contacting a surface of the photopolymerizable layer that is opposite the support. In some other embodiments, the cell pattern layer is printed onto a surface of a film support and a digital layer is formed by coating over the cell pattern layer, which the composite of the film support, cell pattern layer, the digital layer form a digital coversheet that is combined with the photopolymerizable layer before or after selective removal by ablation of the digital layer. In yet other embodiments, the cell pattern layer is printed onto a surface of the photopolymerizable layer that is opposite the support, and will be adjacent to the digital layer. In one embodiment, the ink that prints the features of the microcell pattern is opaque to actinic radiation and is transparent to infrared radiation. In other embodiments, the ink that prints the features of the microcell pattern is opaque to actinic radiation and need not be transparent to infrared radiation. The printing of the cell pattern layer can be done online during manufacture of the digital layer, or online during manufacture of the photosensitive element, or offline separate from either manufacture process. The printing of the cell pattern layer can be done in one pass; or, in multiple passes, using one or more print forms to print the particular features. In some embodiments, the cell pattern layer is printed onto a surface, e.g., digital layer, of an element of the precursor that is in web form. In this embodiment, the cell pattern layer is printed onto the surface of a moving web with a printing form that is cylindrical, such as a CYREL® Round photopolymer form, so that the microcell pattern is continuously printed without seams or disruption to the printed microcell pattern. It is well within the skill of the practitioner in the art to make or manufacture a photosensitive element printing form precursor that includes a layer of the photopolymerizable composition formed by admixing the binder, monomer, photoinitiator, and other optional additives. Since in most embodiments, the cell pattern layer is applied by printing onto a surface of the digital layer that will be adjacent the photopolymerizable layer, the cell pattern layer should withstand and not be disturbed or destroyed by the elevated temperature/s that is typically used to manufacture the photopolymerizable printing form precursor. In most embodiments, the photopolymerizable mixture is formed into a hot melt, extruded, calendered at temperatures above room temperature to the desired thickness between two sheets, such as the support and the temporary coversheet having the digital layer, or between one flat sheet and a release roll. Alternately, the photopolymerizable material can be extruded and/or calendered to form a layer onto a temporary support and later laminated to the desired final support or to a digital coversheet. The printing form precursor can also be prepared by compounding the components in a suitable mixing device and then pressing the material into the desired shape in a suitable mold. The material is generally pressed between the support and the coversheet. The molding step can involve pressure and/or heat. The photosensitive element includes at least one photopolymerizable layer that can be of a bi- or multi-layer construction. Further, the photosensitive element may include an elastomeric capping layer on the at least one photopolymerizable layer. Multilayer cover elements and compositions suitable as the elastomeric capping layer are disclosed in Gruetzmacher et al., U.S. Pat. Nos. 4,427,759 and 4,460,675. Cylindrically shaped photopolymerizable elements may be prepared by any suitable method. In one embodiment, the cylindrically shaped elements can be formed from a photopolymerizable printing plate that is wrapped on a carrier or cylindrical support, i.e., sleeve, and the ends of the plate mated to form the cylinder shape. The cylindrically shaped photopolymerizable element can also be prepared extrusion and calendering in-the-round according to the method and apparatus disclosed by Cushner et al. in U.S. Pat. No. 5,798,019. The photosensitive element can be manufactured in several ways, and sold in one embodiment as a printing form precursor having all requisite layers, i.e., the photopolymerizable layer, the cell pattern layer, and the digital layer. Alternatively, the photosensitive element can sold as separate components, e.g., a digital coversheet having the digital layer and the cell pattern layer on a support; and, a photopolymerizable element having at least the photopolymerizable layer on the optional support, that are manipulated separately, but are assembled to form a photosensitive element prior to imagewise exposure of the photopolymerizable layer.1. In one embodiment, a digital composition is coated onto a web of a polymeric film, such as polyester film, to form the digital layer on the film. The cell pattern layer is printed continuously onto a side of the digital layer that is opposite the film, to form a digital coversheet. The features of the cell pattern layer are printed continuously so that the printed microcell pattern does not include seams, breaks, or segmentation of the pattern on the digital layer web. The photopolymerizable composition is extruded to form the photopolymerizable layer between a base support, e.g., polyester film, and the digital coversheet, wherein the side of the digital coversheet having the cell pattern layer is contacted to the photopolymerizable layer opposite the support. Printing form precursors that include the base support, the photopolymerizable layer, the cell pattern layer, the digital layer, and the polymeric film as an optional coversheet can be cut to any finished size for sale to end-users.2. In one embodiment, a digital composition is coated onto a web of a polymeric film, such as polyester film, to form the digital layer on the film. The cell pattern layer is printed non-continuously onto a side of the digital layer that is opposite the film, to form a digital coversheet. The features of the cell pattern layer are printed non-continuously so that the printed microcell pattern can include seams, breaks, or segmentation of the pattern on the digital layer web. The photopolymerizable composition is extruded to form the photopolymerizable layer between a base support, e.g., polyester film, and the digital coversheet, wherein the side of the digital coversheet having the cell pattern layer is contacted to the photopolymerizable layer opposite the support. Printing form precursors that include the base support, the photopolymerizable layer, the cell pattern layer, the digital layer, and the polymeric film as an optional coversheet can be cut to a finished size according to the seams or breaks in the pattern of the digital coversheet.3. In one other embodiment, a digital composition is coated onto a web of a polymeric film, such as polyester film, to form the digital layer on the film, which is then cut to specific size/s of sheets. The cell pattern layer is printed onto the sheets on a side of the digital layer that is opposite the film using a sheet fed printing press, to form a digital coversheet. The digital coversheet can be laminated to a photopolymerizable layer to form the printing form precursor.4. In yet another embodiment, a photopolymerizable composition is formed into a layer by any method, e.g., extrusion and calendering, molding, etc. as described above. A cell pattern layer is printed on a surface of the photopolymerizable layer (after removal of coversheet if present) that is opposite the support. In one embodiment, the digital composition is applied by coating to the surface of the photopolymerizable layer having the printed microcell pattern layer, and optionally a coversheet is applied for protection. This method of construction may have particular utility to provide continuous printing form precursors, i.e., in-the-round or cylindrical photopolymerizable printing blanks or printing sleeves, with a microcell pattern.5. In another variation of the embodiment described in 4, a digital composition is coated onto a polymeric film, such as polyester film, to form the digital layer on the film; and the digital layer on the film is applied by lamination to the surface of the photopolymerizable layer having the printed microcell pattern layer.6. In still another embodiment, a polymeric film, such as polyester film, is printed with a microcell pattern to form the cell pattern layer on film. A digital composition is coated to form the digital layer onto the surface of the film having the cell pattern layer, forming a digital coversheet. The digital coversheet (which could be sold separate from the photopolymerizable layer or element) is digitally imaged, e.g., by ablating the digital layer or applying heat to thermally image the digital layer, by a digital imager device, which results in the coversheet having a mask formed of the digital layer and the cell pattern layer. The coversheet having the mask and the cell pattern layer, is applied by lamination to a surface of the photopolymerizable layer that is opposite the support, which forms the photosensitive printing precursor.7. In another variation of the embodiment described in 6, the digital coversheet is prepared to have the mask and the cell pattern layer, but instead of lamination to a solid photopolymerizable layer, the coversheet is utilized in a liquid flexographic plate making system. In this case, the coversheet having the mask and the cell pattern layer is placed on a support surface in a liquid plate making device, and liquid photopolymerizable composition is applied to form a layer on the coversheet. The liquid photopolymerizable layer is exposed to actinic radiation through the mask and the microcell pattern on the coversheet.8. In yet another embodiment, a polymeric film, such as polyester film, is printed with a microcell pattern to form the cell pattern layer on the film. A mask of a radiation opaque material is created by ink-jetting onto the cell pattern layer of the film, to create a modified digital coversheet. The modified digital coversheet can be laminated to a surface of the (solid) photopolymerizable layer, or used in the liquid flexographic plate making system as described in 7.9. In yet another embodiment, a polymeric film, such as polyester film, is printed with a microcell pattern to form the cell pattern layer on the film; and a layer of a thermally imageable composition is applied on the cell pattern layer on the film to create a digital coversheet that is imaged thermally to create a mask. In an alternate embodiment, the microcell pattern is printed with the ink to form the cell pattern layer on a layer of the thermally imageable composition on a film. Either embodiment is laminated to a surface of the photopolymerizable layer to form a photosensitive element.10. In yet another embodiment, a polymeric film, such as polypropylene film, is printed with a microcell pattern of an ink to form the cell pattern layer on the film. A digital layer of a photopolymerizable printing form precursor is digitally imaged by a digital imager to form a mask disposed above the photopolymerizable layer. The polymeric film with the cell pattern layer is laminated to a surface of the precursor having the mask. Digital mask formation can be accomplished by imagewise application of the digital material in the form of inkjet inks on the photosensitive element. Imagewise application of an ink-jet ink can be directly on the photopolymerizable layer or disposed above the photopolymerizable layer on another layer of the photosensitive element. Another contemplated method that digital mask formation can be accomplished is by creating the mask image of the radiation opaque layer on a separate carrier. In some embodiments, the separate carrier includes a radiation opaque layer that is imagewise exposed to laser radiation to selectively remove the radiation opaque material and form the image. The mask image on the carrier is then transferred with application of heat and/or pressure to the surface of the photopolymerizable layer opposite the support. The photopolymerizable layer is typically tacky and will retain the transferred image. The separate carrier may then be removed from the element prior to imagewise exposure. Method of Preparing Printing Form from the Photosensitive Element The method for preparing the printing form includes providing the photosensitive element of the present invention, exposing the photosensitive element to the actinic radiation, and treating the exposed element to form the printing form. In an embodiment in which the photosensitive element forms a printing form, the method for making the printing form includes the steps of providing the photosensitive element having an integrated printed cell pattern layer; digitally forming a mask adjacent to the photopolymerizable layer; imagewise exposing the photosensitive element to actinic radiation through the mask to create exposed portions and unexposed portions of the photosensitive layer; and treating the exposed element to remove the unexposed portions to form a surface suitable for printing. In one embodiment, the method of preparing a relief printing form from a printing form precursor includes a) imagewise removing the digital layer with infrared laser radiation to form a mask on the photosensitive element as described above that includes actinic radiation opaque areas and open areas, wherein removing of the digital layer reveals the features of the cell pattern layer; b) exposing the photosensitive element to actinic radiation through the mask forming exposed portions and unexposed portions in the photopolymerizable layer; and, c) treating the element of step b) to remove the unexposed portions of the photopolymerizable layer, thereby forming a relief surface suitable for printing. Exposing the photosensitive element to actinic radiation through the in-situ mask is an imagewise exposure of the photopolymerizable layer. The cell pattern layer is not changed or removed by infrared laser radiation that is used to imagewise remove, i.e., ablate, the digital layer since the cell pattern layer is composed of an ink that is transparent to, i.e., does not absorb, infrared radiation. Since the features of the cell pattern layer are revealed in the open areas of the digital layer to be present during imagewise exposure and are composed of the ink that is opaque to actinic radiation, the features (after treating) create microcells that can appear as irregularities, dimples, or very tiny reverses, on an uppermost surface, i.e., printing surface, of the raised elements of the relief surface. The microcells provide the printing form with the capability to carry or transfer ink sufficiently for uniform and dense printing of solids. In yet another embodiment in which the photosensitive element forms a relief printing form, the method for making the printing form comprises the steps of providing the photopolymerizable printing precursor having a cell pattern layer disposed between the digital layer and the photopolymerizable layer as described above; imagewise exposing the digital layer of the precursor to infrared laser radiation to selectively ablate or remove the digital layer and form an in-situ mask having open areas in which one or more features, (typically a plurality of features) of the cell pattern layer are uncovered; imagewise exposing the precursor to actinic radiation through the in-situ mask to create exposed portions (i.e., polymerized portions) and unexposed portions (i.e., unpolymerized portions) of the photopolymerizable layer; and treating the exposed precursor to remove the unexposed portions to form a relief surface suitable for printing. FIG.2depicts one embodiment of a photosensitive element10shown inFIG.1, after an embodiment of the present method in which the digital layer has been imagewise/selectively removed by ablation with infrared laser radiation to form an in-situ mask having open areas and radiation opaque areas. The cell pattern layer20that is disposed between the photosensitive layer14and the digital layer16, is uncovered and revealed in the open areas of the mask. Digital methods of creating the mask image require one or more steps to prepare the photosensitive element prior to imagewise exposure to actinic radiation. Generally, digital methods of mask formation either selectively remove or transfer the digital layer, from or to a surface of the photosensitive element opposite the support. In most embodiments, the digital layer is sensitive to infrared laser radiation, particularly near-infrared laser radiation. The method by which the mask is formed with the digital layer on the photosensitive element is not limited. Digital workflow is the formation of the mask digitally with laser radiation, and may also be referred to as a digital exposure or process, and the use of a digitally formed mask may be referred to as digital direct-to plate image process. Some suitable direct-to-plate image formation methods are disclosed in U.S. Pat. Nos. 5,262,275; 5,719,009; 5,607,814; van Zoeren, U.S. Pat. No. 5,506,086; and EP 0 741 330 A1. For the digital workflow, the presence of the digital layer is required. An image-bearing mask is formed directly onto the digital layer using an infrared laser of a digital imager device, such as disclosed in U.S. Pat. Nos. 5,760,880 and 5,654,125. The exposure can be carried out using various types of infrared lasers, which emit in the range 750 to 20,000 nm, preferably in the range 780 to 2,000 nm. Diode lasers may be used, but Nd:YAG lasers emitting at 1060 nm, and Ytterbium fiber lasers emitting at 1090 nm are preferred. Alternative methods of forming the mask digitally, i.e., by transfer of actinic radiation opaque mask, or lamination of a digitally formed mask, as well as formation of the mask by ink-jetting are described above for the photosensitive element. After mask formation digitally, the photosensitive element is then exposed to actinic radiation through the mask. Imagewise exposure of printing form precursors through such digitally formed mask to actinic radiation can be done in the presence of atmospheric oxygen; in an environment of an inert gas; or in controlled environment having an inert gas and a concentration of oxygen that is less than atmospheric but greater than completely inert gas. In other embodiments, imagewise exposure of the precursor to actinic radiation can be done with or without a coversheet or other protective film that is transparent to actinic radiation, that is placed on or disposed above the mask, with or without lamination, or with or without a vacuum. On exposure, the transparent areas of the negative or the blank areas of the digital mask allow addition polymerization or crosslinking to take place, while the opaque areas remain uncrosslinked. Imagewise exposing the photopolymerizable element to actinic radiation creates exposed portions that polymerize, and unexposed portions that remain unpolymerized of the photopolymerizable layer. Exposure is of sufficient duration to crosslink the exposed areas down to the support or to the back exposed layer, i.e., floor. Imagewise exposure time is typically much longer than backflash time. Exposure time can vary from a few seconds to tens of minutes, depending on the intensities and wavelengths of the actinic radiation, the nature and volume of the photopolymerizable layer, the desired image resolution, and the distance from the photosensitive element. The next step in preparing the relief printing form, the photosensitive element of the present invention is exposed to actinic radiation from suitable sources. Actinic radiation sources encompass the ultraviolet and visible wavelength regions. The suitability of a particular actinic radiation source is governed by the photosensitivity of the initiator and the at least one monomer used in preparing the photosensitive element. The preferred photosensitivity of most common relief printing forms is in the UV and deep visible area of the spectrum, as they afford better room-light stability. Examples of suitable visible and UV sources include carbon arcs, mercury-vapor arcs, fluorescent lamps, electron flash units, electron beam units, lasers, and photographic flood lamps. The most suitable sources of UV radiation are the mercury vapor lamps, particularly the sun lamps. Examples of industry standard radiation sources include the Sylvania 350 Blacklight fluorescent lamp (FR48T12/350 VL/VHO/180, 115w), and the Philips UV-A “TL”-series low-pressure mercury-vapor fluorescent lamps. These radiation sources generally emit long-wave UV radiation between 310-400 nm. Flexographic printing plates sensitive to these particular UV sources use initiators that absorb between 310-400 nm. It is contemplated that the imagewise exposure to infrared radiation for those embodiments which include the infrared-sensitive layer and the overall exposure to actinic radiation can be carried out in the same equipment. The radiation source can be used at a distance of about 1.5 to about 60 inches (about 3.8 to about 153 cm) from the photosensitive element. Exposure temperatures are preferably ambient or slightly higher, i.e., about 20° C. to about 35° C. Imagewise exposure of the present photosensitive element can occur in the presence of atmospheric oxygen (conventional digital workflow); in the absence of atmospheric oxygen, such as under an inert gas blanket or a layer of fluid, or with an oxygen barrier film or layer; or, in a controlled environment having an inert gas and a concentration of oxygen that is less than atmospheric but greater than a completely inert gas environment (modified digital workflow). Conventional digital workflow methods imagewise expose the photosensitive element to actinic radiation in air under normal atmospheric conditions, which is 78% nitrogen, ˜21% oxygen, <1% each argon and carbon dioxide, and trace amounts of other gases. In other words, the concentration of oxygen is about 210,000 ppm when the imagewise exposure is in air. In some embodiments, imagewise exposure of the present photosensitive element occurs in a modified digital workflow, which is in a controlled environment of an inert gas and concentration of oxygen. Imagewise exposure of the photosensitive element to actinic radiation is conducted in an environment that includes the presence of an inert gas and an oxygen concentration of between 190,000 to 100 part per million (ppm). The inert gas is a gas that exhibits no or a low reaction rate with the photosensitive element (that is, inert to the polymerization reaction), and is capable of displacing oxygen in the exposure environment (i.e., closed exposure chamber). Suitable inert gases include, but are not limited to, argon, helium, neon, krypton, xenon, nitrogen, carbon dioxide, and combinations thereof. Although the inert gas and combinations or mixtures of inert gases may include a small portion of oxygen, the presence of the small portion of oxygen does not significantly alter the capability of the inert gas to replace the atmospheric air in the chamber or to maintain the desired oxygen concentration in the chamber. In one embodiment, the inert gas is nitrogen. Imagewise exposure of the photosensitive element in the particular environment of inert gas and oxygen concentration between 190,000 and 100 ppm provides the printing form with a relief structure of a plurality of raised surfaces each having a ink carrying top surface area that is structurally similar to an ink carrying top surface area created in a printing form that was prepared with analog workflow. That is, the top surface area of the raised surfaces in the relief printing form prepared according to the present method is flat or substantially flat, and not rounded as is typical of conventional digital workflow wherein the element is exposed in the presence of atmospheric oxygen. Imagewise exposure in the modified digital workflow also provides for the creation and retention of the microcells on the top surface area, i.e. printing surface of the resulting printing form. In one embodiment, the photosensitive element does not include any additional layers on top of the in-situ mask, which additional layers may act as a barrier to the environment to the surface being imagewise exposed. Exposure devices that provide a chamber for exposing the photosensitive element in a controlled environment are disclosed. Exposure devices include a closed exposure chamber, a source of actinic radiation, a source of gas for introduction to the closed exposure chamber, and a means for measuring the concentration of oxygen within the closed exposure chamber. The source of actinic radiation is capable of impinging the actinic radiation on a side of the photosensitive element having the in-situ mask while the photosensitive element resides in the closed exposure chamber. The source of actinic radiation can be located adjacent to the photosensitive element. In some embodiments, the source of actinic radiation is located adjacent the closed exposure chamber. For modified digital workflow, during imagewise exposure of the photosensitive element, the photosensitive element is encased or substantially encased within the closed exposure chamber, such that the closed exposure chamber has an internal environment that is different during exposure from an environment external to the closed exposure chamber. The internal environment in the closed exposure chamber is a particular environment of a gas or gases, i.e., inert gas, and a concentration of oxygen between 190,000 ppm and 100 ppm. The closed exposure chamber encloses the photosensitive element in the internal environment during exposure so as to control or maintain the oxygen concentration in the exposure chamber. The closed exposure chamber can be a separate enclosure appended within or mounted to an existing exposure apparatus, or can be incorporated into the frame of an exposure apparatus, or can be formed from an existing structure integrated in an exposure apparatus, such as a housing. In one embodiment, the closed exposure chamber is an integral part of an exposure apparatus, such that the exposure apparatus can accommodate all workflows, that is, analog workflow process with exposure under vacuum, conventional digital workflow with exposure in air, and modified digital workflow with exposure in the environment of inert gas and oxygen concentration between 190,000 and 100 ppm. The source of actinic radiation can be located within or outside the closed exposure chamber, provided that the source is capable of impinging the actinic radiation onto the side of the photosensitive element having the in-situ mask. The source of actinic radiation is or can be positioned adjacent the closed exposure chamber, and in particular is or can be positioned adjacent the photosensitive element. In particular, the source of actinic radiation should be located, positioned, or positionable such that the source can expose the photosensitive element through the in-situ mask while the element is enclosed in the chamber. For printing form precursors that will be used as relief printing forms, the method usually includes a back exposure and a front image-wise exposure. The back exposure or “backflash” can take place before, after, or during image-wise exposure. Backflash prior to image-wise exposure is generally preferred. A backflash is an overall or blanket exposure of actinic radiation through the support of the photopolymerizable precursor, for a time that can range from a few seconds to about 30 minutes. The backflash creates a shallow layer of polymerized material, or a floor, on the support side of the photopolymerizable layer and sensitizes the photopolymerizable layers, helps highlight dot resolution and also establishes the depth of the relief surface for the printing form. The floor improves adhesion of the photopolymerizable layer to the support, and provides better mechanical integrity to the photosensitive element. The floor thickness varies with the time of exposure, exposure source, the thickness of the photopolymerizable layer, etc. In some embodiments, the backflash exposure suitable to establish the floor is conducted during manufacture of the precursor, after the precursor is structurally assembled and includes photopolymerizable layer adjacent the support with the at least one indicia. In most other embodiments, a backflash exposure of minimal time and/or energy is conducted during manufacture of the precursor to assure adhesion of the photopolymerizable layer to the support, and another backflash exposure of a time and/or energy is conducted by the user during conversion from precursor to printing form to establish the floor and depth of the relief. Following overall exposure to UV radiation through the image-bearing mask, the photosensitive printing element is treated to remove unpolymerized areas in the photopolymerizable layer and thereby form a relief image. The treating step is not limited, and includes conventional steps to transform the exposed photosensitive element into the desired printing form. Treating can include treatment with one or more solutions, such as washout or by applying heat, etc. as appropriate for the particular type of photosensitive element that converts the imaged photosensitive layer to a printing form. Treatment of the photosensitive printing element can include (1) “wet” development wherein the photopolymerizable layer is contacted with a suitable developer solution to washout unpolymerized areas and (2) “dry” development wherein the photopolymerizable layer is heated to a development temperature which causes the unpolymerized areas to melt or soften or flow and is contacted with an development medium to blot or wick away the unpolymerized material. Dry development may also be called thermal development. Wet development is usually carried out at about room temperature. The developer solution can include an organic solvent, an aqueous or a semi-aqueous solution, or water. The choice of the developer solution will depend primarily on the chemical nature of the photopolymerizable composition to be removed. A suitable organic solvent developer includes an aromatic or an aliphatic hydrocarbon, an aliphatic or an aromatic halohydrocarbon solvent, or a mixture of such solvents with a suitable alcohol. A suitable semi-aqueous developer can contain water and a water miscible organic solvent and an alkaline material. A suitable aqueous developer can contain water and an alkaline material. Other suitable aqueous developer solution combinations are described in U.S. Pat. No. 3,796,602. Development time can vary, but it is preferably in the range of about 2 to about 25 minutes. The developer solution can be applied in any convenient manner, including immersion, spraying, and brush or roller application. Brushing aids can be used to remove the unpolymerized portions of the photosensitive printing element. Washout can be carried out in an automatic processing unit which uses developer and mechanical brushing action to remove the unexposed portions of the resulting relief printing form, leaving a relief constituting the exposed image and the floor. Following treatment by developing in solution, the printing forms are generally blotted or wiped dry, and then more fully dried in a forced air or infrared oven. Drying times and temperatures may vary, however, typically the plate can be dried for about 60 minutes to about 120 minutes at about 60° C. High temperatures are not recommended because the support can shrink, and this can cause registration problems. In thermal development, the photopolymerizable layer can be heated to a development temperature typically between about 40° C. and 200° C. which causes the unpolymerized areas to liquefy, that is, to melt, soften, or flow. The photopolymerizable layer can then be contacted with a development medium, such as an absorbent material, to remove the unpolymerized photopolymerizable composition. The polymerized areas of the photopolymerizable layer have a higher melting temperature than the unpolymerized areas and therefore do not melt at the development temperatures (see U.S. Pat. No. 5,215,859 and WO 98/13730). Apparatus suitable for thermal development of photosensitive printing elements is disclosed in U.S. Pat. Nos. 5,279,697 and 6,797,454. The printing forms prepared by the method of the present invention can be uniformly post-exposed to ensure that the photopolymerization process is complete and that the photosensitive printing form will remain stable during printing and storage. This post-exposure step can utilize the same radiation source as the main exposure. Detackification is an optional post-development treatment which can be applied if the surface of the flexographic printing plate is still tacky, such tackiness not generally being removed in post-exposure. Tackiness can be eliminated by methods well known in the art, such as treatment with bromine or chlorine solutions, and by exposure to radiation sources having a wavelength not longer than 300 nm. After treating, the printing form has a relief surface of raised elements for carrying and transferring ink imagewise to a substrate, and recessed portions that do not print. The features of the printed cell pattern layer create microcells, which are image elements that alter a print surface that can appear as dimples and/or very tiny reverses, and that are each smaller in at least one dimension than the spacing between halftone dots of the highest line screen halftone areas (if areas of halftone dots are being printed) by the relief printing form. The microcells are each smaller in at least one dimension than the spacing between smallest periodic structures on the printing form. The present method provides the printing form with the raised printing surfaces composed of fine raised surface elements, in which each raised surface element is well-characterized by its three-dimensional relief shape and has a flat or substantially flat top surface area sufficient to accurately reproduce the desired image on the substrate. No longer is the relief structure in a relief printing form fabricated by digital workflow limited by oxygen inhibition effect on the photopolymerizable layer. The present invention provides for the capability to create the relief surface of the raised surface elements on the printing form that essentially is the recreation of the in-situ mask image, particularly in terms of size of openings in mask relative to the size of the raise surface element (e.g., halftone dot). The present invention avoids the cost and production disadvantages associated with analog workflow, and capitalizes on the efficiencies of digital workflow while avoiding the difficulty of establishing a completely inert environment. Depending upon many factors, but not limited to, the composition of the photopolymerizable layer; the method used to digitally create the mask; the assembly of the photosensitive element that forms the printing form precursor; the workflow used to imagewise expose the photosensitive element to actinic radiation; the features that were printed in the cell pattern layer provide a one-to-one correspondence, or substantially a one-to-one correspondence with the microcells that are formed in the printing surface of the relief printing form. The photosensitive element of the present invention is particularly useful in forming a relief printing form for flexographic printing on surfaces which are soft and easily deformable, such as packaging materials, e.g., cardboard and plastic films. The photosensitive elements of the present invention are converted to printing forms that can be used in the form of plates, plates-on-sleeves, plates-on-carriers, plate segments-on-carriers, or as seamless, continuous flexographic printing forms. Those skilled in the art, having benefit of the teachings of the present invention as hereinabove set forth, can effect numerous modifications thereto. These modifications are to be construed as being encompassed within the scope of the present invention as set forth in the appended claims. EXAMPLES In the following examples, all percentages are by weight unless otherwise noted. CYREL® photopolymerizable printing plates, CYREL® exposure unit, and CYREL® processor are all available from The DuPont Company (Wilmington, DE). Example 1 This example demonstrates the method of creating a digital printing form precursor having a layer of cell pattern that was printed with an ink and integrated between an infrared-sensitive laser ablatable layer and a photopolymerizable layer. More than one design of printed cell patterns are demonstrated as capable of increasing the density of ink in solid areas that are printed by a printing form prepared from the digital precursor having the integrated cell pattern. Preparation of Printing Plates for Printing Cell Pattern Several relief printing plates were prepared in order to print a cell pattern with ink onto the layer of the laser ablatable composition of a digital coversheet. A CYREL® 45DPR photopolymerizable printing plate precursor, which included in order a base support, a layer of a photopolymerizable composition, a layer of an infrared laser ablatable composition, and a polyester coversheet, was used to make relief printing plate having a relief surface suitable to print a cell pattern onto a digital coversheet. The 45DPR has a thickness of the photopolymerizable layer and the base support after processing that is about 45 mils. Five different cell pattern units were designed, tiled, and each stored as an image file in a digital imager unit having an infrared laser radiation suitable for forming a digital mask on the precursor. As shown inFIG.3athroughFIG.3e, each cell pattern unit includes black blocks which represent areas of the digital layer (of the 45DPR precursor) that will be removed or ablated by infrared laser radiation; and, clear or white blocks which represent areas of the digital layer that will remain on the precursor. Each cell pattern unit has a percent mask transparency value which is obtained by dividing the total number of black blocks by the total number of blocks in the pattern. The mask transparency value is one easy way of distinguishing patterns, but it is not all inclusive. In some instances, cell pattern units can have the same percent mask transparency value, but could produce different results, i.e., solid ink density or graininess. Each cell pattern unit was tiled to provide desired coverage and used by the digital imager unit to form an in-situ mask of the digital layer on the 45DPR precursor. A relief printing plate was prepared for printing each of the five cell patterns as follows. The coversheet was removed from the 45DPR precursor. The precursor was mounted on a drum of an Esko CDI Advance 5080 digital imager unit (from Esko-Graphics, a Danaher company (Gent, Belgium)), that was equipped with Optics 40, High Resolution Optics and Pixel+ imager at 4000 pixels per inch, and an in-situ mask was formed on the precursor by laser ablating the infrared ablatable layer by repeating one of the particular cell pattern units as described inFIG.3athroughFIG.3e. The CDI digital imager used laser energy of 3.8 Joules/cm2, and Pixel+ amplitude of 210. The precursor was placed in a CYREL® 3000 ETL-D exposure unit and exposed to ultraviolet radiation at 365 nm at about 16 milliWatts/cm2in a chamber having nitrogen gas environment for imagewise exposure through the in-situ mask for a time that was sufficient to imagewise cure the photopolymerizable layer. The nitrogen gas environment eliminated oxygen from the chamber during exposure so that the resulting relief surface of the printing plate would hold the extremely fine details that were necessary to print cell patterns on the laser ablatable layer of a Digital Coversheet. The precursor was overall exposed through the support at the wavelength and energy described above for a time sufficient to form a floor of photopolymer for the relief plate. The exposed precursor was treated in a CYREL® processor using CYLOSOL washout solvent, dried, post-exposed, and light finished in accordance with the conditions recommended for 45DPR plate precursors to form a printing plate having a relief surface suitable for flexographic relief printing. The printing plate was cut to 7×11.5 in. size for printing. Printing Cell Pattern on Digital Coversheet For each Test Digital Coversheet, one of the printing plates made above (from 45DPR precursor) was mounted using 3M 1020™ tape on a plate cylinder of a Mark Andy 830™ press. The plate cylinder had a 0.130 inch cutback and a 96 tooth gear to give a 12 inch repeat pattern. Printing was done with an anilox roll having 2000 LPI, with volume of 0.7 BCM. The printing was done at 180 feet per minute. The press was loaded with Sun Chemical TXLFW5834901 Aquaverse Process Cyan ink. The ink is opaque to actinic radiation, specifically ultraviolet (uv) radiation, but is transparent to the wavelength of laser radiation used in the digital imager, i.e., infrared (IR) radiation. Earlier, the ink was evaluated for its ability to be opaque to ultraviolet radiation and transparent to infrared radiation, by printing the ink as a solid area with the same or substantially the same print density as will be used to print the cell pattern layer on a clear (i.e., transparent) polyester film, and measuring the printed area of ink for UV radiation absorbance, and testing the IR radiation transmittance on the digital imager. The UV radiation absorbance of the ink was about 1.5 units, which means that less than about 4% of the UV radiation passed through the printed solid area of ink, and thus is sufficiently opaque to UV radiation. The area of the printed ink on the film was placed on the drum of the digital imager and then exposed to the IR laser radiation. The solid ink area was shown not effected, i.e., not altered, changed, or ablated, by the IR radiation from the digital imager. This meant that the ink sample does not absorb at the wavelength of light that was used in the digital imager (1064 nanometers). Separately, an infrared sensitive ablatable composition was prepared and coated as a layer onto a web of a MYLAR® polyester film substantially as described in Example 1 of U.S. Pat. No. 6,238,837. When dried, the infrared sensitive ablatable layer included about 67 wt % of a polyamide (Macromelt® 6900) and about 33 wt % of carbon black. The infrared sensitive layer on the web of polyester film is referred to as an infrared sensitive element. The polyester film functions as a support for the laser ablatable layer, but will function as a protective coversheet when joined with the Laminated Plate as described below. The infrared sensitive element web was mounted on the press so that the ink was printed by the printing plate as a cell pattern on a surface of the infrared ablatable layer that is opposite the polyester film support. The web, which now included the particular micro pattern printed in ink, was cut to size to form Test Digital Coversheet. Reproduced microscopic images of each of the five different cell patterns after printing on a laser ablatable layer are shown inFIG.4athroughFIG.4e. Clearly, the small size of these features approaches the limit as to what can be printed using flexography, especially with the particular press that was used. The printed patterns shown inFIG.4a,FIG.4b, andFIG.4cwere all faithfully reproduced on the laser imaging layer. The printed pattern shown inFIG.4dandFIG.4ewas not well reproduced since the ink tended to run together resulting in the patterns shown. Preparation of Lamination Plates Several CYREL® photopolymerizable printing plates, type DSR (67 mil) were modified for use as Printing Plate Precursors for this example. Type DSR photopolymerizable printing plates include in order, a base support, a layer of a photopolymerizable composition, an infrared laser-ablatable layer, and a coversheet. The photopolymerizable layer included an elastomeric binder of an ABA block copolymer, monomer/s, photoinitiator, and other additives. The 67DSR has a thickness of the photopolymerizable layer and the base support after processing that is about 67 mils. The Printing Plate Precursors were prepared from DSR printing plates except that the coversheet and the laser ablatable layer were replaced with a sheet of 601 MYLAR® polyester (PET) film (from DuPontTeijin Films, Chester, VA, USA), which is a clear sheet of PET film having surface with a siliconized coating. This is resulted in a construction structure consisting of in order the base support, the photopolymerizable layer, and the siliconized PET film, that will be referred to as a Lamination Plate throughout the remainder of the Example. The Lamination Plate is useful, because the siliconized PET film can be easily removed without affecting the photopolymerizable and base support layers; and, other coversheets (having the laser ablatable layer and a particular cell pattern layer) can then be easily laminated to the photopolymerizable layer in order to test printing plate precursors having different coversheets with the same type of photopolymerizable composition. Preparation of Test Printing Plate Precursors A Lamination Plate, size 8×25 inch, was placed on a 20×30 inch sheet of stainless steel (2 mils thick). The siliconized PET film was removed from the Lamination Plate, uncovering the photopolymerizable layer of the Lamination Plate. A Cromalin™ Laminator was heated to 100° C. A Test Digital Coversheet (prepared as described above), which was at least 1 inch larger than the Lamination Plate in all directions, was held so that its leading edge contacted a leading edge of the Lamination Plate; and, was oriented so that the layer of the printed cell pattern would be disposed between the infrared-sensitive ablation layer of the Test Coversheet and the photopolymerizable layer of the Lamination Plate. The assembly of the Lamination Plate with the Test Coversheet was then fed, leading edge first, through the heated laminator with minimal pressure. The resultant printing plate precursor was then placed in a drying oven at 60° C. overnight to insure adequate bonding of the laser ablatable layer of the Test Coversheet to the photopolymerizable layer. Portions of the Test Coversheet that were excess, i.e., overhung the photopolymerizable layer, were then trimmed and removed, and the Printing Plate precursor was ready for imaging. For each Test Coversheet that was prepared as described above, a Test Printing Plate Precursor was prepared from a Lamination Plate and each Test Coversheet by the lamination process described. Each of the Test Coversheets having the infrared-sensitive ablation layer on a support, and a particular cell pattern printed with an ink that is UV-opaque and IR-transparent on the infrared-sensitive ablation layer was laminated to a Lamination Plate using the method described above. The final structure of the Test Printing Plate Precursor was, in order, a polyester film support, a photopolymerizable layer, a layer of printed cell pattern, an infrared-sensitive laser ablatable layer used to form mask, and a removable polyester film support as a protective coversheet. In addition to preparing the Test Printing Plate Precursors by laminating each Test Coversheet to a Lamination Plate, a Control Printing Plate Precursor was also prepared by laminating a conventional coversheet having the infrared laser ablatable layer that did not include a printed cell pattern. The Test Printing Plate Precursors were formed of the Laminated Plate and the Digital Coversheet as described above, and allowed to age for about 1 week at ambient conditions. Conversion of Test Printing Plate Precursors to Relief Printing Plates For each Test Printing Plate Precursor, the coversheet (which was the support for the infrared ablation layer) was removed, the Test Printing Plate Precursor was mounted on the drum of the digital imager unit as described above, and then an in-situ mask was formed on the Test Printing Plate Precursor by selectively exposing with infrared laser radiation to ablate, i.e., remove, the infrared-sensitive ablation layer. The in-situ mask was a simple solid pattern, in which the infrared-sensitive ablation layer was removed, i.e., ablated, from the entire plate surface. Although the infrared laser radiation removed the infrared ablatable layer from the Test Printing Plate Precursor, the printed cell pattern that was disposed between infrared ablation layer and the photopolymerizable layer was not affected. The Plate Precursor was placed in a CYREL® 3000 ETL-D exposure unit and exposed to ultraviolet radiation at 365 nm at about 16 milliWatts/cm2in a chamber having an environment of nitrogen gas and controlled concentration of oxygen of about 3% for imagewise exposure through the in-situ mask for a time that was sufficient to imagewise cure the photopolymerizable layer. Exposure in the controlled environment of nitrogen gas and oxygen concentration of 3% was sufficient to form desired shape of the raised elements, such as flat-topped highlight dots, and form the microcell pattern on the print surface of the relief printing plate without the extra time and control required to assure complete inert gas environment of nitrogen. Similar to the preparation of the 45DPR printing plates to print the cell pattern, the Plate Precursor was then exposed to ultraviolet radiation through the support, washout developed in solvent solution, dried, post-exposed and light finished as described above, but in accordance with the standard practices for a DSR plate, to produce Test Relief Printing Plate having a relief surface. A reproduction of the microscope image of the printing surface, i.e., uppermost ink-carrying surface of the “solid” raised portion of the relief surface, of each of the resulting Test Relief Printing Plates is shown inFIG.5athrough5e. For each of the five cell patterns printed for the Digital Coversheet, a microcell pattern was formed into the uppermost ink-carrying surface of the Test Relief Printing Plate. As shown inFIG.5a,FIG.5b, andFIG.5c, each cell pattern (generated by the cell pattern units represented inFIG.3a,FIG.3b, andFIG.3crespectively) was faithfully reproduced overall on the ink-carrying surface of the solid raised portion forming repeating microcell structures (i.e., recesses in the ink-carrying surface) that are well-formed or substantially well-formed, wherein each cell of the microcell patterns is between 5 and 10 microns. ForFIG.5dandFIG.5e, each cell pattern (generated by cell pattern units represented inFIG.3dandFIG.3e, respectively) the microcell structures that were reproduced overall on the ink-carrying surface of the solid raised portion have substantially larger structures (i.e., greater than 15 microns) since the cell patterns were not faithfully reproduced during printing. Each of the Test Relief Printing Plates was used to print the solids onto a substrate. Each Test Relief Printing Plate was mounted onto a PCMC Avanti Central Impression flexographic printing press, and Sun Process GS Cyan CRVFS5134539/K525 solvent-based printing ink was used to print onto a Bemis 20″ wide, 1.5 mil Film (White LLDPE Mono (MA11-A104-E0) as the substrate. The ink density of the solid printed areas was measured using a Techkon SpectroJet scanning spectrophotometer-densitometer (from Techkon USA (Danvers, MA, U.S.A)). The solid ink density values on the substrate that were created by the Test Relief Printing Plates are reported below. Cell PatternMicrocellEXAMPLE 1Printed onPatternTest ReliefDigitalFormed onPrintingCell PatternCoversheetSolid AreaSolid InkPlateUnit Shown inShown inShown inDensityTest Plate 1FIG. 3aFIG. 4aFIG. 5a1.34Test Plate 2FIG. 3bFIG. 4bFIG. 5b1.41Test Plate 3FIG. 3cFIG. 4cFIG. 5c1.45Test Plate 4FIG. 3dFIG. 4dFIG. 5d1.3Test Plate 5FIG. 3eFIG. 4eFIG. 5e1.28ControlnonenoneNone1.27 As shown in the results, Test Plate1, Test Plate 2, and Test Plate 3 gave a visually significant increase in solid ink density over the Control that was made without a cell pattern printed image on the laser ablation layer. Test Plate 4 and Test Plate 5 did not give a visually noticeable increase in solid ink density compared to the Control. This is because the cell pattern units (ofFIG.3dandFIG.3e) that were designed for printing on the laser ablation layer were not faithfully reproduced during the printing process as shown in the images of the Digital Coversheets ofFIG.4dandFIG.4e, respectively. The cell pattern units ofFIG.3dandFIG.3emay have been faithfully reproduced by printing with the specific ink on the infrared-sensitive laser ablation layer of the Digital Coversheet and thus effective at creating suitable microcell pattern on the relief printing plate, if the printing of the cell pattern on the Digital Coversheets was done on a better press with improved resolution as compared to the Mark Andy 830 that used during this test, and could faithfully print the desired cell patterns. In general, if the percent mask transparency value is too low, little improvement in solid ink density is observed; and if the value is too high, it can be difficult to print the cell pattern since the ink tends to flow together and can becomes a solid (instead of printing individual elements of the pattern). Example 1 (Test Plate 1 through Test Plate 5) demonstrated that significant increases in solid ink density can be accomplished by a relief printing form that incorporates a microcell pattern as an integral layer of a printing form precursor having a digitally imageable layer, i.e., an infrared-sensitive laser ablatable layer. Example 1 also demonstrated that a cell pattern, which is useful in forming microcell pattern on a relief printing form, can be incorporated into a printing form precursor by printing a cell pattern image with a particular ink onto a surface of a laser ablatable layer, which is then joined with a photopolymerizable layer to create the digital precursor. Best results are achieved with the cells of the printed cell pattern that have a size that is less than 20 microns, and more preferably less than 10 microns. The printed image of cell pattern that is included with the digital coversheet should be transparent to the wavelength of the laser radiation, i.e., near infrared radiation, used to ablate the laser ablatable layer from the precursor and form the in-situ mask, so that the cell pattern is not also removed during ablation; and also should be opaque or sufficiently opaque to actinic radiation, e.g., ultraviolet radiation, so that the printed cell pattern can produce microcell structures on the printing surface of the printing form that will result in printing with increased solid ink density. Example 2 This example demonstrates the method of creating a digital printing form precursor having a layer of a cell pattern, which was printed with an ink and integrated between an infrared-sensitive laser ablatable layer and a photopolymerizable layer of the precursor. Additional designs of printed cell patterns are demonstrated as capable of increasing the density of ink in solid areas that are printed by a printing form prepared from the digital precursor having the integrated cell pattern. Example 1 was repeated as described above with the following differences. A new cell pattern unit was designed as shown inFIG.3f, and used by the digital imager unit to form an in-situ mask for the 45DPR precursor, which was prepared into a printing plate and used to print the cell pattern onto a surface of an infrared-sensitive laser ablatable layer and form a Digital Coversheet for Test 5 Printing Plate. Additionally, a new cell pattern was created on the infrared-sensitive laser ablatable layer by sequential printing of two different repeating cell pattern units, instead of the steps as described in Example 1 of designing and storing as an image file in a digital imager unit a cell pattern unit as shown inFIG.3gthat would be used in forming a digital mask on the precursor. Theoretically, the sequential printing of two different repeating cell pattern units should have created or substantially created as the cell pattern unit that is shown inFIG.3g. The Digital Coversheet of Test 6 was printed on an infrared-sensitive laser ablatable layer was the combination of the repeating cell pattern unit as shown inFIG.3band the repeating cell pattern unit as shown inFIG.3c. This Digital Coversheet of Test 6 was prepared by first printing with ink by the printing plate that was made with the repetition of cell pattern unit ofFIG.3bonto the laser ablatable layer of the infrared-sensitive element web; and, then printing with ink by the printing plate that was made with the repetition of cell pattern unit ofFIG.3conto the previously printed cell pattern layer. However, mis-registration of the two different cell patterns and web stretch resulted in a semi-random pattern as shown in the reproduction of the microscopic image taken of the Digital Coversheet as shown inFIG.4f. Semi-random patterns can have a distinct advantage in avoiding the occasional moiré effects that may be observed when one pattern overlays another. Digital Coversheets that represent Test cell pattern units ofFIG.3athroughFIG.3dwere repeated. However in this example, the printing of the cell pattern on the laser ablation layer of the digital coversheet was done using a PCMC Avanti Central Impression flexographic printing press instead of the Mark Andy press. The ink and the web of the infrared-sensitive laser ablatable layer were the same as described above to form each Digital Coversheet with particular cell pattern layer. However, printing was done with an anilox roll having 2000 cells per inch with a volume of 0.9 BCM and a cell angle of 60 degrees, which was different from the anilox roll used to print the cell pattern on digital coversheet in Example 1. The Test Printing Plate Precursors were formed of the Laminated Plate and the Digital Coversheet as described above, and allowed to age for two weeks at ambient conditions. A Control plate was prepared having the same photopolymerizable layer and an infrared-sensitive laser ablative layer on the photopolymerizable layer, but without any printed cell pattern layer (and without any microcell pattern created in the infrared-sensitive laser ablative layer by the digital imager). The Test Printing Plate Precursors prepared for Example 2 were converted to Relief Printing Plates as described above, by forming in-situ mask, and exposing on the exposure unit except that imagewise exposure of the Precursors occurred in the exposure chamber with a controlled environment of nitrogen as an inert gas and an concentration of oxygen of 3%. Each Test Relief Printing Form was printed as described above, and the resulting density of ink in solid areas on the printed substrate was measured and reported below. Cell PatternEXAMPLE 2Printed onMicrocellTest ReliefDigitalPatternPrintingCell PatternCoversheetFormed onSolid InkPlateUnit Shown inShown inSolid Area?DensityTest Plate 1FIG. 3a—Yes1.34Test Plate 2FIG. 3b—Yes1.28Test Plate 3FIG. 3c—Yes1.28Test Plate 4FIG. 3d—Yes1.29Test Plate 5FIG. 3f—Yes1.30Test Plate 6FIGS. 3b & 3cFIG. 4fYes1.32ControlnonenoneNone1.19 All of the Test Plates of Example 2 that included a printed cell pattern layer provided significant increase in density of ink in solid printed areas compared to the Control plate having no microcell pattern. Example 2 demonstrated that significant increases in solid ink density can be made by printing with a particular ink an image on a laser ablatable layer, which is then incorporated into the digital printing form precursor, and utilized in the method to prepare a relief printing form for flexographic printing from the precursor. The printed image should be transparent to near infrared radiation that is used by the digital imager in the ablation process that forms the in-situ mask so as not to be removed by ablation; and, should be sufficiently opaque to ultraviolet radiation in order to produce the fine microcell structures on the printing surface of the relief printing form that result in increased solid ink density upon printing. Example 3 This example demonstrates the method of creating a digital printing form precursor having a layer of cell pattern, which was printed with an ink and integrated between an infrared-sensitive laser ablatable layer and a photopolymerizable layer of the precursor. Additional designs of printed cell patterns are demonstrated as capable of increasing the density of ink in solid areas that are printed by a printing form prepared from the digital precursor having the integrated cell pattern. Example 1 was repeated as described above with the following differences. A new cell pattern unit was designed as shown inFIG.3h, and used by the digital imager unit to form an in-situ mask for the 45DPR precursor, which was prepared into a printing plate and used to print the cell pattern onto a surface of an infrared-sensitive laser ablatable layer and form a Digital Coversheet of Test 1 for Example 3. The CDI digital imager used laser energy of 3.2 Joules/cm2, and Pixel+ amplitude of 120. A new cell pattern unit was designed as shown inFIG.3i, and used by the digital imager unit to form an in-situ mask for the 45DPR precursor, which was prepared into a printing plate and used to print the cell pattern onto a surface of an infrared-sensitive laser ablatable layer and form a Digital Coversheet of Test 2 for Example 3. The CDI digital imager used laser energy of 3.2 Joules/cm2, and Pixel+ amplitude of 120. A new cell pattern unit was designed as shown inFIG.3j, and used by the digital imager unit to form an in-situ mask for the 45DPR precursor, which was prepared into a printing plate and used to print the cell pattern onto a surface of an infrared-sensitive laser ablatable layer. The CDI digital imager used laser energy of 3.0 Joules/cm2, and Pixel+ amplitude of 120. The printing plate used to print the repeating cell pattern ofFIG.3jwas removed from the drum of the printing press and remounted so that the cell pattern on the printing plate was rotated 90 degrees. The laser ablatable layer with the first printed repeating cell pattern ofFIG.3jwas printed a second time (on top of the first printed pattern) with the repeating cell pattern ofFIG.3jrotated to form a Digital Coversheet of Test 3 for Example 3. The Test Printing Plate Precursors were formed of the Laminated Plate and the Digital Coversheet as described above, and allowed to age for two weeks at ambient conditions. A Control plate was prepared having the same photopolymerizable layer and an infrared-sensitive laser ablative layer on the photopolymerizable layer, but without any printed cell pattern layer (and without any microcell pattern created in the infrared-sensitive laser ablative layer by the digital imager). Each Test Relief Printing Form was printed as described above, and the resulting density of ink and cyan percent graininess in solid areas on the printed substrate were measured using a Personal Image Analysis System having a digital camera loupe, model PIAS®-II unit (from Quality Engineering Associates, Inc., (Billerica, Massachusetts, USA)), using low resolution optics, and reported below. The higher the value of solid ink density is better for print quality. The lower the value for graininess is better for print quality. Graininess is a measure of the uniformity of the ink laid down on the substrate. EXAMPLE 3MicrocellTest ReliefPatternPrintingCell PatternFormed inSolid InkPlateUnit RepresentedSolid Area?GraininessDensityTest Plate 1FIG. 3hYes1.171.39Test Plate 2FIG. 3iYes1.131.39Test Plate 3FIG. 3jYes0.401.40(printed twice,with cellpattern rotated)Controlnonenone2.281.32 All of the Test Plates of Example 3 that included a printed cell pattern layer provided significant increase in density of ink in solid printed areas compared to the Control plate having no microcell pattern; and, provided a significant reduction in graininess of the solid printed areas compared to the Control plate having no microcell pattern. Example 3 demonstrated that significant increases in solid ink density and significant reduction in graininess of solid printing can be made by printing with a particular ink an image on a laser ablatable layer, which is then incorporated into the digital printing form precursor, and utilized in the method to prepare a relief printing form for flexographic printing from the precursor. The printed image should be transparent to near infrared radiation that is used by the digital imager in the ablation process that forms the in-situ mask so as not to be removed by ablation; and, should be sufficiently opaque to ultraviolet radiation in order to produce the fine microcell structures on the printing surface of the relief printing form that result in increased solid ink density upon printing. Example 4 Example 4 is designed to demonstrate the concept of printing a microcell pattern directly onto a plate surface. A DSR plate was made with 601 MYLAR® polyester as described in the “Preparation of Lamination Plates” section. This time, the coversheet was removed and the raw plate was wrapped around a 3 inch plastic core. As described in the “Preparation of Printing Plates for Printing Cell Pattern” section a relief plate with the image inFIG.3Cwas mounted to a Mark Andy 830 press loaded with Sun Chemical TXLFW5834901 Aquaverse Process Cyan ink. The concentric adjustments screws of the press were adjusted so that the plate cylinder contacted the anilox roll, but not the substrate. While the press was running, the raw plate on the 3 inch plastic core was lowered onto the relief plate in such a way that about half of the plate was printed with the microcell pattern. The raw plate was then laminated with a LAMS coversheet as described in the “Preparation of Test Printing Plate Precursors” section. The finished relief plate was then created as described in the section “Conversion of Test Printing Plate Precursors to Relief Printing Plates”. The finished plate was then printed on a Mark Andy 830 press using Sun Chemical TXLFW5834901 Aquaverse Process Cyan ink on biaxially oriented polypropylene film. Print measurements were then taken using a PIAS-II™ image quality analysis unit from Quality Engineering Associates. The results for the area with and without the preprinted microcell pattern are shown below. These results shown that the preprinted microcell pattern improved both the print density and the graininess of the final print. AreaCyan Density MeanCyan Density GraininessWithout the Preprinted1.451.1microcell patternWith the Preprinted1.580.8microcell pattern | 118,297 |
11858253 | DETAILED DESCRIPTION A machine01, for example a printing press01, in particular a security printing press01, for generating optically variable image elements03on a substrate02, for example a web-format or sheet-format printing substrate02, comprises an application device04, for example a printing unit04, by which optically variable coating agent06, for example optically variable printing ink06or varnish06, at at least one application point, for example printing nip, can be applied to at least one first side of the substrate02, for example of the printing substrate02, across the entire surface area or in partial regions in the form of print image elements08, and a device07for aligning particles P that are contained in the optically variable coating agent06applied to the substrate02and that are responsible for the optical variability (see, for example,FIG.1). In the following, this device07is also referred to as an alignment device07for short or, since it produces an image of the optically variable pattern or motif as a result of a defined alignment of the particles P, is also referred to as an image-producing alignment device07. An application of coating agent06that contains particles P and a subsequent image-producing alignment are schematically shown, for example, inFIG.2on the left side (FIG.2a)) based on the illustration of the numeral I by way of the alignment of previously randomly oriented particles P. The Roman numeral I denotes a state I in which the coating agent06has been applied and is present in randomly oriented form, and numeral III denotes a state III in which an image-producing alignment has taken place. The print image elements08made up of a variable coating agent06, which are applied onto the substrate02by the application unit04prior to the treatment by the alignment device07can correspond to the optically variable image elements03to be generated in terms of size and position, or possibly may also be larger than these, and possibly can even extend across the surface area of several multiple-up copies09. In the case of larger print image elements08, for example, an optically variable image element03is not generated by alignment on the entire surface area that is coated with optically variable coating agent06. The particles P responsible for the optical variable contained here in the coating agent06, for example the printing ink06or the varnish06, are magnetic or magnetizable, non-spherical particles P, for example pigment particles P, hereafter also referred to as magnetic flakes for short. They preferably have a non-spherical, flat shape, having a longitudinal axis extending in the direction of the longest extension, an axis extending perpendicularly thereto in the direction of the width, and a thickness extending with respect to both axes and being smaller compared to the length and width. The machine01is preferably designed to produce multiple-up copies09, for example securities09, in particular banknotes09, or intermediates of such securities09, for example print images of multiple printing substrate sections containing such securities09. The substrate02, for example printing substrate02, can be formed by, for example cellulose-based or preferably cotton fiber-based paper, by plastic polymer or by a hybrid product thereof. It may be uncoated, or may already have been coated, prior to being coated in the aforementioned application device04, and it may be unprinted or already have been printed once or multiple times or have been mechanically processed in another manner. On a longitudinal section of web-format substrate02or a sheet of a sheet-format substrate02, preferably several multiple-up copies09, for example banknotes09to be produced, are arranged in a row next to one another, and several such rows of multiple-up copies09or their print image are arranged one behind the other in the transport direction T or are to be arranged in the course of the processing operation of the substrate02(indicated, for example, inFIG.2). The machine01designed as a printing press01can generally comprise one or more printing units04including one or more printing mechanisms of arbitrary printing methods. In a preferred embodiment, however, it comprises a printing unit04comprising at least one printing mechanism11;12operating according to the flexographic printing method, or preferably according to the screen-printing method, by which the optically variable coating agent06is or can be applied onto a first side of the printing substrate02. A greater film thickness, compared to other printing methods, can be applied by the described printing methods, in particular the screen-printing method. The expression of the “first side” of the substrate02or printing substrate02is selected arbitrarily and is intended to refer to the side of the printing substrate02onto which the optically variable coating agent06is or was or can be applied. In the illustrated and preferred embodiment, the printing press01comprises a printing substrate infeed13, for example a roll unwinder13, or preferably a sheet feeder13, from which the, for example, web-format or preferably sheet-format, printing substrate02is or can be fed, possibly via further printing or processing units, to the printing unit04, for example flexographic or in particular screen printing unit04, which applies the optically variable coating agent06and comprises at least one printing mechanism11;12, for example flexographic, and in particular screen printing, mechanism11;12. In the illustrated and advantageous embodiment, two screen printing mechanisms11;12are provided, which are preferably combined in the same printing unit04and, between a respective forme cylinder14;16, for example in a screen printing cylinder14;16, and a shared impression cylinder17, form two printing nips for the same, here the first, side of the printing substrate02(see, for example,FIG.4). As a result of being designed as a screen-printing mechanism11;12, it is also possible to apply coating agent06in a greater film thickness. A drying and/or curing device18, for example a UV dryer18, which is directed at the first side of a printing substrate02to be conveyed through the printing unit04, can be provided in the transport path between the two printing nips. Optically variable coating agent06can be applicable or be applied with only one or both of the screen-printing mechanisms11;12. Preferably, the printing mechanism11;12comprises a forme cylinder14;16as the image-producing cylinder, including a multiplicity of, in particular like and/or identical, image-producing print motifs or, in particular like and/or identical, groups of image-producing print motifs around the circumference, which, on a circumferential length corresponding to a print image length, are arranged in multiple, for example a number, for example, between four and eight, in particular between five and seven, for example six, columns that are arranged equidistantly from one another transversely to the transport direction T and, on a cylinder width corresponding to the print image width, in multiple rows that are arranged equidistantly from one another in the transport direction T. In the case of a printing mechanism11;12operating according to the flexographic printing method, these print motifs are designed in the manner of letterpress print reliefs, and in the case of the preferred case of a printing mechanism11;12operating according to the screen-printing method, they are designed in the manner of screen-printing stencils. From the printing unit04applying the optically variable coating agent06, the printing substrate02can be fed via conveying means of a first conveyor device19to the alignment device07. In the case of web-format printing substrate02, this can be one or more positively driven or non-driven rollers, via which the printing substrate02can be guided or is guided on the input side into the alignment device07. For the preferred case of sheet-format printing substrate02, that is, individual printing substrate sheets02passing through the machine01, sheet-conveying means are provided as conveying means. In an embodiment that is not shown, these sheet-conveying means can be formed by one or more transfer cylinders or drums, which receive the printing substrate sheet02from the printing unit04, for example from the impression cylinder17, and possibly deliver it via one or more further transfer cylinders or drums on the input side to the alignment device07. In the embodiment shown here, however, the first conveyor device19is designed as a revolving gripper conveyor19, for example as a so-called chain gripper system19, which comprises continuous drawing means21, for example continuous chains21, revolving on both sides of the frame and carrying gripper bars22that extend transversely to the transport direction T. Due to the gripper bars22, leading sheet ends can be gripped, and the printing substrate sheets02can thus be transported along the conveyor path and, at the destination, be delivered to the appropriate conveying or receiving means. Preferably, a respective sprocket wheel23;24, also referred to as a chain gripper wheel23;24, is located at least in the receiving area of the printing substrate sheet02from the printing unit04and in the region of the transfer of the same to the alignment device07. After having passed through the alignment device07, which is described in greater detail below, the printing substrate02can be guided via conveying means of a further, for example second, conveyor device26to a product receiving system27for receiving the printing substrate02that has been processed and/or worked in the machine01, for example a winder27in the case of web-format printing substrate02or a pile delivery27in the preferred case of sheet-format printing substrate02. For the case of web-format printing substrate02, this can again be one or more positively driven or non-driven rollers, which continue the transport path of the first conveyor device19through the alignment device07and via which the printing substrate02can be guided or is guided on the input side into the winder27. For the preferred case of sheet-format printing substrate02, sheet-conveying means are provided as the conveying means. These can be formed, as described above, by one or more transfer cylinders or drums, which receive the printing substrate sheet02from the alignment device07and deliver it downstream to the pile delivery27. Preferably, the second conveyor device26, similarly to the first conveyor device, is designed as a revolving gripper conveyor26, for example a chain gripper system26, comprising revolving continuous drawing means28, for example continuous chains28, one or more sprocket wheels31or chain gripper wheels31, as well as gripper bars29, which receive the printing substrate sheets02from the transport path section of the alignment device07and, for example, feed them to the pile delivery27(see, for example,FIG.1). An additional drying device comprising one or more dryers32, for example radiation dryers32, directed at the first side of the printing substrate02, can be provided at the transport path leading away from the alignment device07. In a refinement that is not shown, a cooling unit is provided on the transport path between the alignment device07and the pile delivery27, in particular downstream from the additional drying device in the transport path between the alignment device07and the product receiving system27. This cooling unit can be designed as a cooling roller, for example, which is arranged between the second conveyor device26coming from the alignment device07and a third conveyor device, for example likewise designed as a revolving gripper conveyor, for example a chain gripper system. In a refinement, an inspection device, which is not shown, for example an area scan camera or a line camera, can be provided and, for example, be directed at a circumferential surface segment, located in the transport path, of the roller designed as a cooling roller or in another manner. Even though the alignment device07described hereafter in detail is essentially arbitrary in terms of its designs, variant embodiments or configurations, it is preferably provided or can be provided in an above-described machine01or printing press01. In an advantageous embodiment, it is designed in the manner of a module and can be inserted into the transport path of the machine01to be fitted therewith using input-side and output-side interfaces to the open section ends of a conveyor system, which continues upstream and downstream. The alignment device07for creating optically variable image elements03, for example for creating the optically variable effect in the optically variable coating agent06applied previously, for example in the form of print image elements08, onto the substrate02, in particular printing substrate02, has a defined transport path along which the substrate02to be conveyed through the alignment device07is fed or can be fed from an entrance area, in which the substrate02to be treated and comprising, on its first side, variable coating agent06, is brought into operative connection in a defined manner with an alignment device33;33′ that generates magnetic fields and comprises magnets44, preferably in such a way that the magnets44of the alignment device33;33′ which serve image-producing orientation purposes and the printing substrate02printed with the printing ink06containing the particles P move synchronously with respect to one another, at least on a section of the transport path. The alignment device33;33′ is preferably designed as a magnetically active cylinder33;33′, magnetic cylinder33;33′ for short, which around the circumference comprises the arrangement of magnets44and over which the printing substrate02is guided or conveyed in the direction of an exit area of the alignment device07. Preferably, the printing substrate02is guided, with the previously printed image elements03pointing to the outside, over the magnetic cylinder33;33′. In addition to a one-piece or individual, possibly engraved permanent magnet or individual solenoid, the term “magnet”44here shall also be understood to mean a plurality of individual permanent magnets and/or solenoids, which are combined to form a magnetically acting unit44, for example so as to induce, for example by overlap, a certain external magnetic field deviating in particular from the field of an individual magnetic dipole. The first side comprising the optically variable coating agent06shall, in particular, be understood to mean the side onto which the optically variable coating agent06can be applied or is being or has been applied, for example upstream in the transport path, by the application device04. For a simpler distinction of the term compared to further alignment devices42;43described in more detail below, the aforementioned first alignment device33;33′ introducing the image information here is also referred to, for short, as “image-producing” alignment device33;33′ within the meaning of an introduction of image information caused by the magnetic action of the alignment device33;33′. A production of an image shall be understood to mean any, in particular inhomogeneous, image information caused by an, in particular inhomogeneous, alignment of the magnetic particles, which can generally be a pattern, alphanumeric symbols, a graphical representation, or a combination thereof. Generally, it is also possible for two such first or image-producing or image information-introducing alignment devices33;33′, in particular cylinders33;33′, to be provided in the transport path, which are arranged on the same side, or else on different sides, of a substrate02to be conveyed along the transport path (see, for example,FIG.5). In the example ofFIG.5, these are arranged on the same side of the transport path, wherein a cylinder34designed as a transport or transfer cylinder34is provided therebetween. In the embodiment comprising a first or image-producing or image information-introducing alignment devices, at least one further alignment device42;43can be assigned to this first alignment device33; upstream and/or simultaneously. In the embodiment comprising two first or image-producing alignment devices, however, at least one further alignment device42;43can be assigned to each alignment device33;33′ upstream and/or simultaneously. In addition to the image-producing first alignment device33;33′ within the above meaning or the magnetic cylinder33;33′, in a first particularly advantageous embodiment at least one further alignment device42, which serves pre-orientation purposes and comprises a plurality of magnets46, arranged in a stationary manner in the machine or device during operation, is arranged upstream from the first alignment device33in the transport path of the substrate02to be conveyed in such a way that this alignment device can induce a pre-orientation of the particles P, in surface areas that are at least adjacent to the image-producing partial regions. In particular, the magnets46in this second alignment device42are configured and oriented in such a way that the particles P of the surface area passing through their active region are at least aligned with respect to the progression of their longitudinal axis in the substrate plane, for example parallel to one another or homogeneously in another manner. The magnets46of this second alignment device42, however, are preferably configured and oriented in such a way that the particles P of the surface area passing through their active region are biaxially aligned, for example parallel to one another or homogeneously in another manner, so that a homogeneous optical impression is created across this surface area. This means, for example, that the particles P are aligned, for example parallel to one another or homogeneously in another manner, both with respect to their longitudinal direction and with respect to the progression in the direction of the width. Even though, ideally, a homogeneous, substantially parallel alignment is to be preferred over a background for a subsequent application of image information, in a broader sense a homogeneous optical impression or a homogeneous alignment can also be interpreted as a color or intensity profile that changes steadily in one direction, that is, without step-like perceptible changes. Such a profile arises, for example, from an inclination of the relevant axis profile changing only slowly and steadily, that is, without step-like changes, in one direction. In an embodiment to be preferred, the magnets46are configured and arranged in such a way that their resulting magnetic fields align the particles P, which, for example, are planar and have a length that is larger compared to the width, in the relevant surface area of the image element03with their flat side parallel to the substrate surface and/or with their longitudinal extension all pointing in the same direction. In addition to a one-piece or individual, possibly engraved permanent magnet or solenoid, the term “magnet”46here shall in particular also be understood to mean a plurality of individual permanent magnets and/or solenoids, which are combined to form a magnetically acting unit46, for example so as to induce, for example by overlap, a certain external magnetic field deviating in particular from the field of an individual magnetic dipole. These are preferably present in the form of a magnetically acting unit46as a result of a complex structure made of a plurality of permanent magnets. In an embodiment that is not shown, in which a further alignment device for the pre-orientation of particles P is arranged upstream from a first alignment device33;33′ designed as a magnetic cylinder33;33′, and a transport cylinder (for example comparable to the transport cylinder34) is arranged upstream for the conveyor device19arranged upstream from the magnetic cylinder33;33′ instead of a revolving gripper conveyor19, the further alignment device42provided for pre-orientation purposes is preferably designed, as shown inFIG.5, around the circumference of the transport cylinder34, and preferably with curved magnets46′. Instead, or preferably in addition to this first further alignment device42, in a particularly advantageous embodiment or refinement, a further alignment device43, which serves simultaneous orientation purposes and comprises one or more magnets47, is provided, which is arranged at the transport path, on the side of the transport path located opposite the first alignment device33, in such a way that identical and/or mutually adjacent surface areas of an identical image element03, which is to be produced by applying the coating agent onto the substrate02, at the same time cooperate, at at least one point in the transport path, with the first and with the further alignment devices33;43serving a simultaneous orientation of particles P. In other words, particles P of an image element03are or have been acted upon by an aligning force at at least one point of the transport path by the magnetic field of a magnet44of the first alignment device33and, at the same time, the same and/or other particles P of the same image element03are or have been acted upon by an aligning force by the magnetic field of a magnet47of the further alignment device33serving simultaneous orientation purposes. In addition to a one-piece or individual, possibly engraved permanent magnet or solenoid, the term “magnet”47here shall also be understood to mean a plurality of individual permanent magnets and/or solenoids which are combined to form a magnetically acting unit47, for example so as to induce, for example by overlap, a certain external magnetic field deviating in particular from the field of an individual magnetic dipole. These are preferably present in the form of a magnetically acting unit44as a result of a complex structure made of a plurality of permanent magnets. FIG.2on the right side (FIG.2b)) schematically shows the action of a pre-orientation and/or simultaneous orientation, wherein the Roman numeral II represents a state II in which the coating agent06was, for example, pre-oriented or simultaneously oriented, an image-producing alignment within the above meaning, however, has not yet taken place or was disregarded in the illustration. Details and preferred embodiment details regarding a further alignment device42serving pre-orientation purposes and regarding a further alignment device43serving simultaneous orientation purposes are described in greater detail below. The first or only magnetic cylinder33is arranged in the transport path of the substrate02to be conveyed, preferably on its second side, so as to point outwardly with its first side, which is coated in particular upstream in-line with optically variable coating agent06, while being transported over the first or only magnetic cylinder33. In the region of its outer circumference, the magnetic cylinder33comprises a plurality of magnets44, which are used to orient at least some of the magnetic or magnetizable particles P of the coating agent06applied onto the passing printing substrate02. Here, in general, magnets shall be understood to mean magnetically active devices that, permanently or switchably, at least toward the side of the transport path, induce a magnetic field (that is sufficiently strong, in particular for aligning particles P contained in the coating agent06on the substrate02being guided over the same, as described here). The magnets44can be formed by one or more permanent magnets with or without engraving, by solenoids, or by combinations of one or more permanent magnets and/or one or more solenoids. Regardless of whether a single magnet or a combination of multiple magnetic elements, for example permanent magnets and/or solenoids is involved, associated magnetic elements that, collectively, form an acting unit are referred to hereafter as magnets44for short. Such a magnet may, for example, be joined from several differently oriented permanent magnets, which in sum supply an outwardly active magnetic field. For the case of the aforementioned plurality of multiple-up copies09per substrate02, for example per substrate section or printing substrate or substrate sheet02, several rows of magnets44that are spaced apart from one another transversely to the transport direction T are provided, or can be provided, around the circumference, which, when rolled out on the substrate02, correspond to the pattern of the image elements03to which magnetic fields are to be applied on the substrate02. The aforementioned guidance of the substrate02over the magnetic cylinder33, wherein, for example, its first side points outwardly when transported over the first cylinder33, results in the particles P being aligned or oriented by means of the magnets44, here, for example, through the substrate02. The non-fitted cylinder is also referred to as cylinder body here, which can be fitted with magnets44and is active as a magnetic cylinder33. Preferably, the magnets44are arranged or can be arranged detachably, possibly together with a corresponding mount, at the cylinder33in such a way that they, in the mounted state, can be arranged at a defined location around the circumference of the cylinder33and can preferably be completely removed from the cylinder33and/or can be positioned around the circumference of the cylinder33in the axial and/or circumferential directions. For this purpose, the magnets44can be arranged or are arrangeable in or at multiple, for example between four and eight, in particular between five and seven, for example six, ring elements37that can be axially spaced apart from one another and preferably be positioned in the axial direction, wherein in or at these ring elements37, in turn, in each case at least one, preferably multiple, for example between two and twelve, advantageously between five and ten, magnets44are arranged or can be arranged one behind the other in the circumferential direction and preferably are positioned or can be positioned in the circumferential direction (see, for example,FIG.6). In the region of their outer circumference, the ring elements37are closed, for example, by peripheral coverings48, for example covers48connected in one piece to the ring ribs or cover plates48placed thereon, in which, for example, aforementioned suction openings49as well as cut-outs, which are not denoted in detail, are provided at the respective location of the magnetic elements44(indicated, by way of example, for a portion of the right ring element37inFIG.6). As an alternative, a cover plate48that extends axially across all ring elements37can be provided, which has cut-outs and/or suction openings49at the relevant points. The suction openings49, in particular suction channels51therebeneath, have a line connection to a vacuum pump, for example via an end-face rotary feedthrough. For the case of web-format substrates02, the magnetic cylinders33can be designed without any holding means acting on the substrate02. If necessary, the aforementioned suction air openings can be provided around the circumference, which are connected to a vacuum pump and ensure that the substrate02rests securely on the outer cylindrical surface. For the case of sheet-format substrate02preferred here, holding means36, for example grippers36of a so-called gripper bar, are provided around the circumference of the cylinder33, by which a substrate sheet02to be conveyed via the cylinder33can be received at its leading end, and can be held or is held during a rotation of the cylinder33over an angular region. A magnetic cylinder33configured in this way at the same time serves to transport the substrate02. The magnetic cylinder33is rotatably mounted on both sides in frame walls38;39, for example side parts38;39of a frame carrying the components of the alignment device07. As was already mentioned above, applied particles P, for example at least in a surface area that is relevant for the image or motif to be represented, prior to cooperating with the alignment device33;33′ provided for the image-producing alignment and/or upstream thereof and/or at at least a point in time or during a time period during the cooperation with the alignment device07provided for the image-producing alignment, can be oriented with the aid of at least one further alignment device42;43serving pre-orientation and/or simultaneous orientation purposes (see, for example,FIG.8toFIG.12). The effect of such a pre-alignment is illustrated based on the schematic representations inFIG.2, where on the left side,FIG.2a), an alignment using only the image-producing alignment device33;33′ is outlined, and on the right side,FIG.2b), an alignment using at least one of the further alignment device42;43inducing a pre-orientation and/or simultaneous orientation is outlined for comparison. In the case of the latter, for example, particles P, instead of being present with random orientation outside of an image motif or pattern, are organized, for example, parallel or homogeneously in another manner, and thus form a background that provides improved contrast for a pattern or image motif having differently oriented particles P. The further alignment device42serving pre-orientation purposes is preferably fixed to the frame at the transport path during normal operation. Preferably, the magnets46of the further alignment device inducing a pre-orientation are provided on the side of the transport path, which is located opposite the side on which, in the upstream transport path, most recently a printing operation was carried out or onto which the coating agent06was applied. This means, the magnets46are preferably provided on the side of the conveyed substrate02that was not most recently or freshly printed. Even though, generally, a one-piece or multi-piece magnet46that continues across the entire active width of the alignment device42can be provided, the further alignment device42provided for pre-orientation purposes preferably comprises, transversely to the transport direction T, a plurality, for example between four and eight, in particular between five and seven, for example six, magnets46, which are spaced apart from one another transversely to the transport direction T. In this way, disruption due to undesirable field overlaps is minimized. So as to be able to carry out adaptations by replacement and/or so as to be able to achieve operation without pre-orientation in a simple manner, the magnets46of the further alignment device42are detachably arranged at a supporting frame52. In addition, or as an alternative, the supporting frame52, including the magnets46, can be removably arranged in the frame of the alignment device07. In a particularly advantageous refinement of the magnets46that can be detached and removed from the supporting frame52, these can be exchanged for filler pieces56, for example, guide plates56. This enables an operation without this additional alignment and without the positions of the particles P being “disturbed” by the magnets46. At the same time, the substrate02is protected by the filler pieces56against damage. For removing or inserting magnets46, for example, a gripper tool63, for example a handle63, is provided, which comprises magnetic or magnetizable elements in the region cooperating with the magnet46. So as to avoid localized contact of the handle63with the magnet surface, the handle63can comprise a plate that can be placed in a planar manner on the magnet surface. In an advantageous embodiment, the filler piece56can be made of a magnetizable material, for example a magnetizable stainless steel. In this embodiment, the filler piece, for removal or for insertion, can likewise be held by a releasable gripper tool64, for example a releasable handle64, which comprises, for example, magnetically active elements, for example one or more permanent magnets, in the region cooperating with the filler piece56. In an advantageous embodiment, the magnets46of the further alignment device42serving pre-orientation purposes are arranged at the supporting frame52so as to be adjustable in a horizontal direction transversely to the transport direction T, for example in order to allow multiple-up copies09of differing formats and/or multiple-up copies09including image elements03that are differently positioned on the multiple-up copy09to be produced. For this purpose, the magnets46of this further alignment device42are mounted so as to be transversely movable at one or more cross members53, for example in one or more guides57, for example linear guides57. For fixation in the desired position, a holding device58, for example a clamping mechanism58, is provided, which can preferably be operated manually and without tools. This may be a hand wheel, for example, by which a screw bolt can be set against and removed from the cross member53carrying the magnet46. For example, so as to be able to establish and/or ensure a defined distance between the magnet46, the substrate02or the transport path thereof, the magnets46rest against stop means59, as viewed in the direction perpendicular to the transport path. Preferably, the magnets44are acted upon or can be acted upon by a spring force, for example by one or more spring elements62, with a force pointing in the direction of the transport path, and in particular against the stop means59. The stop means59can be designed adjustably as a fitted element59and, for example, be effectuated by a fitted bolt59. Depending on the arrangement, the head of the fitted bolt can form the stop or, as is shown here, the lower head ring or a washer held by the same. Preferably, the magnet46of the further alignment device42is fixed or can be fixed by the fitted bolt59to a mount54, wherein, for example, the distance with respect to the transport plane of the substrate02can be adjusted by the screw-in depth. In an advantageous embodiment, the magnet46can be easily detached from the supporting frame52, for example from a mount54, for example a rider54, that carries the magnet46and is arranged in particular so as to be transversely movable on the cross member53. In the process, on its upper side the rider54can comprise a carrier plate69on which the magnet46is attached. The magnet46of the further alignment device42is held, for example, by way of a connection59,61;67;68that is positively active in the direction of the transport path, which can be released by a movement of the magnet46having at least one movement component that is located in a plane extending parallel to the transport plane. Such a positive connection can, for example, be formed on a side, for example at an end, by the aforementioned fitted bolt59and an in particular keyhole-shaped cut-out61in the manner of an accordingly shaped elongated hole or slot61, and, for example, corresponding thereto, on another side, for example the other end, likewise by a stop means67that, for example, is active in the direction of the transport path, for example in the above-described manner a fitted bolt67that is active as a fitted element67, which likewise engages in a cut-out68, for example a likewise keyhole-shaped elongated hole68or preferably a slot68that is open at the edge (see, for example,FIG.11). The fitted bolts59;67and cut-outs61;68can be recessed in troughs65, for example so-called pockets65, comprised by the magnet46, striking with the stop surface thereof against the bottom of the trough65or, in the case of a bottom receiving the magnet46, against the same. In an advantageous refinement, a blower device78can be provided, by which the substrate02is pressed against the magnets46. The blower device78can comprise a blower tube79, which extends transversely to the transport direction T and has blower air openings pointing in the direction of the transport path, which is supplied via a supply line from a blower air source. In this way, a defined position is achieved and/or, due to the close contact, a substantially homogeneous magnetic field is induced in the coating. If the transport occurs via a revolving gripper conveyor19, all or at least one or more of the grippers of the gripper bar22can be made of a non-magnetic or non-magnetizable material. As was already mentioned above and is illustrated inFIG.1,FIG.4andFIG.8toFIG.10, the magnets46of the further alignment device42inducing a pre-orientation can be arranged at a linear transport path section and, at least on the side facing the transport path, can have a planar shape that is elongated in the transport direction T. This is the case, for example, when the conveyor device19includes a linear section in the region of the alignment device42. In particular in the case that, however, a curved transport path section, for example a transport cylinder34, is arranged upstream from the alignment device07or the image-producing alignment device33;33′, the magnets46of the further alignment device42can be arranged at a curved transport path section, which is formed, for example, by a circumferential section of such a rotating transport means, and, at least on the side facing the transport path, can have a curved, in particular circular segment-like, shape that is elongated along the transport path. Instead of the aforementioned first further alignment device42, or preferably in addition thereto, the aforementioned second further alignment device43comprising one or a plurality of magnets47is advantageously provided, which is arranged at the transport path on the side of the transport path which is located opposite the first alignment device33. This alignment device43serving orientation purposes is also preferably fixed to the frame at the transport path during normal operation. The magnets47of this alignment device43are preferably provided around the circumference of the image-producing alignment device33, designed as a magnetic cylinder33, on the opposite side of the transport path. Preferably, the further alignment device43provided for simultaneous orientation comprises, transversely to the transport direction T, a plurality, for example between four and eight, in particular between five and seven, for example six, magnets47that are spaced apart from one another transversely to the transport direction T. Preferably, the magnet or magnets47of this further alignment device43is or are arranged at a supporting frame71, which is mounted so as to be able to vary the position thereof in a frame of the device in such a way that the magnets47can be moved from a working position into a makeready or inactive position at a distance with respect to the transport path which is greater compared to the working position, and vice versa. Preferably, the supporting frame71carrying the magnets47of the further alignment device, for this purpose, is pivotably mounted about an axis72extending transversely to the transport direction T, for example a pivot axis72, in a frame of the alignment device07. In a particularly advantageous embodiment, for example with respect to high product variability, the magnets47of the further alignment device43are arranged at the supporting frame71so as to be movable or adjustable in a horizontal direction transversely to the transport direction T. For this purpose, the magnets47of the further alignment device43are, for example, transversely movably mounted at one or more cross members73. They can be fixable in a desired position by a holding device76designed as a clamping mechanism76, which is comparable, for example, to the above clamping mechanism58. For this purpose, the magnets47of this further alignment device43are mounted so as to be transversely movable at one or more cross members77, for example by way of an appropriate mount77, for example one or more riders77, guided in one or more guides74, for example linear guides74. In particular in the case of the preferred embodiment of the image-producing alignment device33,33′ serving as magnetic cylinders33;33′, the magnets47of the further alignment device43serving simultaneous orientation purposes are arranged at a curved transport path section, in particular at the circumference of the magnetic cylinder33,33′, and, at least on the side facing the transport path, have a curved, in particular circular segment-like, shape that is elongated along the transport path. Regardless of the arrangement of only one or both of the further alignment devices42;43at the transport path, in an embodiment that is to be preferred, a drying and/or curing device41;41′ is arranged so as to act on a point of the transport path still located in the active region of the image-producing alignment device33;33′. In a particularly advantageous embodiment of the drying and/or curing device41;41′, this device is directed at a circumferential section, located in the transport path, of the first alignment device33designed as a magnetic cylinder33;33′. Such a drying and/or curing device41;41′ is preferably implemented as a radiation dryer41;41′, in particular as a UV radiation dryer41;41′ and/or as an LED dryer41;41′, in particular as a UV LED dryer41;41′. In an advantageous embodiment of the machine01, the respective further alignment device42;43preferably comprises a number of magnets46;47corresponding to the number of the aforementioned columns, for example between four and eight, in particular between five and seven, for example six, which are arranged in the transport path in such a way that the print motifs or groups of image-producing print motifs along the transport path in each case are at least partially aligned with the lateral position of the magnets46;47of the relevant further alignment device42;43. Although the disclosure herein has been described in language specific to examples of structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described in the examples. Rather, the specific features and acts are disclosed merely as example forms of implementing the claims. | 42,232 |
11858254 | DETAILED DESCRIPTION Methods and systems of actively cooling a card while the card is within a card processing machine are described where one or more cooling stations are provided within the card processing machine to actively cool the card prior to performing a processing operation, during a processing operation, and/or after a processing operation on the card in order to reduce a temperature of the card or a surface of the card. Actively cool, active cooling, and the like as used herein are intended to mean that energy is consumed in the process of cooling the card. In this case, an energy consuming mechanism is provided within the card processing machine at a suitable location to interact with the card in order to reduce the temperature of the card. In one example, the energy consuming mechanism is a fan that is provided within the card processing machine to blow air (or other gas) onto the card to reduce the temperature of the card. Other energy consuming mechanisms can be used as well. Active cooling could be applied directly to the card itself, or to a structure that the card is in contact with so that the structure in contact with the card operates like a cooling plate to cool the card. In another embodiment, passive cooling can be utilized or is used separately from and in addition to active cooling. With passive cooling, an energy consuming device is not used to cool the card. Instead, the card can be transported to a desired location in the card processing machine and stopped or “parked” for a period of time allowing the card to passively cool. Therefore, actively cool, active cooling, and the like as used herein is distinguished from and is different than passive cooling. Reducing the temperature of the card includes and encompasses, but is not limited to, reducing the temperature of the entire card so that the card has a substantially uniform temperature, reducing the temperature of a surface of the card so that the surface has a temperature that is lower than the remainder of the card, and reducing the temperature of one surface of the card so as to cause a reduction in the temperature of the other surface of the card so that a temperature differential exists across the thickness of the card. A card processing machine as used herein is intended to encompass, but not be limited to, both desktop card personalization machines and central issuance card personalization machines. A desktop card personalization machine is a type of machine that is typically designed for relatively small scale, individual card personalization and production, for example on the order of tens or hundreds per hour. In these machines, a single card to be personalized is input into the printer, which typically includes one or two personalization/processing capabilities, such as printing and laminating. These printers are often termed desktop printers because they have a relatively small footprint intended to permit the machine to reside on a desktop. Many examples of desktop printers are known, such as the SD or CD family of desktop card printers available from Entrust Datacard Corporation of Shakopee, Minnesota Other examples of desktop card printers are disclosed in U.S. Pat. Nos. 7,434,728 and 7,398,972, each of which is incorporated herein by reference in its entirety. A central issuance card personalization machine is typically designed for large volume batch production of personalized cards, often employing multiple processing stations or modules, including one or more printing mechanisms, to process multiple cards at the same time to reduce the overall per card processing time. Examples of central issuance card personalization machines include the MX and MPR family of central issuance machines available from Entrust Datacard Corporation of Shakopee, Minnesota Other examples of central issuance machines are disclosed in U.S. Pat. Nos. 4,825,054, 5,266,781, 6,783,067, and 6,902,107, all of which are incorporated herein by reference in their entirety. The card may be referred to herein as a plastic card or just a card. A plastic card encompassed herein includes, but is not limited to, financial (e.g., credit, debit, or the like) cards, driver's licenses, national identification cards, business identification cards, gift cards, and other plastic cards which bear personalized data unique to the cardholder and/or which bear other card information. A plastic card is primarily made of plastic materials but can include materials other than plastic. In some embodiments, the card may be made primarily of materials other than plastic. Examples of processing operations that can be performed on the card in the card processing machine include, but are not limited to, retransfer printing on one or both surfaces of the card, direct to card printing on one or both surfaces of the card, laminating one or both surfaces of the card, embossing or indenting one or both surfaces of the card, applying a security feature such as a hologram to one or both surfaces of the card, programming a magnetic stripe on the card, contact or contactless programming of an integrated circuit chip on the card, and other known card processing operations. Further information on the construction and operation of a card processing machine that can employ the active cooling described herein is disclosed in US Published Application No. 2016/0300128, the entire contents of which are incorporated herein by reference. Referring now toFIG.1, an example of a card processing machine10that employs active cooling is illustrated. The card processing machine10includes a housing12having a front side14, rear side16, top side18, and a bottom side20. The card processing machine10includes a card input22for inputting cards into the card processing machine10. The card input22can be located at any position on the card processing machine10. In the illustrated example, the card input22is located at the front side14of the housing12. However, the card input22could be located at the rear side16, the top side18or the bottom side20. Cards are input one-by-one into the machine10along a card travel path24. The card input22can be an input slot through which a single card is fed, or as in the illustrated example, the card input22can be a card input hopper that holds a plurality of cards waiting to be input and processed in the card processing machine10. The card processing machine10also includes a card output26into or through which processed cards are output from the interior of the card processing machine10. The card output26can be located at any position on the card processing machine10. In the illustrated example, the card output26can be located at the front side14of the housing12. However, the card output26could be located at the rear side16(seeFIG.1), the top side18or the bottom side20(seeFIG.1). Processed cards are output one-by-one from the machine10into or through the card output26. The card output26can be an output slot through which a single processed card is discharged, or as in the illustrated example, the card output26can be a card output hopper that holds a plurality of cards after being processed in the card processing machine10. Still referring toFIG.1, the card processing machine10also includes at least one card processing station30that is configured to perform a processing operation on the card. Examples of card processing stations30include, but are not limited to, a retransfer printing station that performs retransfer printing on one or both surfaces of the card, a printing station that performs direct to card printing on one or both surfaces of the card, a laminator that performs laminating one or both surfaces of the card, an embosser or indenter that performs embossing or indenting one or both surfaces of the card, a foil or patch applicator that applies, for example by lamination, a security feature such as a hologram to one or both surfaces of the card, and other known card processing stations. For sake of convenience, the card processing station30will be described with further reference toFIG.2as being a retransfer printing station that performs retransfer printing. An example of a card personalization machine that can perform retransfer printing is described in U.S. Published Application No. 2016/0300128, filed on Apr. 8, 2016, which is incorporated herein by reference in its entirety. The general construction and operation of retransfer printers, including the print ribbon, the retransfer film, printing an image on the retransfer film, and transferring the printed image onto a surface of a card, is well known in the art. The retransfer printing station illustrated inFIG.2includes a print side that includes print ribbon supply32from which a supply of monochrome or multi-color print ribbon34is supplied, and a print ribbon take-up36that takes-up used print ribbon34. The print ribbon is directed past a print head38, which in the illustrated example can be stationary, which transfers dye or pigment ink from the print ribbon34onto a retransfer film40. After printing, the used print ribbon34is then wound onto the take-up36. The retransfer film40is supplied from a film supply42on a retransfer side, and after retransfer the remaining film is wound onto a film take-up44also on the retransfer side. The retransfer film40is directed past a platen roller46positioned opposite the print head38and which in the illustrated example can be moved toward and away from the print head38to press the retransfer film40and the print ribbon34between the print head38and the platen roller46during printing onto the retransfer film40. Once a desired image is printed onto the retransfer film40, the section of the retransfer film40with the printed image thereon is advanced to a transfer station48where the printed image on the retransfer film40is transferred onto a surface50, such as the rear surface, of a card52. The surface50can include features such as a signature panel that provides a location for the intended card holder to sign their name, text, graphics, and other features commonly found on the rear surfaces of plastic cards. In this example, the transfer station48includes a heated transfer mechanism54, for example a transfer roller, that is movable toward and away from a fixed platen56positioned on the opposite side of the card travel or transport path24. The heated transfer mechanism54presses the portion of the retransfer film40containing the printed image against the surface50of the card52which is backed by the platen56, with the retransfer film40and the card52then being transported together past the heated transfer mechanism54to transfer the layer of the retransfer film40containing the printed image onto the card surface50. The retransfer film40and the card52are then transported to a stripping station60that includes a stripping mechanism where the retransfer film40is stripped from the card surface50leaving behind the printed image on the card surface50. The remainder of the retransfer film40, minus the transferred image, is then wound onto the film take-up44. Returning toFIG.1, a card reorienting mechanism66(or card flipper66) is located downstream of the stripping station60in the card travel path24. The card reorienting mechanism66can receive the card52after the printed image has been applied to the surface50, and flip the card52over (i.e. flip the card 180 degrees) so that the opposite surface68, such as the front surface, is now facing upward. The surface68can include features such as the intended card holders name, an account number, a portrait image of the intended card holder, text, graphics, and other features commonly found on the front surfaces of plastic cards. The card52can then be transported back upstream of the transfer station48in order to retransfer print a printed image onto the surface68. Examples of card reorienting mechanisms are described in U.S. 2013/0220984 and U.S. Pat. No. 7,398,972 each of which is incorporated herein by reference in its entirety. In some embodiments, in the case of retransfer printing, the rear surface50is printed first followed by printing on the front surface68. However, other printing sequences can be used. The card52is transported along the card travel path24by a card transport mechanism, such as sets of rollers64. The card transport mechanism transports the card52throughout the card processing machine10including from the card input, to and/or through the card reorienting mechanism66, to and/or through a cooling station (described below), to and/or through the card processing station30, and to the card output26. In some embodiments, one or more additional card processing stations can be included within and/or connected to the card processing machine10. For example, referring toFIG.1, a contact and/or contactless chip programming station80can be provided along a vertical card transport path82extending from the card reorienting mechanism66. The chip programming station80is configured to perform contact or contactless programming of an integrated circuit chip on the card52. In another example, a magnetic stripe programming station84can be provided along the vertical card transport path82. The magnetic stripe programming station84is configured to magnetically read and/or write data from/to a magnetic stripe on the card52. An additional card processing station86can be located at the rear of the machine10in communication with the outlet26in the rear wall16. Alternatively, an additional card processing station88can be located at the bottom of the machine10in communication with the outlet26in the bottom wall20. Further information on additional card processing stations80,84,86,88are disclosed in U.S. Published Application No. 2016/0300128, filed on Apr. 8, 2016, which is incorporated herein by reference in its entirety. One or more card cooling stations are provided at suitable locations in the card processing machine10. The cooling station(s) is configured to actively or passively cool either of the card surfaces50,68in order to reduce a temperature of the surface of the card52. Prior to performing a processing operation (such as, but not limited to, retransfer printing) on the card, during the processing operation, or after the processing operation, a surface of the plastic card is cooled while the card52is at the cooling station in order to reduce a temperature of the surface of the card. Any form of active or passive cooling that results in a reduction of the temperature of the card surface prior to transferring the image or prior to a subsequent card processing operation can be utilized. In some embodiments, the card can be cooled so that the temperature of the first side of the card is approximately the same as the temperature of the second side during the stripping process. In some embodiments, the card is cooled so that one or both surfaces are cooled to room temperature. For example, referring toFIG.1, the card reorienting mechanism66also forms a cooling station at which the card52is cooled. In this embodiment, a cooling fan70is located near the card reorienting mechanism66. The cooling fan70is positioned and oriented to direct a stream of air onto the card52while the card52is within the card reorienting mechanism66. For example, if the card52is held in the reorienting mechanism66with the card surface50facing generally upward, the fan70can direct a stream of air onto the surface50in order to cool the surface50. The angle of the card52relative to the stream of air from the fan70can also be adjusted by the card reorienting mechanism66via suitable rotation thereof. In another possible example, with reference toFIG.2, the cooling station can be located at a position upstream of the transfer station48, with the fan70positioned above the card travel path24(as illustrated) or below the card travel path24(not illustrated) to direct a stream of air onto the card52. The cooling station and the fan70can be located anywhere in the card processing machine10where the card is able to be actively cooled by a stream of air from the fan70or other cooling mechanism. The card52can be transported to and held at the cooling station any time prior to performing the processing operation, during the processing operation, or after the processing operation. For example, the card52can be transported to the cooling station anytime:1—the card52is waiting for the print process onto the retransfer film40or another process to complete.2—purposely for a user-defined predetermined time or time delay prior to performing a card processing operation. The time delay provides additional cooling time during which the card52waits in the cooling station. The time delay can include or be in addition to any cooling time incurred when waiting for another process to complete. Examples of when the time delay can be implemented include, but are not limited to, before transferring the printed image onto the card, waiting to hand off the card to another card processing mechanism such as to an upstream card processing module, or the like. The time delay can be set by the user & adjusted based on factors such as, but not limited to, environmental conditions and card type. In one non-limiting embodiment, the time delay can be in the range of 5-10 seconds.3—between double applications of retransfer media from the retransfer film40onto the surface50or the surface68, for example after performing a first retransfer printing operation on the surface50or68and prior to performing a second retransfer printing operation on the same surface50or68.4—before handing the card off to another card processing mechanism (which could be within the card processing mechanism10or connected to the card processing mechanism10to receive the card directly from the card processing mechanism). FIG.3illustrates an example of the fan70directing a stream of air72onto the surface, for example the surface50, of the card52. In this example, the stream of air72contacts the surface at an angle θ. In one embodiment, the angle θ can be about 45 degrees. In other embodiments, the stream of air72can contact the surface of the card at substantially a 90 degree angle to the surface (i.e. substantially perpendicular to the surface) of the card. However, any angle that results in sufficient cooling of the card can be utilized. In one example, where the processing station30is a retransfer printing station as described above inFIG.2, the time to program a chip or write data to the magnetic stripe on the card52may be shorter than the time for printing an image onto the retransfer film40. Accordingly, in such an embodiment, the card can be transported to the chip programming station80to program the chip and/or to the magnetic stripe programming station84to write data to the magnetic strip, and thereafter the card52can be transported to the cooling station, such as the card reorienting mechanism66, and the card52“parked” in the cooling station for a period of time during which the card52is actively cooled by the fan70. The card52can then be moved out of the cooling station and transferred to the retransfer printing station where the image can be printed/applied to a surface of the cooled card52. In another example, the card52can be “parked” in the cooling station for a period of time during which the card52is cooled, either actively or passively as discussed further below, after printing on one side of the card52and while the image for the opposite side of the card52is being produced/printed onto the retransfer film40prior to retransfer onto the card surface. In an alternative embodiment, passive cooling can be utilized to cool the card52. For example, the card52can be transported to a cooling station, such as but not limited to the card reorienting mechanism66, where the card52is held stationary or “parked” for a period of time while the card52passively cools. For example, where the processing station30is a retransfer printing station as described above inFIG.2, the time to program a chip or write data to the magnetic stripe on the card52may be shorter than the time for printing an image onto the retransfer film40. Accordingly, in such an embodiment, the card can be transported to the chip programming station80to program the chip and/or to the magnetic stripe programming station84to write data to the magnetic strip, and thereafter the card52can be transported to the cooling station, such as the card reorienting mechanism66, and the card52“parked” during the remaining time where the image is being printed on the retransfer film40. During that remaining time, the card52passively cools while the card52is parked in the cooling station. The card52can then be moved out of the cooling station and transferred to the retransfer printing station where the image can be printed/applied to a surface of the cooled card52. The examples disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. | 21,254 |
11858255 | DESCRIPTION OF PREFERRED EMBODIMENT A processing machine01is preferably in the form of a printing press01and/or a shaping machine01, in particular a die-cutting machine01. The printing press01is preferably configured as a flexographic printing press01. The processing machine01is preferably referred to as a printing press01if it comprises at least one application mechanism614, preferably in the form of a printing couple614, and/or at least one printing unit600in the form of a unit600, in particular regardless of whether or not it comprises additional units for processing substrate02. A processing machine01in the form of a printing press01also comprises, for example, at least one additional such unit900, for example at least one shaping unit900, which is preferably in the form of a die-cutting unit900, more preferably a die-cutting device900. The processing machine01is preferably referred to as a shaping machine01if it comprises at least one shaping mechanism914and/or at least one shaping unit900, in particular regardless of whether or not it comprises additional units600for processing substrate02. The processing machine01is preferably referred to as a die-cutting machine01if it comprises at least one die-cutting mechanism914in the form of a shaping mechanism914and/or at least one die-cutting unit900and/or at least one die-cutting device900, in particular regardless of whether or not it comprises additional units600for processing substrate02. A processing machine01in the form of a shaping machine01or die-cutting machine01also comprises, for example, at least one additional unit600for processing substrate02, for example at least one printing unit600and/or at least one printing couple614. In the foregoing and in the following, the processing or treating of a substrate02describes the alteration of at least one property of the substrate02in question with regard to its physical properties and/or material properties, in particular its mass and/or shape and/or appearance. The substrate02can be converted into at least one intermediate product for further processing and/or at least one end product by at least one processing operation. In a preferred embodiment, the processing machine01, in particular a sheet processing machine01, preferably comprises a unit100in the form of a sheet feeder100and/or at least one printing couple614in the form of an application mechanism614for applying at least one print image to substrate02. Thus, if the processing machine01comprises at least one printing couple614and/or at least one printing unit600and also comprises at least one shaping mechanism914and/or at least one shaping unit900, it is configured both as a printing press01and as a shaping machine01. If the processing machine01comprises at least one printing couple614and/or at least one printing unit600and also comprises at least one die-cutting mechanism914and/or at least one die-cutting unit900and/or at least one die-cutting device900, it is therefore configured both as a printing press01and as a shaping machine01, in particular a die-cutting machine01. The processing machine01is preferably configured as a sheet processing machine01, i.e. as a processing machine01for processing sheet-format substrate02or sheets02, in particular a sheet-format printing material02. For example, the sheet processing machine01is configured as a sheet-fed printing press01and/or as a sheet-fed shaping machine01and/or as a sheet-fed die-cutting machine01. The processing machine01is further preferably configured as a corrugated cardboard sheet processing machine01, i.e. as a processing machine01for processing sheet-format substrate02or sheets02of corrugated cardboard02, in particular sheet-format printing substrate02made of corrugated cardboard02. More preferably, the processing machine01is configured as a sheet-fed printing press01, in particular as a corrugated cardboard sheet-fed printing press01, i.e. as a printing press01for coating and/or printing sheet-format substrate02or sheets02of corrugated cardboard02, in particular sheet-format printing material02made of corrugated cardboard02. The printing press01is configured as a printing press01that operates according to a printing forme-based printing method, for example. Unless an explicit distinction is made, the term sheet-format substrate02, in particular printing material02, specifically sheet02, generally includes any flat substrate02in the form of sections, i.e. including substrates02in tabular form or panel form, i.e. including boards or panels. The sheet-format substrate02or sheet02thus defined is formed, for example, from paper or paperboard, i.e. as sheets of paper or paperboard, or as sheets02, boards, or optionally panels made of plastic, cardboard, glass, or metal. The substrate02is more preferably corrugated cardboard02, in particular corrugated cardboard sheets02. Preferably, the at least one sheet02is made of corrugated cardboard02. The thickness of a sheet02is preferably understood as the dimension orthogonally to the largest surface area of the sheet02. This largest surface area is also referred to as the main surface area. Printing fluid is preferably applied to at least part of the main surface of the sheet02and/or at least one side of the sheet. The thickness of the sheets02is, for example, at least 0.1 mm (zero point one millimeters), more preferably at least 0.3 mm (zero point three millimeters) and even more preferably at least 0.5 mm (zero point five millimeters). With corrugated cardboard sheets02, significantly greater thicknesses are also common, for example at least 4 mm (four millimeters) or even 10 mm (ten millimeters) or more. Corrugated cardboard sheets02are relatively stable and therefore are not very flexible. Appropriate adjustments to the processing machine01therefore facilitate the processing of sheets02of great thickness. In the foregoing and in the following, the term sheet02refers in particular both to sheets02that have not yet been processed by means of at least one shaping device900and to sheets02that have already been processed by means of the at least one shaping device900and/or by means of at least one separation device903and in said processing may have been altered in terms of their shape and/or their mass. The at least one sheet02preferably comprises at least one multiple-up1101, preferably at least two multiple-ups1101, more preferably at least four multiple-ups1101, further preferably at least eight multiple-ups1101, more preferably a multiplicity of multiple-ups1101. A forward edge03, e.g. leading edge03, of the sheet02is preferably the edge03of the sheet02with which the relevant, preferably at least one sheet02first encounters a unit100;300;600;700;900;1000as it is transported through the processing machine01. The forward edge03is preferably oriented parallel to a direction A, in particular transverse direction A, and/or orthogonally to a direction T, in particular direction of transport T, along the transport path within the processing machine01. Preferably oriented perpendicular to the forward edge03of the sheet02is a direction Y, which is preferably oriented parallel to a side edge of the sheet02, in particular if the relevant sheet02, preferably the at least one sheet, is rectangular in shape. The direction Y is preferably oriented parallel to the direction of transport T and/or orthogonally to the transverse direction A. The sheet02preferably has a rear edge04, e.g. trailing edge04, with which the relevant sheet02, preferably the at least one sheet, last encounters a unit100;300;600;700;900;1000as it is transported through the processing machine01. The rear edge04is preferably arranged parallel to the forward edge03of the sheet02, particularly if the sheet02is rectangular in shape. Preferably oriented parallel to the forward edge03of the sheet02is a direction X, which is preferably oriented orthogonally to a side edge of the sheet02, in particular if the relevant, preferably the at least one, sheet02is rectangular in shape. The direction X is preferably oriented parallel to the transverse direction A and/or orthogonally to the direction of transport T. Two side edges of the sheet02and the forward edge03of the sheet02and the rear edge04of the sheet02preferably delimit the main surface of the sheet02. The sheet02, preferably the at least one sheet, is preferably made of paper or cardboard or paperboard. More preferably, the sheet02, preferably the at least one sheet, is made of cardboard, preferably corrugated cardboard. According to DIN 6730, paper is a flat material consisting essentially of fibers, mostly of vegetable origin, which is formed by dewatering a fiber suspension on a sieve. This produces a fiber felt, which is then dried. The grammage of paper is preferably a maximum of 225 g/m2(two hundred and twenty-five grams per square meter). According to DIN 6730, cardboard is a flat material consisting essentially of fibers of vegetable origin, which is formed by dewatering a fiber suspension on one or between two sieves. The fiber structure is compressed and dried. Cardboard is preferably manufactured from pulp by gluing or pressing it together. Cardboard is preferably formed as solid cardboard or corrugated cardboard02. In the foregoing and in the following, corrugated cardboard02is cardboard composed of one or more layers of a corrugated paper which is glued onto one layer or between multiple layers of another preferably smooth paper or cardboard. The grammage of cardboard is preferably more than 225 g/m2(two hundred and twenty-five grams per square meter). In the foregoing and in the following, the term paperboard refers to a flat paper structure, preferably coated on one side, preferably with a grammage of at least 150 g/m2(one hundred and fifty grams per square meter) and of no more than 600 g/m2(six hundred grams per square meter). Paperboard preferably has a high strength relative to paper. In the foregoing and in the following, the term application fluid includes inks and printing inks, but also primers, lacquers, and pasty materials. Application fluids are preferably materials that are and/or can be transferred by means of a processing machine01, in particular printing press01, or by means of at least one application mechanism614or one unit600in the form of an application unit600of processing machine01, in particular at least one printing couple614or printing unit600of printing press01, onto a substrate02, in particular a printing substrate02, for example onto at least one sheet02, thereby creating a preferably visible and/or perceptible and/or machine detectable texture, preferably in finely structured form and/or not merely over a large surface area, on the substrate02, in particular printing substrate02. Inks and printing inks are preferably solutions or dispersions of at least one colorant in at least one solvent, for example water and/or organic solvent. Alternatively or additionally, the application fluid may be an application fluid that cures under UV light. Inks are relatively low viscosity application fluids, and printing inks are relatively high viscosity application fluids. Inks preferably contain no binding agent or relatively little binding agent, whereas printing inks preferably contain a relatively large amount of binding agent, and more preferably contain additional auxiliary substances. In the foregoing and in the following, when application fluids and/or inks and/or printing inks are mentioned, this also includes colorless varnishes. In the foregoing and in the following, when application fluids and/or inks and/or printing inks are mentioned, this also preferably includes, in particular, agents, in particular priming agents, for pretreating (priming or pre-coating) the printing material02. The term printing fluid and the term coating medium are to be understood as synonymous alternatives to the term application fluid. An application fluid preferably is not gaseous. An application fluid is preferably liquid and/or powdered. The processing machine01preferably comprises multiple units100;300;600;700;900;1000. A unit in this context is preferably understood as a group of devices that cooperate functionally, in particular in order to carry out a preferably self-contained operation for processing sheets02. At least two, for example, and preferably at least three, and more preferably all of the units100;300;600;700;900;1000are configured as modules100;300;600;700;900;1000or at least each is assigned to such a module. A module in this context is understood in particular as a unit or a structure made up of multiple units, which preferably comprises at least one transport means and/or at least one uniquely dedicated open-loop and/or closed-loop controllable drive, and/or which is configured as an independently functioning module and/or as an individually manufactured and/or separately assembled machine unit or functional assembly. A uniquely dedicated open-loop and/or closed-loop controllable drive of a unit or module is understood in particular as a drive which is used to drive the movements of components of that unit or module and/or which is used to transport substrate02, in particular sheets02, through said unit or module and/or through at least one processing zone of said unit or module and/or which is used to directly or indirectly drive at least one component of said unit or module that is intended for contact with sheets02. These drives of the units100;300;600;700;900;1000of the processing machine01are preferably configured, in particular, as closed loop position-controlled electric motors. Each unit100;300;600;700;900;1000preferably has at least one open-loop drive controller and/or at least one closed-loop drive controller, which is assigned to the respective at least one drive of the respective unit100;300;600;700;900;1000. The open-loop drive controllers and/or closed-loop drive controllers of the individual units100;300;600;700;900;1000can preferably be operated individually and independently of one another. More preferably, the open-loop drive controllers and/or closed-loop drive controllers of the individual units100;300;600;700;900;1000are and/or can be linked in terms of circuitry, in particular by means of at least one BUS system, to one another and/or to a machine control system of the processing machine01in such a way that a coordinated open-loop and/or closed-loop control of the drives of multiple or of all units100;300;600;700;900;1000of the processing machine01is and/or can be carried out. The individual units100;300;600;700;900;1000and/or in particular modules100;300;600;700;900;1000of the processing machine01therefore preferably are and/or can be operated preferably synchronized with one another electronically, at least with respect to their drives, in particular by means of at least one virtual and/or electronic master axis. The virtual and/or electronic master axis is preferably preset for this purpose, for example by a higher-level machine control system of the processing machine01. Alternatively or additionally, the individual units100;300;600;700;900;1000of the processing machine01are and/or can be synchronized with one another mechanically, for example, at least with respect to their drives. Preferably, however, the individual units100;300;600;700;900;1000of the processing machine01are decoupled from one another mechanically, at least with respect to their drives. The virtual and/or electronic master axis preferably has a sequence of temporally equidistant master axis signals. Each of these master axis signals corresponds to a time at which the signal is generated and/or to a virtual angle value. These virtual angle values preferably lie between 0° (zero degrees) and 360° (three hundred and sixty degrees) and are emitted in ascending order one after the other, in particular via the BUS system, wherein upon reaching 360° (three hundred and sixty degrees), angle measurement preferably starts over at 0° (zero degrees). One sequence of angle values from 0° (zero degrees) to 360° (three hundred and sixty degrees) preferably corresponds to one machine cycle. The machine cycle preferably corresponds to one full revolution of a forme cylinder616of the application mechanism614, and/or to a distance between leading edges03of successive sheets02being transported at the same, constant speed, and/or to the time interval between two times at which two successive sheets02are accelerated, each for the first time, by at least one primary acceleration means136. Master axis signals have intervals of 4 ms (four milliseconds), for example. The spatial area provided for the transport of substrate02, which is occupied at least temporarily by the substrate02when it is present, is the transport path. The transport path is preferably defined by at least one device for guiding the substrate02when the processing machine01is in an operating state. Unless otherwise specified, each of the units100;300;600;700;900;1000of the processing machine01is preferably characterized in that the section of a transport path provided for the transport of sheets02which is defined by the respective unit100;300;600;700;900;1000is at least substantially flat and more preferably completely flat. A substantially flat section of the transport path provided for the transport of sheets02is understood in this context as a section which has a minimum radius of curvature of at least two meters, more preferably at least five meters, and even more preferably at least ten meters, and more preferably still at least fifty meters. A completely flat section has an infinitely large radius of curvature and is thus likewise substantially flat and therefore likewise has a minimum radius of curvature of at least two meters. Unless otherwise specified, each of the units100;300;600;700;900;1000of the processing machine01is preferably characterized in that the section of the transport path provided for the transport of sheets02which is defined by the respective unit100;300;600;700;900;1000extends at least substantially horizontally and more preferably exclusively horizontally. This transport path preferably extends in a direction T, in particular direction of transport T. A transport path provided for the transport of sheets02which extends substantially horizontally means, in particular, that within the entire area of the respective unit100;300;600;700;900;1000, the provided transport path has only one or has multiple directions which deviate no more than 30° (thirty degrees), preferably no more than 15° (fifteen degrees), and more preferably no more than 5° (five degrees) from at least one horizontal direction. The transport path provided for the transport of sheets02preferably begins at the point where the sheets02are removed from a feeder pile104. The direction T of the transport path, in particular the direction of transport T, is in particular the direction T in which the sheets02are transported at the point at which the direction T is measured. The direction of transport T intended, in particular, for the transport of sheets02is preferably the direction T which is preferably oriented at least substantially and more preferably fully horizontally and/or which preferably leads from a first unit100;300;600;700;900;1000of processing machine01to a last unit100;300;600;700;900;1000of processing machine01, in particular from a sheet feeder unit100or a substrate feed system100to a delivery unit1000or a substrate output device1000, and/or which preferably points in a direction in which the sheets02are transported, apart from vertical movements or vertical components of movements, in particular from a first point of contact with a unit300;600;700;900;1000of processing machine01located downstream of the substrate feed system100or a first point of contact with processing machine01to a last point of contact with processing machine01. Regardless of whether the infeed device300is an independent unit300or module300or is a component of the substrate feed system100, the direction of transport T is preferably the direction T in which a horizontal component of a direction points, which is oriented from the infeed device300toward the substrate output device1000. A direction A, preferably the transverse direction A, is preferably a direction A which is oriented orthogonally to the direction of transport T of the sheets02and/or orthogonally to the provided transport path of the sheets02through the at least one application unit600and/or through the at least one shaping unit900and/or through the at least one sheet delivery1000. The transverse direction A is preferably a horizontally oriented direction A. A longitudinal axis of the at least one forme cylinder616is preferably oriented parallel to the transverse direction A. A working width of the processing machine01and/or of the at least one application unit600and/or of the at least one shaping unit900and/or of the at least one sheet delivery1000is preferably a dimension extending preferably orthogonally to the provided transport path of the sheets02through the at least one application unit600and/or the at least one shaping unit900and/or the at least one sheet delivery1000, more preferably in the transverse direction A. The working width of the processing machine01preferably corresponds to the maximum width a sheet02may have in order to still be processable by the processing machine01, i.e. in particular a maximum sheet width that can be processed by the processing machine01. In this context, the width of a sheet02is understood in particular as its dimension in the transverse direction A, in particular the direction X. This is preferably independent of whether this width of the sheet02is greater than or less than a horizontal dimension of the sheet02, orthogonally thereto, which further preferably represents the length of said sheet02in the direction Y. The working width of the processing machine01preferably corresponds to the working width of the at least one application unit600and/or the at least one shaping unit900and/or the at least one sheet delivery1000. The working width of the processing machine01, in particular sheet processing machine01, is preferably at least 100 cm (one hundred centimeters), more preferably at least 150 cm (one hundred and fifty centimeters), even more preferably at least 160 cm (one hundred and sixty centimeters), even more preferably at least 200 cm (two hundred centimeters) and more preferably still at least 250 cm (two hundred and fifty centimeters). A vertical direction V preferably refers to a direction which is oriented parallel to the normal vector of a plane spanned by the direction of transport T and the transverse direction A. In the region of the shaping device900, for example, the vertical direction V is preferably oriented such that it points from the printing material02to a plate cylinder901of the shaping device900. The processing machine01preferably has at least one substrate feed system100, which more preferably is configured as a unit100, in particular a substrate supply unit100, and/or as a module100, in particular a substrate supply module100. In the case of a sheet processing machine01, in particular, the at least one substrate feed system100is preferably configured as a sheet feeder100and/or sheet feeder unit100and/or sheet feeder module100. The processing machine01has, for example, at least one unit configured as a conditioning device, in particular a conditioning unit, which is further preferably configured as a module, in particular as a conditioning module. Such a conditioning device is configured, for example, as a pre-processing device, in particular as a pre-processing device for applying primer, or as a post-processing device, in particular as a post-processing device for applying varnish. The processing machine01preferably has at least one unit configured as a pre-processing device, in particular a pre-processing unit, which is further preferably configured as a module, in particular as a pre-processing module and is a conditioning device. The processing machine01preferably has at least one post-processing device. The processing machine01preferably has at least one unit300, preferably an infeed device300, which is more preferably configured as an infeed unit300and/or infeed module300. Alternatively, the at least one infeed device300is a component of the substrate feed system100or of another unit. The processing machine01comprises, at least one unit600, e.g. the application unit600, which is preferably configured as a module600, in particular application module600. The at least one application unit600is preferably positioned and/or structured based on its function and/or its application method. The at least one application unit600preferably serves to apply at least one application fluid or coating medium over the entire surface area and/or at least a portion of the surface area of the sheets02. One example of an application unit600is a printing unit600or printing module600, which serves in particular to apply printing ink and/or ink to substrate02, in particular sheets02. In the foregoing and in the following, an optionally provided priming unit and/or an optional finish coating unit can also be considered as such an application unit600or printing unit600. Independently, in particular, of the function of the application fluid that can be applied by the aforementioned application units600, these units can preferably be distinguished in terms of their application method. One example of an application unit600is a forme-based application unit600, which comprises, in particular, at least one fixed, physical, and preferably exchangeable printing forme for the application of printing fluid. Forme-based application units600preferably operate according to a planographic printing process, in particular an offset planographic printing process, and/or according to a gravure printing process, and/or according to a letterpress printing process, particularly preferably according to a flexographic printing process. The corresponding application unit600is a flexographic application unit600or flexographic printing unit600, in particular a flexographic application module600or flexographic printing module600. Preferably, the at least one application unit600is configured as a flexographic printing unit600. The processing machine01has, for example, at least one unit in the form of a drying device, in particular a drying unit, which is more preferably configured as a module, in particular as a drying module. Alternatively or additionally, at least one drying device506and/or at least one after-drying device, for example, is a component of at least one unit100;300;600;700;900;1000preferably configured as a module100;300;600;700;900;1000. For example, at least one application unit600has at least one drying device506and/or has at least one unit700in the form of a transport device700and/or at least one unit in the form of a transport unit700. The processing machine01preferably has at least one transport device700, which more preferably is configured as a unit700, in particular as the transport unit700, and/or as a module700, in particular as transport module700. The transport device700is also referred to as transport means700. Additionally or alternatively, the processing machine01preferably has transport devices700as components of other units and/or modules, for example. The processing machine01has at least one shaping device900, more preferably configured as a unit900, in particular a shaping unit900or die-cutting unit900, and/or as a module900, in particular as a shaping module900or die-cutting module900, and/or as a die-cutting device900. The processing machine01preferably has at least one shaping unit900configured as a die-cutting unit900. The at least one shaping device900is preferably configured as a rotary die-cutting device900and/or preferably has at least one shaping mechanism914or die-cutting mechanism914. A shaping device900is also understood to be a stamping device and/or a creasing device. A perforating device is preferably likewise one form of a die-cutting device900. The processing machine01preferably comprises at least one unit1000in the form of a substrate output device1000, in particular a delivery1000, in particular a sheet delivery1000, in particular a delivery unit1000, which is more preferably configured as a module1000, in particular as a delivery module1000. The processing machine01comprises, for example, at least one unit in the form of a post-press processing device, in particular a post-press processing unit, which is more preferably configured as a module, in particular as a post-press processing module. The post-press processing unit is preferably located downstream of the at least one shaping device900in the direction of transport T. For example, the post-press processing unit is located downstream of the at least one sheet delivery1000in the direction of transport T. The at least one post-press processing device in each case is in the form of a gluing device and/or folding device, for example. The processing machine01preferably has transport means119;136;700;904;906at one or more locations. At least one of these transport means119;136;700;906is preferably in the form of a suction transport means119;136;700;906, in particular a suction belt and/or a suction box belt and/or a roller suction system and/or a suction roller. Such suction transport means119;136;700;906preferably serve to move sheets02forward in a controlled manner and/or to enable movements while sheets02are held against at least one counterpressure surface of the corresponding suction transport means119;136;700;906. A relative vacuum is preferably used to draw and/or to press the sheets02against at least one transport surface. A transporting movement of the sheets02is preferably generated by a corresponding, in particular circulating movement of the at least one transport surface. Alternatively or additionally, the sheet02, preferably the at least one sheet, is held in its path along the transport path provided for the transport of sheets02, for example, by the at least one suction transport means119;136;700;906, and a transporting movement of the sheet02is generated by a force which is defined by another transport means119;136;700;904;906located upstream and/or downstream, for example. The vacuum is in particular a vacuum relative to an ambient pressure, in particular relative to an atmospheric pressure. A suction transport means119;136;700;906is therefore preferably understood as a device which has at least one counterpressure surface, more preferably in the form of a sliding surface and/or a movable transport surface, in particular, and which is at least partially movable, for example, at least in the direction of transport T. Furthermore, each suction transport means119;136;700;906preferably has at least one vacuum chamber, which more preferably is connected by means of a suction line to at least one vacuum source. The vacuum source has a fan, for example. The at least one vacuum chamber has at least one suction opening, which is used to apply suction to the sheets02. Depending on the embodiment of the suction transport means119;136;700;906and the size of the sheets02, the sheets02are drawn by suction into a position in which they close off the at least one suction opening or are merely drawn by suction against a counterpressure surface in such a way that ambient air can still travel past the sheets02and into the suction opening. The transport surface has one or more suction openings, for example. The suction openings preferably serve to further convey a vacuum pressure from the suction inlet of vacuum pressure chamber to the transport surface, in particular without pressure losses or with very low pressure losses. Alternatively or additionally, the suction inlet acts on sheets02in such a way that the sheets are sucked against the transport surface, even though the transport surface has no suction openings. At least one deflection means is provided, for example, which directly or indirectly ensures a circulating movement of the at least one transport surface. The at least one deflection means and/or the transport surface preferably are and/or can be autonomously driven, in particular to provide for movement of the sheets02. Alternatively, the transport surface allows sheets02to slide along the transport surface. A first embodiment of a suction transport means119;136;700;906is a suction belt. A suction belt in this context is understood as a device that comprises at least one flexible conveyor belt, the surface of which serves as a transport surface. The at least one conveyor belt is preferably deflected by deflecting means in the form of deflecting rollers and/or deflecting cylinders and/or is preferably self-contained, in particular such that endless circulation is enabled. The at least one conveyor belt preferably has a multiplicity of intake openings. The at least one conveyor belt preferably covers the at least one suction opening of the at least one vacuum chamber over at least a portion of its circulation path. In that case, the vacuum chamber is further preferably connected to the surrounding environment and/or to sheets02only via the intake openings of the at least one conveyor belt. Support means are preferably provided, which prevent the at least one conveyor belt from being pulled too far or at all into the vacuum chamber and/or which ensure that the transport surface assumes a desired shape, for example such that it forms a flat surface, at least in the region in which its intake openings are connected to the vacuum chamber. A circulating movement of the at least one conveyor belt then results in a forward movement of the transport surface, with sheets02being held securely on the transport surface precisely in the region where they lie opposite the suction opening that is covered by the at least one conveyor belt, with the exception of the intake openings. A second embodiment of a suction transport means119;136;700;906is a roller suction system. A roller suction system in this context is understood as a device in which the at least one transport surface is formed by at least sections of lateral surfaces of a multiplicity of transport rollers and/or transport cylinders. Thus, each of the transport rollers and/or transport cylinders forms a part of the transport surface, which is closed, for example, and/or which circulates via rotation. The roller suction system preferably has a multiplicity of suction openings. These suction openings are preferably arranged at least between adjacent transport rollers and/or transport cylinders. At least one cover mask is provided, for example, preferably forming a boundary of the vacuum chamber. The cover mask preferably comprises the multiplicity of suction openings. The cover mask preferably forms a substantially flat surface. The transport rollers and/or transport cylinders are preferably arranged in such a way that they are intersected by said flat surface and more preferably protrude only slightly, for example only a few millimeters, above said flat surface, in particular in a direction facing away from the vacuum chamber. In that case, the suction openings are preferably configured as frame-like, with each opening surrounding at least one of the transport rollers and/or transport cylinders. A circulating movement of the transport rollers and/or transport cylinders then results in a forward movement of the corresponding parts of the transport surface, with sheets02being held securely on the transport surface precisely in the region in which they lie opposite the suction opening. Each transport unit700is preferably in the form of at least the one suction transport means700. A suction transport means700preferably comprises at least two roller suction systems, each of which is preferably configured as an individually driven roller suction system. The roller suction system is also referred to as a suction box. A third embodiment of a suction transport means119;136;700;906is a suction box belt. A suction box belt is understood in this context as a device that comprises a plurality of circulating suction boxes, in particular, each of which has an outer surface that serves as a transport surface. A fourth embodiment of a suction transport means119;136;700;906is at least one suction roller. A suction roller in this context is understood as a roller the lateral surface of which serves as a transport surface and has a multiplicity of intake openings, and which has at least one vacuum chamber in its interior, which is connected to at least one vacuum source, for example by means of a suction line. A fifth embodiment of a suction transport means119;136;700;906is at least one sliding suction device. The sliding suction device is preferably configured as a passive transport means and serves, in particular, to establish boundary conditions with respect to the position of a sheet02, preferably the at least one sheet, without setting the sheet02itself, preferably the at least one sheet, in motion. Each sliding suction device preferably has at least one sliding surface and at least one vacuum chamber and at least one suction opening. Said at least one sliding surface then serves as a counterpressure surface and serves as a transport surface. In the case of the sliding suction device, the transport surface configured as a sliding surface preferably is not moved. The sliding surface serves as a counterpressure surface against which corresponding sheets02are pressed. The sheets02can nevertheless be moved along the sliding surface, in particular to the extent that they are acted upon otherwise by a force that is at least also oriented parallel to the sliding surface. A region between two driven suction transport means119;136;700;906can be bridged by means of a sliding suction device, for example. It is possible for different embodiments of suction transport means119;136;700;906to be combined. These suction transport means may have at least one common vacuum source and/or at least one common vacuum chamber, and/or may cooperate as a suction transport means119;136;700;906and/or may be arranged one behind the other and/or side by side. Each such combination is then preferably assigned to at least two of the embodiments of suction transport means119;136;700;906. Regardless of the embodiment of a given suction transport means119;136;700;906, at least two configurations of said suction transport means119;136;700;906as described below are possible. In a first, preferred configuration, one section of the transport path provided for the transport of sheets02which is defined by the suction transport means119;136;700;906is situated below the transport surface, which is movable, in particular, and which serves, in particular, as a counterpressure surface and is movable at least partially, for example, at least in the direction of transport T. In that case the suction transport means119;136;700;906is configured as an upper suction transport means700;906, for example, with the suction openings or intake openings thereof further preferably facing preferably at least also or only downward, at least while they are connected to the at least one vacuum chamber, and/or the suctioning action thereof preferably being directed at least also or only upward. The sheets02are then preferably transported in a hanging state by the suction transport means119;136;700;906. The at least one transport unit700is preferably configured as an upper suction transport means700. The at least one transport means906is preferably configured as an upper suction transport means906. At least one transport means119;136;700;906of the transport means119;136;700;906, preferably at least the at least one transport unit700, further preferably at least the at least one suction transport means700, in particular the at least one upper suction transport means700, is configured to transport the sheets02in a hanging state. With a hanging transport of sheets02by the at least one transport means119;136;700;906, in particular, the positioning of the at least one sheet02along the transport path is more susceptible to error and/or the positioning is less precise than with a horizontal transport, for example. This is due, for example, to the configuration of the suction transport means700;906, which preferably has no fixed stop and no fixation which is movable along the transport path for the leading edge03of the sheet02. In that case in particular, a position check of the at least one sheet02by sheet sensors164;622;722;922is advantageous. In a second alternative configuration, one section of the transport path provided for the transport of sheets02which is defined by the suction transport means119;136;700;906, is situated above the transport surface, which is movable, in particular, and which serves, in particular, as a counterpressure surface and is movable at least partially, for example, at least in the direction of transport T. In that case, the suction transport means119;136;700;906is configured as a lower suction transport means119;136;700;906, for example, with the suction openings or intake openings thereof further preferably facing preferably at least also or only upward, at least while they are connected to the at least one vacuum chamber, and/or the suctioning action thereof preferably being directed at least also or only downward. The sheets02are then preferably transported lying flat by the suction transport means119;136;700;906. At least two suction transport means119;136are preferably configured as lower suction transport means119;136. The processing machine01for processing sheets02comprises the at least one application unit600and at least one sheet sensor622associated with said application unit600. In the foregoing and in the following, associated with preferably describes at least one functional connection, i.e. a direct or indirect connection, between the at least two elements associated with one another, in particular the at least one sheet sensor622and the respective application unit600. By means of a signal from the sheet sensor622, at least one element of the respective application unit600is controlled in particular, preferably at least primarily, preferably exclusively in an open loop and/or a closed loop. The processing machine01is preferably in the form of a sheet processing machine01comprising the substrate feed system100and the at least one application unit600and the at least one shaping device900and more preferably comprising the at least one delivery1000located downstream of the at least one shaping device900along the transport path provided for the transport of sheets02. The substrate feed system100preferably comprises the infeed unit300. The infeed unit300preferably comprises the at least one feeder pile104. The feeder pile104preferably comprises a multiplicity of sheets02, which are provided stacked, preferably at least temporarily, in a holding area166. In the direction of transport T, the holding area166is preferably delimited by at least one front stop137. The front stop137is preferably configured such that a single sheet02at a time can be transported in the direction of transport T beneath the front stop137with respect to the vertical direction V. For the transport of sheets02in the direction of transport T, in particular for the transport of the bottommost sheet02with respect to the vertical direction V, the at least one transport means136, preferably configured as an acceleration means136, is associated with the holding area166. The acceleration means136is preferably configured as a lower suction transport means136. The acceleration means136preferably serves to accelerate sheets02of the feeder pile104to a target transport speed, in particular a processing speed for sheets02, preferably at which the sheets02are preferably transported through the units100;300;600;700;900;1000within the processing machine01for processing of the sheets02. The transport means119configured as a secondary acceleration means119is preferably located downstream of the acceleration means136in the direction of transport T. The secondary acceleration means119is preferably configured as a conveyor belt and/or transport roller, more preferably as a lower suction transport means119. The secondary acceleration means119is preferably configured to adapt an actual transport speed of sheets02to the processing speed as soon as their actual transport speed deviates from the processing speed. The at least one transport unit700, in particular a first transport unit700, is preferably located downstream of the infeed unit300, in particular downstream of the secondary acceleration means119, in the direction of transport T. At least one transfer means is preferably provided, for example, for transferring sheets02from the secondary acceleration means119to the transport unit700, which is preferably configured as an upper suction transport means700. The at least one application unit600having the at least one application mechanism614in the form of a printing couple614is preferably located downstream of the first transport unit700in the direction of transport T. In each case, the at least one application unit600comprises the at least one printing couple614having the forme cylinder616and an individual drive associated with the forme cylinder616. The at least one application unit600is preferably embodied as a flexographic application unit600. The processing machine01preferably has at least four application units600, in particular flexographic application units600. For example, the processing machine01comprises at least six application units600, the individual application units600preferably differing at least in part in terms of the printing fluid they handle and/or in terms of the print image element they apply to the printing material02. At least one transport means700is preferably positioned between every two application units600. The at least one printing couple614is preferably embodied as a flexographic printing couple, which is configured in particular according to the principle of the flexographic printing method for applying printing fluid to the sheet02, preferably to the at least one sheet. In a preferred embodiment, the application mechanism614comprises the at least one forme cylinder616, at least one impression cylinder617, at least one anilox roller618, and at least one ink fountain619. The ink fountain619preferably has printing fluid and is configured to deliver the printing fluid to the anilox roller618. The anilox roller618is configured to transfer the printing fluid to at least one printing forme of the forme cylinder616for printing a printing material02. The forme cylinder616and the impression cylinder617preferably define a processing point621of the application mechanism614. In particular, the at least one application unit600, preferably the at least one printing couple614, has the at least one processing point621. The lateral surface of the forme cylinder616and the lateral surface of the impression cylinder617preferably define the processing point621in the form of a printing nip621, through which sheets02can preferably pass through the printing couple614. The printing nip621is preferably the specific region in which a forme cylinder616and its respective impression cylinder617are closest to one another. Each printing couple614comprises the at least one forme cylinder616. The forme cylinder616has at least the one printing forme and at least one holder626for the at least one printing forme. The holder626for the printing forme is in the form of a clamping device, for example. The holder626for the printing forme is preferably configured as a non-printing region of the lateral surface of the forme cylinder616along the lateral surface of the forme cylinder616in the circumferential direction. The non-printing region of the forme cylinder616preferably has a length in the circumferential direction of the forme cylinder616which is preferably at least 3%, preferably at least 5%, more preferably at least 8% of the circumferential length of the forme cylinder616. The length of the non-printing region is preferably determined by the length in the circumferential direction of the printing region of the forme cylinder616, in particular the length of the at least one printing forme in the circumferential direction of the forme cylinder616. In the non-printing region of the lateral surface of the forme cylinder616, preferably no printing fluid is transferred from the lateral surface of the forme cylinder616to sheets02when the processing machine01is in printing operation. Printing fluid is preferably transferred from the forme cylinder616to sheets02only within the specific region of the lateral surface of the forme cylinder616which has the at least one printing forme. The specific region of the lateral surface of the forme cylinder616which has the at least one printing forme is preferably the printing region of the lateral surface of the forme cylinder616. The at least one printing forme, more preferably exactly one printing form, and the at least one non-printing region, preferably exactly one non-printing region, are preferably arranged one behind the other along the circumferential direction of the lateral surface of the forme cylinder616. The holder626is preferably located upstream of the printing region of the forme cylinder616in the direction of rotation of the forme cylinder616, more preferably the rear edge of the non-printing region of the forme cylinder616is arranged upstream of the printing region of the forme cylinder616in the direction of rotation of the forme cylinder616. The forward edge of the printing region of the forme cylinder616is preferably identical to the rear edge of the non-printing region of the forme cylinder616. The forme cylinder616is preferably configured to be drivable and/or driven by the drive in the form of an individual drive. The individual drive of the forme cylinder616is preferably embodied as a preferably closed loop position-controlled electric motor. Each forme cylinder616is driven mechanically independently of every other cylinder and/or roller of the printing couple614. A preferred embodiment of the impression cylinder617preferably has a continuous surface along a circumferential direction of the impression cylinder617. This is the case, for example, when the lateral surface of the impression cylinder617is in the form of a sleeve. The impression cylinder617in this embodiment can be driven, for example, by the individual drive of the forme cylinder616, in addition to the forme cylinder616. Alternatively or additionally, the impression cylinder617preferably has a separate individual drive, in particular a preferably closed loop position-controlled electric motor. Alternatively or additionally, the impression cylinder617is and/or can be driven via a drive of the virtual and/or electronic master axis. The impression cylinder617, which has a continuous surface, has a circumference, for example, which differs from the circumference of the forme cylinder616associated with it and is preferably smaller than the circumference of the forme cylinder616associated with it. If the impression cylinder617has a separate individual drive or if the impression cylinder617is driven via the at least one drive of the virtual and/or electronic master axis, the impression cylinder617is configured to move preferably independently of the at least one signal from the at least one sheet sensor622. In a further preferred embodiment of the impression cylinder617, it is preferably configured as a plate cylinder and preferably additionally or alternatively has at least one impression plate. The diameter of the impression cylinder617in the form of a plate cylinder preferably corresponds to the circumference of the forme cylinder616. The impression cylinder617has at least one holder627for mounting the at least one impression plate. The holder627of the impression cylinder617is preferably the same size along the lateral surface of the impression cylinder617as the holder626along the lateral surface of the forme cylinder616. The holder627of the impression cylinder617is preferably arranged along the lateral surface of the impression cylinder617such that, with a rotational movement of the impression cylinder617associated with the processing speed and a rotational movement of the forme cylinder616associated with the processing speed, the positions of the holders626;627can be synchronized with one another. With a rotational movement associated with the processing speed, the holders626;627preferably both arrive at the printing nip621at the same time, each holder626;627with its forward edge. With a rotational movement associated with the processing speed, the holders626;627preferably both leave said printing nip621at the same time, each holder626;627with its rear edge. At least one first application unit600in the direction of transport T is configured as a priming mechanism and/or at least one last application unit600in the direction of transport T is configured as a coating mechanism. The at least one shaping device900having the at least one shaping mechanism914is preferably located downstream of the at least one application unit600, preferably downstream of the last application unit600in the direction of transport T. The at least one shaping device900is preferably in the form of a die-cutting device900and/or a rotary die-cutting device900. Just one shaping device900, in particular die-cutting device900and/or rotary die-cutting device900, is provided, for example. The at least one shaping device900has at least one and more preferably exactly one processing point909, preferably in the form of a shaping point909. The at least one shaping device900preferably has the at least one and more preferably the exactly one processing point909in the form of a shaping point909, which is formed by at least one and more preferably exactly one plate cylinder901, in particular configured as a die plate cylinder901, on the one hand, and at least one counterpressure cylinder902on the other. The shaping point909is preferably the region in which the plate cylinder901and the counterpressure cylinder902are closest to one another. The at least one shaping point909is preferably configured as at least one die-cutting point909. The shaping device900, in particular the shaping mechanism914, preferably comprises at least one tool, and more preferably, the at least one plate cylinder901comprises at least one tool. In a preferred embodiment, the tool of the shaping device900, in particular of the shaping mechanism914, preferably the tool of the plate cylinder901, is at least temporarily in direct contact with the counterpressure cylinder902, in particular in the region of the shaping point909. A sheet02which has been processed by the shaping device900, i.e. which is located downstream of the at least one shaping point909on the transport path in the direction of transport T, preferably has at least one die-cut impression1103. The at least one die-cut impression1103is in the form of a crease and/or ridge and/or embossment and/or cut and/or perforation, for example. In particular if the at least one die-cut impression1103is in the form of a perforation and/or cut, it is preferably formed to at least partially separate at least one multiple-up1101from at least one scrap piece and/or from at least one other multiple-up1101. A sheet02which has been processed by the shaping device900, i.e. which is located downstream of the at least one shaping point909on the transport path in the direction of transport T, preferably has at least one multiple-up1101, preferably at least two multiple-ups1101, and at least one scrap piece. In the foregoing and in the following, in accordance with DIN 16500-2, the term multiple-up1101preferably refers to the number of identical articles produced from the same piece of material and/or arranged on one common substrate material, for example one common sheet02. A multiple-up1101is preferably the particular region of a sheet02which is a product of the sheet processing machine01, in particular an intermediate product for producing an end product, for example a blank, and/or which will be further processed and/or is configured to be further processable to form the desired or required end product, for example. The at least one multiple-up1101of each sheet02preferably has the at least one printed image. In this case, the desired or required end product which is produced from each multiple-up1101or preferably by post-press processing of each multiple-up1101is preferably a folder-type box and/or a telescope-type box and/or a slide-type box and/or a rigid-type box. The end product of the at least one multiple-up1101of the multiple-ups1101is preferably a folder-type box and/or a telescope-type box and/or a slide-type box and/or a rigid-type box. In the foregoing and in the following, an offcut piece, preferably a scrap piece, is that region of a sheet02which does not correspond to any multiple-up1101. An offcut piece is preferably in the form of a scrap piece and/or trimmed piece and/or broken-off piece and is preferably at least partially removable from at least one multiple-up1101. The at least one scrap piece is preferably produced at the at least one shaping point909of the shaping device900during operation of the sheet processing machine01, for example in at least one die-cutting process, and is preferably removed at least partially, preferably completely, from a sheet02, preferably the at least one sheet, during operation of the sheet processing machine01. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the at least one separation device903for removing at least one scrap piece from at least one sheet02is located downstream of the at least one shaping point909, preferably downstream of the at least one processing point909of the shaping device900, configured as a shaping point909, along the transport path provided for the transport of sheets02. The separation device903is preferably configured for removing at least one scrap piece at least partially, preferably completely. The separation device903is preferably configured for the complete removal of scrap pieces from the sheet02, preferably the at least one sheet. Thus, the at least one separation device903serves in particular to separate the offcut pieces, in particular the former parts of the sheet02, preferably the at least one sheet, which have already been fully or partially separated from the sheet02and are to be removed from the sheet02, from multiple-ups1101, in particular those parts of the sheet02that are to continue to be treated as sheets02and, if necessary, are to be processed further. The at least one separation device903is configured as a separation unit903and/or as a separation module903, for example. Alternatively, the at least one separation device903is a component of another unit900or module900, in particular of the at least one shaping unit900or shaping module900. The at least one separation device903preferably has at least one transport means904in the form of a separation transport means904, in particular for transporting sheets02. The at least one separation transport means904preferably serves to transport sheets02along the transport path provided for the transport of sheets02and/or in the direction of transport T while scrap pieces are removed from said sheets02. The scrap pieces are preferably each transported in a direction at least one component of which is oriented orthogonally to the direction of transport T, preferably counter to a vertical direction V, for example vertically downward. Preferably, at least the force of gravity is also used to remove such scrap pieces from said sheet02, preferably the at least one sheet. Thus it is preferably necessary only to apply a force that will separate a scrap piece from said sheet02, preferably the at least one sheet, and the scrap piece is then carried away by the force of gravity in a direction at least one component of which is oriented orthogonally to the direction of transport T, preferably downward. Preferably, exactly one separation transport means904is located along the transport path provided for the transport of sheets02. Alternatively, multiple differently configured separation transport means904, for example, are arranged along the transport path provided for the transport of sheets02. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the at least one separation transport means904is configured to act and/or to be capable of acting on sheets02both from above and from below. This enables sheets02to be transported with sufficient accuracy along the transport path provided for the transport of sheets02despite the action of the at least one separation device903. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the at least one separation transport means904has multiple upper separation conveyor belts arranged side by side and spaced apart from one another with respect to the transverse direction A and/or multiple lower separation conveyor belts arranged side by side and spaced apart from one another with respect to the transverse direction A. Separation conveyor belts are configured, for example, as endless and/or circulating belts, which further preferably have a relatively small dimension in the transverse direction A, for example less than 5 cm (five centimeters), preferably less than 2 cm (two centimeters), and more preferably less than 1 cm (one centimeter). The distances between adjacent separation conveyor belts are preferably relatively large with respect to the transverse direction A, for example at least 2 cm (two centimeters), more preferably at least 5 cm (five centimeters), even more preferably at least 10 cm (ten centimeters) and more preferably still at least 20 cm (twenty centimeters). This allows scrap pieces to be moved in a direction at least one component of which is oriented orthogonally to the direction of transport T, preferably in or counter to the vertical direction V, more preferably downward and/or upward between the separation conveyor belts, in particular to drop through. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the at least one separation transport means904is different from any suction transport means, i.e. is not configured as a suction transport means. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the at least one separation device903is configured as at least one jogging device903and/or in that the at least one separation device903has at least one jogging drive. The at least one jogging drive can preferably be used to deflect at least one separation conveyor belt orthogonally to its localized transfer direction. A localized transfer direction in this context is understood as the specific direction in which an element of a given separation conveyor belt is moved based on a circulating movement of that separation conveyor belt, in particular apart from any superimposed deflecting movements. The at least one jogging drive thus preferably serves to jog the sheet02, preferably the at least one sheet, in particular by movements in directions orthogonally to the direction of transport T. Such movements are necessary only in the case of a small deflection, for example. The at least one jogging drive is arranged to act and/or to be capable of acting, for example, directly or indirectly on the at least one separation transport means904and/or at least one separation conveyor belt, for example via at least one impact shaft. The at least one jogging drive is positioned to act or to be capable of acting directly or indirectly, for example, on at least one deflecting means and/or at least one guide means of at least one separation conveyor belt. At least one electric and/or at least one pneumatic and/or at least one hydraulic and/or at least one magnetic drive is provided as the jogging drive, for example. Alternatively or additionally, the at least one separation device903has at least one separation fan, for example, which further preferably serves to remove scrap pieces from the sheets02, preferably from the at least one sheet, by means of at least one at least intermittently activated flow of gas. Alternatively or additionally, the sheet processing machine01is preferably characterized in that at least one transport means906configured as a selective transport means906is arranged along the transport path provided for the transport of sheets02, in particular downstream of the at least one separation transport means904along the transport path provided for the transport of sheets02. The at least one transport means906configured as a selective transport means906is preferably arranged following the at least one separation transport means904along the transport path provided for the transport of sheets02, in particular directly following the at least one separation transport means904. A selective transport means906in this context is understood in particular as a transport means906which is configured to transport and/or to be capable of transporting only selected objects, for example exclusively sheets02and/or no offcut pieces. At least one position and/or at least one dimension of a respective object, in particular with respect to the transverse direction A, is used as a distinguishing criterion. Preferably, the at least one selective transport means906is configured as at least one upper suction transport means906for the hanging transport of sheets02, more preferably as at least one exclusively upper suction transport means906and/or for an exclusively hanging transport of sheets02. In that case, any offcut pieces can fall away, still counter to the vertical direction V, preferably downward, also downstream of the at least one separation transport means904and can be moved away from the sheets02without interfering with subsequent processes. The sheet processing machine01is preferably characterized in that the sheet processing machine01has at least one transport means906, in particular an upper suction transport means906, which is configured for the hanging transport of sheets02, preferably for the hanging transport of the at least one remaining part of the at least one sheet02which has been processed by the shaping device900and which contains the at least one multiple-up1101, said transport means being located downstream of the separation device903in the direction of transport T along the transport path provided for the transport of sheets02. Downstream of the at least one shaping unit900, more preferably downstream of the at least one separation device903, more preferably following the at least one transport means906in the direction of transport T, the at least one substrate output device1000is preferably located. The substrate output device1000preferably comprises at least one delivery pile carrier48and at least one diverted delivery51. The substrate output device1000embodied as a delivery1000preferably has at least one preferably adjustable and/or controllable sheet diverter49, which is configured to guide sheets02either to the delivery pile carrier48or to the diverted delivery51. At least one transport means in the form of a sheet decelerating means is preferably arranged downstream of the at least one selective transport means906along the transport path provided for the transport of sheets02and more preferably is arranged at least partially and more preferably entirely above a delivery pile carrier of the sheet delivery1000. The at least one sheet decelerating means serves in particular to decelerate sheets02before they are deposited onto a delivery pile on the delivery pile carrier48. Additionally or alternatively, the sheet processing machine01is preferably characterized in that, upstream of the delivery1000in the direction of transport T, at least one alteration of the transport path provided for the transport of sheets02, in particular the sheet diverter49, is preferably closed-loop controlled and/or open-loop controlled and/or is configured for open-loop control and/or closed-loop control. The alteration of the transport path is preferably formed to channel and/or divert sheets02onto a transport path that bypasses the actual transport path. The alteration of the transport path, in particular the sheet diverter49, is preferably configured to channel and/or divert sheets02onto a transport path that bypasses the at least one sheet decelerating means. The alteration of the transport path, in particular the at least one sheet diverter49, serves, for example, to channel out at least one sheet02, in particular a sample sheet to be inspected and/or at least one waste sheet. A waste sheet has at least one defect by which it differs from the target state of sheets02. More preferably, the sheet processing machine01is characterized in that the alteration of the transport path, in particular the at least one sheet diverter49for channeling sheets02onto a transport path that bypasses the at least one sheet decelerating means, is arranged between the at least one separation device903and the at least one sheet decelerating means along the transport path provided for the transport of sheets02. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the delivery unit1000, preferably the sheet delivery1000, has at least one forward pile limiter and/or in that a delivery pile area is delimited at least by the at least one rear sheet stop and the at least one forward pile limiter and/or in that the sheet delivery1000has at least one upper sheet transport system configured for the hanging transport of sheets02and comprising at least one imbricating device and/or in that the at least one imbricating device produces imbrication for an imbricated, hanging transport of at least two sheets02at at least one point located above the delivery pile area as viewed in the vertical direction V. A sheet02which is located downstream of the at least one shaping point909and downstream of the at least one separation device903on the transport path in the direction of transport T preferably has at least one multiple-up1101, preferably at least two multiple-ups1101, and at least one sheet opening1102, preferably at least two sheet openings1102. The at least one multiple-up1101of the sheet, preferably of the at least one sheet02, preferably includes the at least one printed image in each case. The sheet02, preferably the at least one sheet, preferably contains at least two multiple-ups1101, each with the at least one printed image. The at least two multiple-ups1101of the one sheet02, preferably of the at least one sheet, preferably each have at least one preferably identical printed image. Preferably, a sheet02which is located downstream of the at least one shaping point909and downstream of the at least one separation device903on the transport path in the direction of transport T, and which additionally or alternatively is located outside of the sheet processing machine01after having passed through the sheet processing machine01, has at least one multiple-up1101, preferably at least two multiple-ups1101, with at least one offcut piece, preferably at least two offcut pieces, which have been removed from the sheet02. The sheet02additionally has, for example, at least one die-cut impression1103, preferably at least two die-cut impressions1103, in particular a die-cut impression1103in the form of a crease and/or score mark and/or embossment. The sheet02preferably has no offcut pieces downstream of the separation device903in the direction of transport T or after passing through the sheet processing machine01. Different multiple-ups1101within one sheet02are configured as separated and/or separable from one another, for example, by at least one die-cut impression1103, for example a perforation and/or an at least partial cut and/or a crease. Downstream of the separation device903in the direction of transport T, a sheet02preferably has no scrap pieces. Downstream of the separation device903in the direction of transport T, at each of the positions of the scrap pieces, a sheet02preferably has a sheet opening1102, the dimensions and/or the contours of which correspond to the dimensions and/or contours of the scrap piece that has been removed. In an alternative or additional embodiment, the dimensions and/or contours of a sheet opening1102correspond, for example, to the dimensions and/or contours of multiple scrap pieces adjoining one another. The processing machine01preferably has at least one inspection device726;728;916. The remaining contour of the sheet02, in particular the remaining contour of the at least one multiple-up1101, preferably corresponds to the contour of the at least one offcut piece removed upstream of the inspection device916and/or to a composite contour of at least two offcut pieces removed upstream of the inspection device916. In the foregoing and in the following, sheet opening1102preferably describes a region of sheet02, preferably in an actual state of the sheet in question, the at least one sheet02, in which, after the at least one processing operation in the shaping device900and additionally or alternatively after the at least one processing operation in the separation device903, the sheet02in question, preferably the at least one sheet, preferably has no mass, and preferably has a gap. The sheet opening1102is in the form of a sheet gap1102, for example. At least one scrap piece of the sheet02in question, preferably the at least one sheet, preferably is and/or can be associated with a respective sheet opening1102. A sheet opening1102is preferably the region of a sheet02from which at least one scrap piece has been removed and/or in which the sheet02has lost mass and/or has no mass remaining as compared with a time prior to the at least one processing operation in the shaping device900and additionally or alternatively prior to the at least one processing operation in the separation device903. Two opposing margins of a sheet opening1102, in particular two opposing edges of the respective sheet02, preferably the at least one sheet, which delimit the sheet opening1102in question are preferably spaced from one another by a distance greater than zero, preferably greater than 5 mm (five millimeters), more preferably greater than 10 mm (ten millimeters), even more preferably greater than 20 mm (twenty millimeters), more preferably greater than 30 mm (thirty millimeters). In the desired or required end product, which is produced from the respective multiple-up1101or by the post-press processing thereof, the at least one sheet opening1102in question forms a handle, for example. In the foregoing and in the following, the printed image describes a representation on the printing material02which corresponds to the sum of all print image elements, in particular the sum of all image forming elements, the individual print image elements being transferred and/or transferable to the printing material02during at least one working step and/or at least one printing operation. At least one print image element can preferably be transferred to the printing material02by one application unit600of the processing machine01at a time. Each image forming element is preferably an element which can be transferred by at least one application unit600of the processing machine01to the sheet, preferably to the at least one sheet02, and which produces the printed image in the sum of all the image forming elements. According to DIN 16500-2, in multicolor printing for example, register is the precise merging of individual print image elements and/or image forming elements and/or color segments to form a printed image. Register is also referred to as color register. According to DIN 16500-2, the precise matching of a printed image on the front and back sides of a printing material02that is printed on both sides is referred to as perfecting register. In the foregoing and in the following, the term register mark16;17;18;19;21;22;23;24or also printing mark is understood as a mark used for inspecting the register and/or the color register. For each application unit600and/or for each application mechanism614, at least one register mark16;17;18;19;21;22;23;24, preferably at least two register marks16;17;18;19;21;22;23;24, more preferably exactly two register marks16;17;18;19;21;22;23;24, are preferably applied to at least one relevant sheet02. A sheet02which is located downstream of the at least one application mechanism614, preferably downstream of the last application mechanism614, on the transport path in the direction of transport T and which has been furnished by the at least one application mechanism614, in particular printing couple614, with printing fluid preferably has at least one register mark16;17;18;19;21;22;23;24, preferably two register marks16;17;18;19;21;22;23;24, for each application mechanism614by which it has been furnished with printing fluid. In the case of four application mechanisms614, for example, a sheet02printed by all four application mechanisms614will have at least four register marks16;17;18;19;21;22;23;24, preferably at least eight register marks16;17;18;19;21;22;23;24. One register mark16;17;18;19from each application mechanism614is preferably established as the first register mark16;17;18;19. One register mark21;22;23;24from each application mechanism614is preferably established as the second register mark21;22;23;24. The first register mark16;17;18;19is preferably located in a forward region of the printable main surface of the sheet02, in particular at a forward edge of the printed image, in the direction Y, and additionally or alternatively, the second register mark21;22;23;24is preferably located in a rear region of the printable main surface of the sheet02, in particular at a rear edge of the printed image, in the direction Y. Each first register mark16;17;18;19is preferably associated with a first reference position06;07;08;09and each second register mark21;22;23;24is associated with a second reference position11;12;13;14. The reference position06;07;08;09;11;12;13;14is the position of the register mark16;17;18;19;21;22;23;24in question in which the register mark16;17;18;19;21;22;23;24is located in the case of an ideally printed sheet02and/or a print master. The first reference positions06;07;08;09are preferably arranged side by side in the direction Y and/or one behind the other in the direction X. Additionally or alternatively, the second reference positions11;12;13;14are preferably arranged side by side in the direction Y and/or one behind the other in the direction X. Preferably, in each case a first reference position06;07;08;09and a second reference position11;12;13;14are arranged one behind the other in the direction Y and/or side by side in the direction X. The sheet processing machine01comprises the at least one sheet sensor164;622;722;922. For example, the processing machine01has a multiplicity of sheet sensors164;622;722;922, which are preferably arranged one behind the other, at least in part, in the direction of transport T. Depending on its position and/or function, preferably the at least one sheet sensor164is configured as a sheet starting sensor164or the at least one sheet sensor622;922is configured as a sheet travel sensor622;922or the at least one sheet sensor722is configured as a sheet monitoring sensor722. Each sheet sensor622;722;922is preferably positioned at the same coordinate with respect to the transverse direction A. In each case, the sheet sensors622;722;922are preferably arranged one behind the other in the direction of transport T, preferably in alignment with one another. Arranging the sheet sensors622;722;922in alignment with one another in the direction of transport T preferably ensures that the leading edge03and/or trailing edge04of each sheet02, preferably of the at least one sheet, can be detected at the same position by the corresponding sheet sensors622;722;922. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the at least one sheet sensor164;622;722;922is configured to detect, in particular as detecting, the location and/or position of each sheet02, preferably of the at least one sheet. This is done, for example, to enable the location and/or position to be subsequently changed in a targeted manner and/or to enable the information about the location and/or position of said sheet02, preferably the at least one sheet, to be subsequently used in the units300;600;700;900;1000that follow a respective sheet sensor164;622;722;922. Information thus obtained is used, for example, to align the sheets02without stops and/or during further transport. Each corresponding sheet sensor164;622;722;922is preferably configured as mechanically movable with respect to the transverse direction A. The at least one sheet sensor164;622;722;922is preferably in the form of an optical sheet sensor164;622;722;922. Preferably, the at least one sheet sensor164;622;722;922is configured as a leading edge sensor for generating a leading edge signal and is preferably configured as generating a leading edge signal, and/or the at least one sheet sensor164;622;722;922is configured as a trailing edge sensor for generating a trailing edge signal and is preferably configured as generating a trailing edge signal. Each sheet sensor164;622;722;922, preferably the at least one sheet sensor, is configured as detecting the leading edge03and/or the trailing edge04and/or the at least one image forming element, for example the register mark16;17;18;19;21;22;23;24, of each sheet02, preferably of the at least one sheet of the sheets02, and is preferably configured as transmitting a corresponding signal. More preferably, the at least one sheet sensor164;622;722;922is configured as both a leading edge sensor and a trailing edge sensor. The at least one sheet sensor164;622;722;922is preferably arranged above the transport path and/or below the transport path and directed toward it. The leading edge03and/or the trailing edge04and/or the at least one register mark16;17;18;19;21;22;23;24and/or at least one printed image of the at least one sheet02is thereby detected by the at least one sheet sensor164;622;722;922. In particular for the purpose of detecting the at least one register mark16;17;18;19;21;22;23;24and/or the at least one printed image, the at least one sheet sensor164;622;722;922is arranged and directed toward the side of the transport path on which the at least one sheet02contains the at least one register mark16;17;18;19;21;22;23;24and/or the at least one printed image. Thus, when the sheet02is guided in a hanging state, for example, preferably at least one of the sheet sensors164;622;722;922is positioned preferably below the transport path and directed toward it. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the at least one sheet sensor164;622;722;922is in the form of a transmitted light sensor. For example, the at least one sheet sensor164;622;722;922in the form of a transmitted light sensor is configured as a light sensor and/or photoelectric sensor. Each sheet sensor164;622;722;922in the form of a transmitted light sensor is characterized in that it has at least two sensor elements171;172;623;624;723;724;923;924and in that the sensing zone of the corresponding transmitted light sensor extends between at least two of these sensor elements171;172;623;624;723;724;923;924. At least one sensor element171;623;723;923of these at least two sensor elements171;172;623;624;723;724;923;924in each case is configured as a transmitter171;623;723;923, in particular as a transmitter171;623;723;923for transmitting electromagnetic radiation. At least one sensor element172;624;724;924of these at least two sensor elements171;172;623;624;723;724;923;924in each case is configured as a receiver172;624;724;924, in particular as a receiver172;624;724;924for receiving electromagnetic radiation and/or as a receiver172;624;724;924associated with the at least one transmitter171;623;723;923. At least one reflector is provided, for example, which is likewise a sensor element. In each case, at least one sensor element171;172;623;624;723;724;923;924of the sheet sensor164;622;722;922is preferably arranged above the transport path provided for the transport of sheets02, and in each case at least one sensor element171;172;623;624;723;724;923;924of the sheet sensor164;622;722;922is preferably arranged below the transport path provided for the transport of sheets02. The sheet sensor164;622;722;922preferably in the form of a transmitted light sensor preferably has a particularly high response rate and therefore preferably enables a particularly precise monitoring of the transport of the sheets02. The at least one sheet sensor164;622;722;922preferably has a sampling frequency of at least 2 kHZ (two kilohertz), more preferably at least 5 kHZ (five kilohertz), even more preferably at least 9 kHZ (nine kilohertz), even more preferably at least 19 kHZ (nineteen kilohertz), and more preferably still at least 29 kHz (twenty-nine kilohertz). Additionally or alternatively, the processing machine01preferably comprises the substrate feed system100having the at least one sheet sensor164. The at least one sheet sensor164, configured as a sheet starting sensor164, of the substrate feed system100is preferably directed toward the provided transport path for the purpose of detecting the leading edge03and/or the trailing edge04and/or at least one register mark16;17;18;19;21;22;23;24and/or at least one part of the printed image of each corresponding sheet02. The at least one sheet sensor164configured as a sheet starting sensor164is part of the infeed device300, for example. In an alternative or additional refinement, the processing machine01is preferably characterized in that the at least one sheet sensor164configured as a sheet starting sensor164is arranged downstream of the at least one primary acceleration means136and/or downstream of the at least one front stop137and/or upstream of the at least one secondary acceleration means119with respect to the direction of transport T. Alternatively or additionally, the processing machine01is preferably characterized in that the at least one sheet sensor164, in particular the at least one sheet starting sensor164, is located in the region of the at least one secondary acceleration means119with respect to the direction of transport T. The sheet sensor164configured as a sheet starting sensor164is preferably positioned such that its sensing region intersects with a monitoring section167of the transport path provided for the transport of sheets02. The monitoring section167preferably begins at a starting point168, which lies downstream of the holding area166along the transport path provided for the transport of sheets02, and/or preferably ends at an end point169, which lies upstream of the at least one application unit600along the transport path provided for the transport of sheets02. If the processing machine01comprises only one shaping device900, the monitoring section167preferably ends at the end point169, which lies upstream of the at least one processing point909preferably configured as a shaping point909along the transport path provided for the transport of sheets02. The monitoring section167preferably defines a region which can be used for an advantageous positioning of the sensing region of the at least one sheet sensor164. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the starting point168is spaced from the holding area166by a starting distance of at least 50 mm (fifty millimeters), more preferably at least 90 mm (ninety millimeters), even more preferably at least 120 mm (one hundred and twenty millimeters), more preferably at least 140 mm (one hundred and forty millimeters), and more preferably still at least 145 mm (one hundred and forty-five millimeters). The closer the starting point168and/or the sensing region of the at least one sheet starting sensor164is to the holding area166, the earlier an accelerated sheet02can be detected and the earlier it is possible to react to a corresponding measured value. Maintaining a minimum distance preferably ensures that each sheet02to be detected is already traveling at the desired transport speed, in particular the corresponding processing speed, when it is detected. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the end point169is spaced from the at least one, in particular the first processing point621by an ending distance of at least 200 mm (two hundred millimeters), more preferably at least 250 mm (two hundred and fifty millimeters), more preferably at least 290 mm (two hundred and ninety millimeters), even more preferably at least 320 mm (three hundred and twenty millimeters), more preferably at least 340 mm (three hundred and forty millimeters), and more preferably still at least 350 mm (three hundred and fifty millimeters). The closer the end point169is to the first processing point621, in particular, the more distance and/or time remains for verifying the results of compensatory measures, particularly if the at least one sheet starting sensor164is used for this purpose. The end point169is preferably spaced from the at least one, more preferably from the first, and even more preferably from each transport means700located downstream of the secondary acceleration means119in the direction of transport T by an ending distance of at least 200 mm (two hundred millimeters), more preferably at least 250 mm (two hundred and fifty millimeters), more preferably at least 290 mm (two hundred and ninety millimeters), even more preferably at least 320 mm (three hundred and twenty millimeters), even more preferably at least 340 mm (three hundred and forty millimeters), and more preferably still at least 350 mm (three hundred and fifty millimeters). This ensures that compensatory accelerations of a corresponding sheet02, preferably of the at least one sheet, are completed before the sheet02engages with the transport means700, which is more preferably operated at a constant speed, in particular at the processing speed. If the at least one sheet starting sensor164is positioned too close to the first transport means700located downstream of the secondary acceleration means119in the direction of transport T, a compensatory movement may no longer be possible before a corresponding sheet, preferably the at least one sheet02, comes in contact with the transport means700. In that case, the sheet transport and thus the processing speed of the sheet processing machine01as a whole would have to be permanently reduced. The starting distance and/or the ending distance in each case are preferably based on the maximum sheet length of the sheets02to be processed by the sheet processing machine01and/or from the maximum processing speed at which the sheet processing machine01is to be operated. The starting distance is preferably at least as great as an acceleration distance over which corresponding sheets02can be and/or are accelerated to the processing speed by means of the at least one primary acceleration means136. The ending distance is preferably at least as great as the distance traveled by sheets02at the processing speed within the time that is required to calculate and carry out a corresponding compensatory operation. Alternatively or additionally, the sheet processing machine01is preferably characterized in that the at least one secondary acceleration means119comprises at least three conveyor belts arranged side by side and spaced from one another with respect to a transverse direction A, and more preferably in that a sensing region of the at least one sheet starting sensor164extends between the at least three conveyor belts arranged side by side and spaced from one another with respect to a transverse direction A. This results, in particular, in the advantage that at the moment when a sheet02is detected by the at least one sheet starting sensor164, the sheet is held particularly well. Each sheet02is preferably assigned a movement profile which can be represented as a mathematical function in which the location of the sheet02, preferably of the at least one sheet, along the transport path provided for the transport of sheets02is described as a function of the progression of the sequence of master axis values. In that case, when a sheet02, preferably the at least one sheet, is detected by means of the at least one sheet sensor164, a master axis value, for example, is preferably assigned to the time at which the sheet is detected. This can then be compared with the time or the master axis value at which the sheet02would have been expected at the at least one sheet sensor164. Any difference in these values resulting from the comparison is preferably used to infer how that sheet02would need to be transported, for example by means of the at least one secondary acceleration means119, in order to compensate as much as possible for the difference in values or to completely eliminate the difference. By accelerating and/or decelerating the sheet02using the at least one secondary acceleration means119, in particular when a value difference is previously ascertained, the sheet02is preferably adjusted to the processing speed. Additionally or alternatively, the processing machine01preferably comprises at least two sheet starting sensors164, which are preferably arranged orthogonally to the transport path for sheets02and which are more preferably arranged one behind the other in the transverse direction A and/or more preferably side by side in the direction of transport T. The at least two sheet sensors164configured in particular as sheet starting sensors164are preferably configured to detect sheets02that are in a skewed position. Each of these at least two sheet starting sensors164arranged one behind the other in the transverse direction A is preferably configured to detect the leading edge03and/or the trailing edge04and/or the at least one register mark16;17;18;19;21;22;23;24and/or at least one part of the printed image of each sheet02, preferably of the at least one sheet. More preferably, the sheet processing machine01is alternatively or additionally characterized in that at least two sheet sensors164are provided, the sensing regions of which differ in terms of their position with respect to the transverse direction A. In that case, a skewed position of a sheet02, preferably of the at least one sheet, is preferably measured. The sensing regions of these at least two sheet sensors164are preferably in the same position with respect to the direction of transport T, with the exception of a tolerance of no more than 10 mm (ten millimeters), more preferably no more than 5 mm (five millimeters), and more preferably no more than 2 mm (two millimeters). If the skewed position is too great, compensatory measures are implemented, for example, or the corresponding sheet02is rejected or marked, or the machine is shut down. The at least one sheet sensor622configured as a sheet travel sensor622is preferably positioned directly upstream, in the direction of transport T, of the respective associated application unit600, preferably the at least one application unit, which comprises the respective forme cylinder616. The at least one sheet sensor622is configured to control the position and/or the rotational speed of said forme cylinder616in a closed loop and/or an open loop. The at least one application unit600, more preferably each of the at least two application units600, is associated with at least one uniquely dedicated sheet sensor622, in particular one sheet travel sensor622. At least one sheet sensor622, in particular one sheet travel sensor622, is associated uniquely with each application unit600. The at least one sheet sensor922, in particular the sheet travel sensor922, is preferably associated uniquely with the at least one shaping unit900, preferably with each shaping unit900. Each sheet travel sensor622is positioned upstream, in the direction of transport T, of the application unit600with which it is associated, and/or each sheet travel sensor922is preferably positioned upstream, in the direction of transport T, of the shaping unit900with which it is associated. The at least one sheet sensor622;922is configured to detect the time at which sheets02arrive at the position of the sheet sensor622;922. The processing machine01, which is preferably in the form of a sheet-fed printing press01, is preferably characterized in that the at least one sheet sensor622;922configured as a sheet travel sensor622;922is preferably directed toward the provided transport path, at least for the purpose of detecting the arrival time of each sheet02, in particular the arrival time of the respective leading edge03and/or of at least one register mark16;17;18;19;21;22;23;24and/or of at least one part of the printed image of each sheet02, preferably of the at least one sheet. The sheet processing machine01is characterized in that each sheet travel sensor622;922is positioned upstream of the respective processing point621;909in the direction of transport T. The sheet travel sensors622;922, each of which is associated with an application unit600or a shaping unit900, are arranged at the same position in each case with respect to the transverse direction A. This ensures that the same position on the leading edge03and/or the trailing edge04and/or on the at least one register mark16;17;18;19;21;22;23;24and/or on the at least one part of the printed image of each sheet02, preferably of the at least one sheet, can be and/or is detected in each case. In each case, the sheet travel sensor622;922is preferably arranged on a transport device700which is preferably arranged immediately upstream of the relevant unit600;900in the direction of transport T. At least one sheet travel sensor622;922of the sheet travel sensors622;922is preferably arranged in each case between two application units600arranged adjacent to one another in the direction of transport T, or between an application unit600and a shaping device900arranged adjacent thereto in the direction of transport T, or between a substrate feed system100and an application unit600arranged adjacent thereto in the direction of transport T. The corresponding sheet travel sensor622;922is preferably arranged such that at least one part of the transport device700, in particular at least one part of the transport means700in question, is located between the sheet travel sensor622;922in question and the corresponding processing point621;909of the relevant unit600;900. In a preferred embodiment of the transport device700, the transport means700is in the form of an upper suction transport means700, in particular in the form of the at least one roller suction system. In that case, at least one transport roller and/or at least one transport cylinder, and more preferably a maximum of three transport rollers and/or three transport cylinders, of the upper suction transport means700are preferably arranged between the sheet travel sensor622;922in question and the processing point621;909of the relevant unit600;900with respect to the direction of transport T. The at least one sheet travel sensor622;922is preferably spaced by a minimum distance and/or a maximum distance from the processing point of the application unit600associated with it or from the shaping device900associated with it. Preferably, the sheet travel sensor622;922is spaced from the processing point621;909associated with it by a minimum distance of at least 200 mm (two hundred millimeters), preferably at least 300 mm (three hundred millimeters), more preferably at least 350 mm (three hundred and fifty millimeters), and even more preferably at least 400 mm (four hundred millimeters). Additionally or alternatively, the sheet travel sensor622;922is preferably spaced from the processing point621;909associated with it by a maximum distance of no more than 650 mm (six hundred and fifty millimeters), more preferably a maximum of 600 mm (six hundred millimeters), even more preferably a maximum of 550 mm (five hundred and fifty millimeters), and even more preferably 450 mm (four hundred and fifty millimeters). Each sheet travel sensor622which is associated with an application unit600is preferably spaced from the corresponding processing point621by a distance which is shorter than the distance of a sheet travel sensor922which is associated with a shaping unit900from the corresponding processing point. Positioning the sheet travel sensor622;922at a minimum distance from the respective processing point621;909preferably ensures that the stretch of transport path between the sheet travel sensor622;922and the respective processing point621;909is long enough to allow the arrival time of the sheet02, in particular the leading edge03thereof, to be synchronized with the forward edge of the printing region of the forme cylinder616. Positioning the sheet travel sensor622;922at a maximum distance from the respective processing point621;909preferably ensures that the shortest possible stretch of transport path exists between the sheet travel sensor622;922and the respective processing point621;909, in order to avoid any further influence by the transport path on the speed of the sheet02, preferably the at least one sheet, thus avoiding any impact on its arrival time. The respective at least one sheet travel sensor622;922is configured to detect the arrival time of the sheet02, in particular the arrival time of the leading edge03and/or of the at least one register mark16;17;18;19;21;22;23;24and/or of at least one part of the printed image of the sheets02, preferably before said sheet02, preferably the at least one sheet, reaches the processing point621;909of the associated unit600;900. The at least one sheet travel sensor622;922preferably detects the arrival time of the at least one sheet02of the sheets02, preferably before the sheet reaches the processing point621;909in question of the associated unit600;900. Each sheet02is preferably assigned a movement profile which can be represented as a mathematical function in which the location of the sheet02along the transport path provided for the transport of sheets02is described as a function of the progression of the sequence of master axis values. In that case, when a sheet02is detected by means of the at least one sheet sensor622;922, in particular by the at least one sheet travel sensor622;922, a master axis value, for example, is preferably assigned to the time at which the sheet is detected. This is then preferably compared with the time or the master axis value at which the sheet02would have been expected at the at least one sheet sensor622;922. In the following, the structure, the arrangement, and the principle of the at least one sheet sensor622;922will be described based on the embodiment of an application unit600with which at least one sheet sensor622is associated. The structure and/or the arrangement and/or the principle of the sheet travel sensor622of the application unit600can preferably be applied to the sheet travel sensor922of the shaping unit900. In the case of the shaping unit900, the plate cylinder901has at least one tool for processing sheets02along at least a part of its lateral surface. In a figurative sense, the region of the lateral surface of the plate cylinder901that contains the at least one tool preferably corresponds to the printing region of the forme cylinder616of the application unit600. The plate cylinder901is preferably configured to process the sheets02using its tool. If the sheet sensor622is assigned to an application unit600, the master axis value for the sheets02, which corresponds to the respective time of detection by the sheet sensor622, is preferably comparable to a master axis value for the position of the holder626of the forme cylinder616, and thus preferably to a master axis value for the forward edge of the printing region of the forme cylinder616. The position of the leading edge03of the sheets02and/or the position of at least one register mark16;17;18;19;21;22;23;24and/or the position of at least one part of the printed image relative to the position of the forward edge of the printing region of the forme cylinder616can preferably be determined, in particular via the master axis value assigned in each case. Alternatively or additionally, to achieve a printed image which is true to register using the application unit600and/or to achieve a die-cut pattern which is true to register using the shaping unit900, the processing speed of the sheets02is preferably adapted to the rotational velocity and/or rotational speed of the forme cylinder616;901, and more preferably is additionally adapted to the rotational velocity and/or rotational speed of the impression cylinder617;902, such that the leading edge03of the sheet02in question, preferably of the at least one sheet in question, and the forward edge of the printing region of the forme cylinder616, or alternatively, the leading edge of the region of the plate cylinder901that contains the tool, pass through the respective processing point621;909at the same time. The position of the leading edge03of the sheet02in question, preferably of the at least one sheet, preferably corresponds, in particular, to the assigned master axis value, and the position of the forward edge of the printing region of the forme cylinder616preferably corresponds, in particular, to the assigned master axis value when the leading edge03of the sheet02in question and the forward edge of the printing region of the forme cylinder616are located at the processing point621of the respective unit600. The arrival time of the sheet02, preferably of the at least one sheet, in particular the arrival time of the leading edge03and/or of at least one register mark16;17;18;19;21;22;23;24and/or of at least one part of the printed image of the sheet02preferably corresponds to the arrival time of the forward edge of the printing region of the forme cylinder616at the processing point621. In the event of a possible difference in values between the assigned master axis value for the position of the forward edge of the printing region of the forme cylinder616and the assigned master axis value for the position of the leading edge03and/or of at least one register mark16;17;18;19;21;22;23;24and/or of at least one part of the printed image of the sheet02in question, at least one adjustment and/or at least one variation of the assigned master axis value for the position of the forward edge of the printing region of the forme cylinder616relative to the assigned master axis value for the position of the leading edge03and/or relative to at least one register mark16;17;18;19;21;22;23;24and/or relative to at least one part of the printed image of the sheet02in question is necessary, for example, in order to maintain the proper register. In a preferred embodiment of the processing machine01, the forme cylinder616, in particular the position of the forward edge of the printing region of the forme cylinder616, is preferably configured as adjustable in the event of a difference in values between the assigned master axis value for the position of the forward edge of the printing region of the forme cylinder616and the assigned master axis value for the position of the leading edge03and/or the at least one register mark16;17;18;19;21;22;23;24and/or the at least one part of the printed image of the sheet02in question. Preferably, the forme cylinder616is accelerated and/or decelerated as long as at least part of the non-printing region of the forme cylinder616is located at the processing point621, so that the arrival time of the sheet02at the processing point621will coincide with the arrival time of the printing region of the forme cylinder616at the processing point621. Accelerating and/or decelerating the forme cylinder616while at least part of the non-printing region is passing through the processing point621ensures that the arrival time of the sheet02, in particular the arrival time of the leading edge03of the sheet02, at the processing point621will coincide with the arrival time at the processing point621of the forward edge of the printing region of the forme cylinder616. The start of the processing of sheets02at the processing point621can preferably be adapted and/or determined and/or adjusted by accelerating and/or decelerating the forme cylinder616. For example, as long as at least part of the printing region of its lateral surface is located at the processing point621, the speed of the forme cylinder616differs at least to some extent from the speed of the forme cylinder616as long as at least a part of the non-printing region of its lateral surface is located at the processing point621. The impression cylinder617is preferably also accelerated and/or decelerated in a manner complementary to the forme cylinder616. In the foregoing and in the following, the speed of the forme cylinder616preferably corresponds to the circumferential speed at which said forme cylinder616rotates in its respective direction of rotation. The direction of rotation of the forme cylinder616is preferably the specific direction in which the forme cylinder616in question rotates and/or is configured to rotate so as to transport sheets02along the transport path, preferably in the direction of transport T. As soon as the leading edge03of the sheet02reaches the processing point621, the forme cylinder616is preferably operated at the speed that corresponds to the processing speed of sheets02in the respective unit600. As long as at least part of the printing region of its lateral surface is located at the processing point621, the speed of the forme cylinder616is constant, for example. Alternatively, the speed of the forme cylinder616preferably varies at least to some extent as long as at least part of the printing region of its lateral surface is located at the processing point621. This varying speed exists in particular to produce a change in the print length l2relative to the reference length l1, preferably to minimize the difference between the print length l2and the reference length l1, so that the register of the printed image is adapted and/or improved and/or adjusted. The change in the print length l2is achieved by accelerating and/or decelerating the forme cylinder616while at least part of the printing region of its lateral surface is located at the processing point621. As a result, the print image which is applied to the sheet02is stretched and/or compressed, for example, relative to the printing forme used for printing. This may be necessary, for example, if the dimensions of sheets02change, in particular in the direction of transport T, during the processing of said sheets by multiple units100;300;600;700;900;1000, in particular as a result of the processing, for example the application of the at least one printing fluid and/or the passage through the at least one processing point622;909. Additionally or alternatively, the transport speed of sheets02can be adjusted relative to the processing speed of the processing machine01at the position in question, for example, by accelerating and/or decelerating the sheet02using the at least one part of the transport means700upstream of the processing point621;909. For this purpose, the sheet02is preferably accelerated and/or decelerated by at least one part of the transport means700, for example by at least one transport roller and/or transport cylinder of the roller suction system, in particular by at least the transport roller and/or transport cylinder located immediately upstream of the processing point621;909in the direction of transport T. Accelerating and/or decelerating the sheet02preferably causes the position of the leading edge03of the sheet02to coincide with the rear edge of the non-printing region of the forme cylinder616;901and/or with the forward edge of the printing region of the forme cylinder616;901when the processing point621is reached. In a preferred embodiment of the processing machine01, at least one image forming element on sheet02, for example at least one part of the printed image of the sheet02and/or at least one register mark16;17;18;19;21;22;23;24, is detected and/or evaluated by machine operators using at least one sheet02in the form of a sample sheet as a basis. Preferably, the at least one register of the printed image, and additionally or alternatively the at least one image forming element of sheets02, and additionally or alternatively the at least one measurement of the print length l2of the at least one printed image of a sheet02, preferably of the at least one sheet, and additionally or alternatively at least one defect in the at least one processing of a sheet02, preferably the at least one sheet, and additionally or alternatively at least one defect in the at least one printed image of a sheet02, preferably the at least one sheet, is detected and/or evaluated by machine operators using at least one sample sheet as a basis. For this purpose, the at least one sheet02in the form of a sample sheet is preferably routed onto an alternate transport path from the actual transport path and is preferably removed manually or mechanically from the processing machine01and inspected outside of the processing machine01. Additionally or alternatively, the processing machine01is preferably characterized in that the processing machine01comprises the at least one inspection device726;728;916. The processing machine01is preferably characterized in that the at least one inspection device726;728;916is located downstream of the forme cylinder616of the at least one printing couple614along the transport path for sheets02. The at least one inspection device726;728;916is preferably located downstream of the at least one application unit600in the direction of transport T, preferably downstream of the last application unit600in the direction of transport T. More preferably, at least two inspection devices726;728;916, and even more preferably three inspection devices726;728;916are located downstream of the at least one application unit600in the direction of transport T, preferably downstream of the last application unit600in the direction of transport T. The at least two inspection devices726;728;916are preferably arranged in the processing machine01one behind the other in the direction of transport T. The inspection device726;728;916is preferably in the form of a printed image monitoring system726and/or as a register monitoring system728and/or as a die-cutting monitoring system916. The inspection device726;728;916is preferably configured to detect at least one image forming element on the sheet02, preferably on the at least one sheet02of the sheets02, for example at least one part of the printed image of the sheet02and/or at least one register mark16;17;18;19;21;22;23;24. Each image forming element on a sheet02is preferably part of at least one print image element and/or one register mark16;17;18;19;21;22;23;24and/or one element which produces an image on the sheet02in question. The inspection device726;728;916is configured to detect the at least one register of the printed image, and additionally or alternatively the at least one image forming element of sheet02, and additionally or alternatively the at least one measurement of the print length l2of the at least one printed image of said sheet02, preferably the at least one sheet, and additionally or alternatively at least one defect in the at least one processing of said sheet02, preferably the at least one sheet, and additionally or alternatively at least one defect in the at least one printed image of said sheet02, preferably the at least one sheet. Defects in the printed image preferably include missing and/or added image forming elements of at least one print image element, and additionally or alternatively the color of the printed image and/or of the respective print image elements, and additionally or alternatively spatters of printing fluid at unintended locations. More preferably, the inspection device726;728;916is configured to detect the at least one image forming element of sheets02, and also to detect the measurement of the at least one print length l2of the at least one printed image of a sheet02, preferably the at least one sheet, and also to detect at least one defect in the at least one processing of a sheet02, preferably the at least one sheet, as well as to detect at least one defect in the at least one printed image of a sheet02, preferably the at least one sheet. The inspection device726;728;916is preferably configured to detect the at least one image forming element, along with the measurement of the at least one print length l2, the at least one processing defect, and the at least one defect in the at least one printed image of the sheet02. To determine the measurement of the print length l2, the inspection device726;728;916preferably detects at least the one first register mark16;17;18;19and at least the one second register mark21;22;23;24associated with the first register mark, or at least two image forming elements on the sheet02. By detecting the first register mark16;17;18;19and the second register mark21;22;23;24associated with the first register mark, a measurement of the print length l2in question is preferably generated and/or calculated, for example by an evaluation unit and/or by the relevant inspection device726;728;916. At least the length of the sheet02and/or the speed of the sheet02at the position in question along the transport path and/or other factors that influence the sheet02are preferably taken into account in determining the measurement of the print length l2. If the processing machine01has just one inspection device726;728;916, the at least one image sensing device of the inspection device726;728;916is preferably configured at least to detect the at least one image forming element on the sheet02, for example at least one part of the printed image of the sheet02and/or at least one register mark16;17;18;19;21;22;23;24. If the processing machine01has just one inspection device726;728;916, the inspection device726;728;916is preferably configured at least to detect the at least one image forming element on the sheet02which has a surface area of at least 0.01 mm2(zero point zero one square millimeter). At least one inspection device726;728, preferably at least two inspection devices726;728, even more preferably exactly two inspection devices726;728, if present, are preferably arranged between the at least one application unit600, preferably between the last application unit600, and the at least one shaping unit900in the direction of transport T. In a preferred embodiment, the processing machine01, which is preferably configured as a sheet-fed printing press01, is additionally or alternatively characterized in that at least one sheet sensor722in the form of a sheet monitoring sensor722is arranged upstream of the at least one inspection device726;728, preferably upstream of the at least two inspection devices726;728, in the direction of transport T. The sheet monitoring sensor722is preferably arranged downstream of the at least one application unit600in the direction of transport T, preferably downstream of the last application unit600of the sheet-fed printing press01and upstream of the at least one inspection device726;728, preferably upstream of the at least two inspection devices726;728in the direction of transport T. The sheet monitoring sensor722is preferably arranged upstream of a first inspection device726;728;916in the direction of transport T. The first inspection device726;728;916preferably refers specifically to the inspection device726;728;916that is positioned upstream of every other inspection device726;728;916in the direction of transport T. The first inspection device726;728;916is configured, for example, as a printed image monitoring system726and/or as a register monitoring system728. If the processing machine01comprises only one shaping unit900, which is not preceded in the direction of transport T, for example, by an application unit600, then the first inspection device726;728;916is preferably configured at least as a die-cutting monitoring system916. The at least one additional inspection device726;728;916, which is positioned downstream of the first inspection device726;728;916in the direction of transport T, is preferably referred to as the second inspection device726;728;916, and the one additional subsequent inspection device726;728;916is referred to as the third inspection device726;728;916. The sheet monitoring sensor722is preferably spaced from the at least one inspection device726;728;916, in particular from the first inspection device726;728;916, by a minimum distance of at least 250 mm (two hundred and fifty millimeters), preferably of at least 300 mm (three hundred millimeters), more preferably at least 330 mm (three hundred and thirty millimeters). Additionally or alternatively, the sheet monitoring sensor722is spaced from the at least one inspection device726;728;916, in particular from the first inspection device726;728, by a maximum distance of no more than 500 mm (five hundred millimeters), preferably a maximum of 450 mm (four hundred and fifty millimeters), more preferably a maximum of 400 mm (four hundred millimeters), even more preferably a maximum of 350 mm (three hundred and fifty millimeters). The sheet monitoring sensor722is preferably spaced from the at least one second inspection device726;728;916by a minimum distance of at least 600 mm (six hundred millimeters), preferably of at least 650 mm (six hundred and fifty millimeters), more preferably at least 700 mm (seven hundred millimeters). Additionally or alternatively, the sheet monitoring sensor722is spaced from the at least one second inspection device726;728;916by a maximum distance of no more than 850 mm (eight hundred and fifty millimeters), preferably no more than 800 mm (eight hundred millimeters), more preferably no more than 750 mm (seven hundred and fifty millimeters). The sheet monitoring sensor722is preferably configured to detect the time at which sheet02arrives at the position of the sheet monitoring sensor722, in particular to detect the time at which the leading edge03and/or the at least one register mark16;17;18;19;21;22;23;24and/or one part of the printed image of sheet02arrives at the position of the sheet monitoring sensor722. The sheet monitoring sensor722is preferably additionally configured to emit at least one signal, preferably at least one electrical signal, more preferably at least one closed-loop control signal or at least one open-loop control signal. The sheet monitoring sensor722is preferably configured to emit the at least one signal, preferably at least the one electrical signal, more preferably the at least one closed-loop control signal or the at least one open-loop control signal, whenever the leading edge03and/or the at least one register mark16;17;18;19;21;22;23;24and/or the part of the printed image in question on sheet02is registered by the sheet monitoring sensor722. The at least one inspection device726;728;916can preferably be controlled in a closed loop and/or in an open loop by the at least one signal, preferably by the at least one electrical signal, more preferably by the at least one closed-loop control signal or by the at least one open-loop control signal, from the at least one sheet monitoring sensor722. The printed image monitoring system726and the register monitoring system728can preferably be controlled in a closed loop and/or in an open loop by the same sheet monitoring sensor722. The time at which at least one acquisition by the at least one inspection device726;728;916is triggered can preferably be controlled in a closed loop and/or an open loop by the at least one signal, preferably by the at least one electrical signal, more preferably by the at least one closed-loop control signal or the at least one open-loop control signal, from the at least one sheet monitoring sensor722. The at least one inspection device726;728;916in each case preferably comprises at least one evaluation means or is connected to an evaluation means. In a preferred embodiment, the inspection device726;728;916is configured to determine the actual state of the at least one sheet02, in particular by means of the image sensing device. The actual state of sheet02is preferably the state of said sheet02, preferably the at least one sheet, in particular in terms of its printed image and/or shape and/or mass and/or contour, at the time it is detected by the inspection device726;728;916. Additionally or alternatively, the sheet processing machine01is preferably characterized in that the inspection device726;728;916comprises the evaluation means or is connected to the evaluation means, and in that the evaluation means is configured to compare the actual state of the at least one sheet02with a target state of said sheet02, preferably of the at least one sheet. The evaluation means is preferably configured to receive data about the actual state of sheet02from the image sensing device of the inspection device726;728;916and to evaluate said data. The target state of the sheet02in question is preferably the state, in particular in terms of its printed image and/or shape and/or mass and/or contour, which the sheet02, preferably an ideally produced sheet02, is meant to have, in particular at the time it is detected by the inspection device726;728;916, and/or which is specified for the at least one sheet02by at least one reference and/or by at least one sample sheet, in particular as a comparison value. For example, the target state of the sheet02in question is the desired and/or required state which a product produced from corresponding sheets02is meant to have. An ideally produced sheet02preferably describes a sheet02which, upon completion of each processing operation preferably within the unit100;300;600;700;900;1000associated with the respective processing operation, preferably corresponds precisely to the reference for that sheet02on which the respective processing operation is based. In a preferred embodiment, the target state of the sheet, preferably the at least one sheet02, in question, is and/or can be determined on the basis of a digital reference and/or a taught-in reference. The digital reference preferably contains at least some of the information, preferably all of the information that is necessary for an unequivocal identification of the required target state of the sheet02in question. The digital reference is preferably in the form of a digital image template. The digital reference is preferably in pdf or tif or jpg file format. The taught-in reference is preferably a sheet02which is in the form of a sample sheet and/or is detected by the inspection device726;728;916, for example, and/or is stored in the evaluation means as a basis for comparison. The inspection device726;728;916is preferably configured to determine the measure of an at least partial deviation of the at least one print image element and/or the printed image of the sheet02from the target state for that sheet02. Depending on the result of the determined measure of the deviation of the sheet02from the target state of that sheet02, preferably of the at least one sheet, each inspection device726;728;916is preferably configured to emit a signal, for example an optical signal and/or an open-loop control signal and/or a closed-loop control signal. If the measure of the deviation is within the tolerance range for the target state of the sheet02in question, the inspection device726;728;916is preferably configured to emit at least one “good” signal, i.e. the sheet02in question is considered to be in order. If the measure of the deviation lies outside of the tolerance range for the target state of the sheet02in question, the inspection device726;728;916is preferably configured to emit at least one “bad” signal, i.e. the sheet02in question is considered to be defective. Additionally or alternatively to the at least one “bad” signal, for example, each inspection device726;728;916is preferably configured to transmit at least one closed-loop and/or one open-loop control signal to the sheet diverter49. The at least one inspection device726;728;916is preferably configured at least as the printed image monitoring system726. The printed image monitoring system726is preferably located downstream of the sheet monitoring sensor722in the direction of transport T, more preferably without any other application unit600or shaping unit900therebetween. The at least one inspection device726is preferably positioned downstream of the at least one application unit600in the direction of transport T, preferably downstream of the last application unit600in the direction of transport T. More preferably, the printed image monitoring system726is located downstream of the at least one application unit600in the direction of transport T, preferably downstream of the last application unit600and upstream of the at least one shaping unit900, preferably upstream of a first shaping unit900, in the direction of transport T. The inspection device726configured as a printed image monitoring system726preferably comprises at least one image sensing device, preferably at least one optical image sensing device. The at least one image sensing device is preferably configured as a camera, more preferably as a color camera, more preferably as a line camera, more preferably as at least one CMOS sensor and/or at least one CCD sensor. At least one light source727in the form of a lighting unit727, for example an LED light source, in particular a light source727of white light, is preferably associated with the printed image monitoring system726. Preferably, at least two light sources727, in particular exactly two light sources727, are associated with the printed image monitoring system726. Preferably, at least one lighting unit727is positioned immediately upstream and/or one lighting unit is positioned immediately downstream of the sensing region of the printed image monitoring system726in the direction of transport T, with each lighting unit being directed toward the sensing region of the printed image monitoring system726. The printed image monitoring system726preferably comprises at least one optical device, for example at least one lens, which is preferably located between the at least one image sensing device and the transport path provided for the transport of sheets02. The at least one image sensing device of the printed image monitoring system726is preferably configured at least to detect the at least one image forming element on the sheet02, for example at least one part of the printed image of the sheet02and/or at least one register mark16;17;18;19;21;22;23;24. The printed image monitoring system726is preferably configured at least to detect the at least one image forming element on the sheet02which has a surface area of at least 0.1 mm2(zero point one square millimeter). In a preferred additional or alternative embodiment, the at least one printed image monitoring system726, in particular the at least one image sensing device of the printed image monitoring system726, is directed toward the transport path for sheets02in such a way that the at least one printed image, which can be applied to sheets02by the at least one application unit600, can be detected and preferably also evaluated at least in part by the printed image monitoring system726, in particular by the at least one image sensing device of the printed image monitoring system726. When sheets02are guided lying flat, for example, the printed image monitoring system726is preferably positioned above the transport path and/or the transport plane, in particular in the vertical direction V, downstream of the transport path and/or the transport plane. Thus the sheet02can be detected and/or inspected at least in part, preferably in full, from above by the printed image monitoring system726. When sheets02are guided lying flat, the at least one printed image is preferably arranged on the main surface of sheet02, facing upward. Thus, in this embodiment, the at least one printed image of the sheet02can be sensed and/or inspected and/or evaluated at least in part, preferably in full, by the printed image monitoring system726. With a preferred hanging guidance of sheets02, the printed image monitoring system726is preferably positioned below the transport path and/or the transport plane, in particular in the vertical direction V upstream of the transport path and/or upstream of the transport plane. Thus, the printed image monitoring system726is configured to detect and/or inspect the sheet02preferably at least in part, preferably in full, from below. With the hanging guidance of sheets02, the at least one printed image is preferably arranged on the main surface of sheet02, facing downward. Thus, at least in this embodiment, the printed image monitoring system726is preferably configured to sense and/or inspect the at least one printed image of the sheet02at least in part, preferably in full, from below, preferably in the vertical direction V, from upstream of the transport path and/or from upstream of the transport plane. The printed image monitoring system726, in particular the at least one image sensing device, is preferably configured to sense at least part of the working width, more preferably the entire working width, of the sheet processing machine01. An image sensing device may sense only part of the working width, for example, in which case the printed image monitoring system726preferably comprises at least two image sensing devices which are configured to sense at least partially different regions of the working width. If present, the at least two image sensing devices of the printed image monitoring system726are preferably arranged side by side in the direction of transport T and/or one behind the other in the transverse direction A. In a preferred embodiment of the processing machine01, the inspection device726in the form of the printed image monitoring system726is configured to detect at least one part of the printed image of sheet02, and preferably the entire printed image of sheet02. Preferably, the at least one inspection device726in the form of the printed image monitoring system726can inspect and/or evaluate at least one part of the printed image of sheet02. Any defects that appear in at least one part of the printed image of sheet02and, additionally or alternatively, any defects that appear in the sheets02themselves can preferably be detected and/or evaluated by the at least one printed image monitoring system726. Potential errors a printed image may have include, for example, spatters of printing fluid in positions on the sheet02that do not match a printing template, for example, and additionally or alternatively a deviation in the color of the printing fluid used in at least one print image element from the specified color of the printing fluid used in the printing template, and additionally or alternatively deviations of the printed image, in particular of at least one print image element, from the print template, for example due to a lack of printing fluid in positions where it is intended. Potential defects in sheets02include, for example, a buckling or unevenness in the sheet surface, and additionally or alternatively, holes or tears in the sheets02, and additionally or alternatively, kinks in the sheets02. In an alternative embodiment, at least the printed image is at least partially inspected and/or evaluated and/or adjusted by machine operators, preferably based on at least one sample sheet. In that case, an additional inspection device726in the form of a printed image monitoring system726is preferably optional in the processing machine01. The at least one inspection device726;728;916is preferably configured at least as a register monitoring system728, in particular as a color register monitoring system728. The register monitoring system728is preferably located downstream of the sheet monitoring sensor722in the direction of transport T, more preferably without any other application unit600or shaping unit900therebetween. Preferably, the at least one inspection device728is positioned downstream of the at least one application unit600in the direction of transport T, preferably downstream of the last application unit600in the direction of transport T. More preferably, the register monitoring system728is positioned downstream of the at least one application unit600in the direction of transport T, preferably downstream of the last application unit600and upstream of the at least one shaping unit900, preferably upstream of a first shaping unit900, in the direction of transport T. For example, the at least one register monitoring system728is located downstream, in the direction of transport T, of the at least one printed image monitoring system726, which in that case is the first inspection device726in the processing machine01. Alternatively, the at least one register monitoring system728is located upstream of the at least one printed image monitoring system726in the direction of transport T, and more preferably is then the first inspection device728in the processing machine01. The inspection device728in the form of a register monitoring system728preferably comprises at least one preferably optical image sensing device, preferably at least two preferably optical image sensing devices, more preferably exactly two preferably optical image sensing devices. The at least one image sensing device is preferably configured in each case as a camera, more preferably as a color camera, more preferably as a line camera, more preferably as a CMOS sensor and/or a CCD sensor. The register monitoring system728preferably has at least one light source, for example an LED light source. The register monitoring system728preferably comprises at least one optical device, which is preferably located between the at least one image sensing device and the transport path provided for the transport of sheets02. The at least one image sensing device of the register monitoring system728is preferably configured at least to detect the at least one image forming element on the sheet, preferably on the at least one sheet02, for example at least one part of the printed image of the sheet02and/or at least one register mark16;17;18;19;21;22;23;24. The register monitoring system728is preferably configured at least to detect the at least one image forming element on the sheet02which has a surface area of at least 0.01 mm2(zero point zero one square millimeter). In a preferred additional or alternative embodiment, the at least one register monitoring system728is directed toward the transport path for the purpose of sensing sheets02. In a preferred additional or alternative embodiment, the at least one register monitoring system728, in particular the at least one image sensing device of the register monitoring system728, is directed toward the transport path for sheets02in such a way that the at least one register mark16;17;18;19;21;22;23;24, each of which can be applied to sheet02by the at least one application unit600, can be detected and/or evaluated at least in part, preferably in full, by the register monitoring system728, in particular by the at least one image sensing device of the register monitoring system728. Each sheet02, preferably the at least one sheet, preferably has at least one register mark16;17;18;19;21;22;23;24, preferably two register marks16;17;18;19;21;22;23;24, for each application mechanism614used, each sheet02more preferably having a first register mark16;17;18;19, preferably in a forward region, in the direction of transport T, of the main surface of the sheet02which is furnished with at least one printed image, and a second register mark21;22;23;24, preferably in a rear region, in the direction of transport T, of the main surface of the sheet02which is furnished with at least one printed image. Preferably, at least one register mark16;17;18;19;21;22;23;24is applied to the at least one sheet02by each application mechanism614. Each register monitoring system728is preferably configured to detect, in particular as detecting, at least one register mark16;17;18;19;21;22;23;24per application mechanism614used. Preferably, the register monitoring system728is configured to detect, in particular as detecting, on a sheet02in question both the at least one first register mark16;17;18;19and the at least one second register mark21;22;23;24from the application mechanism614that was used. In a preferred embodiment, the register monitoring system728comprises at least two image sensing devices, preferably exactly two image sensing devices, which are preferably arranged one behind the other in the direction of transport T, preferably one directly behind the other in the direction of transport T. The first image sensing device of the register monitoring system728in the direction of transport T is preferably configured to detect the at least one first register mark16;17;18;19for each application mechanism614used, which is preferably located in the forward region in the direction of transport T of the main surface of each sheet02which has been furnished with at least one printed image. The second image sensing device of the register monitoring system728in the direction of transport T is preferably configured to detect the at least one second register mark21;22;23;24for each application mechanism614used, which is preferably located in the rear region, in the direction of transport T, of the main surface of the sheet02which has been furnished with at least one printed image. Alternatively, the first image sensing device is configured to detect the at least one second register mark21;22;23;24for each application mechanism614used and the second image sensing device is configured to detect the at least one first register mark16;17;18;19for each application mechanism614used. Therefore, in each case one image sensing device is preferably configured to detect the at least one first register mark16;17;18;19and another image sensing device is configured to detect the at least one second register mark21;22;23;24for each application mechanism614used. When sheet02is guided lying flat, for example, the register monitoring system728is preferably positioned above the transport path and/or the transport plane, in particular in the vertical direction V, downstream of the transport path and/or the transport plane. Thus the sheet02can be sensed and/or inspected at least in part from above by the register monitoring system728. When sheets02are guided lying flat, the at least one register mark16;17;18;19;21;22;23;24is preferably arranged on the main surface of the sheet02, facing upward. Thus, in this embodiment, the at least one register mark16;17;18;19;21;22;23;24on the sheet02can be detected and/or inspected and/or evaluated at least in part, preferably in full, by the register monitoring system728. With a preferred hanging guidance of sheets02, the register monitoring system728is preferably positioned below the transport path and/or the transport plane, in particular in the vertical direction V, upstream of the transport path and/or upstream of the transport plane. Thus, the register monitoring system728is preferably configured to sense and/or inspect the sheet02at least in part from below. With the hanging guidance of sheets02, the at least one register mark16;17;18;19;21;22;23;24is preferably arranged on the main surface of the sheet02, facing downward. Thus, at least in this embodiment, the register monitoring system728is preferably configured to detect and/or inspect the at least one register mark16;17;18;19;21;22;23;24on the sheet02at least in part, preferably in full, from below, preferably in the vertical direction V, from upstream of the transport path and/or from upstream of the transport plane. The register monitoring system728, in particular the sensing by the at least one image sensing device, is preferably configured to cover at least part of the working width of the sheet processing machine01. In an alternative embodiment, at least the register is inspected and/or evaluated and/or adjusted at least in part by machine operators, preferably based on at least one sample sheet. In that case, an additional inspection device728in the form of a register monitoring system728is preferably optional in the processing machine01. In a first printing process of the processing machine01, the register of the application units600relative to one another is preferably adjusted. To adjust the register, a single sheet02or at least two sheets02or as few sheets02as possible are preferably run through the units100;300;600;700;900;1000of the processing machine01in the direction of transport T. The register of the application units600in relation to one another is preferably detected and/or controlled in a closed loop by the register monitoring system728. The register monitoring system728preferably detects the at least one register mark16;17;18;19;21;22;23;24, preferably all of the register marks16;17;18;19;21;22;23;24, on each sheet02. With an ideally produced sheet02, when the processing machine01is in a printing operating state, each sheet02preferably has the at least one register mark16;17;18;19;21;22;23;24per application mechanism614at the reference position06;07;08;09;11;12;13;14associated with it. Depending on the deviation of a register mark16;17;18;19;21;22;23;24from its reference position06;07;08;09;11;12;13;14, varied adjustments may be necessary. Any potentially existing deviation in the register mark16;17;18;19;21;22;23;24from its reference position06;07;08;09;11;12;13;14, which preferably describes a deviation in the register, is preferably detected and additionally or alternatively evaluated by the register monitoring system728. Alternatively, the deviation in the register is preferably detected and/or evaluated by machine operators. If at least one of the register marks16;17;18;19;21;22;23;24deviates from its reference position06;07;08;09;11;12;13;14, the positioning of components of the processing machine01and/or the sheet guidance and/or the speed of the sheets02is preferably adjusted in accordance with the existing deviation. For example, the forme cylinder616preferably is controlled in a closed loop and/or the position of the forme cylinder616is adjusted and/or a subsequent sheet02on the transport path is controlled in a closed loop, in accordance with the existing deviation. If the first register mark16;17;18;19and the respective second register mark21;22;23;24of the same application mechanism614both deviate in the direction Y from their reference position06;07;08;09;11;12;13;14, for example, preferably by the same amount, which preferably corresponds to a displacement in the direction of transport T in the processing machine01, then the first register mark16;17;18;19and the respective second register mark21;22;23;24of the same application mechanism614are preferably displaced from their respective reference positions06;07;08;09;11;12;13;14by the distance ay. If the first register mark16;17;18;19and the second register mark21;22;23;24of an associated application mechanism614are preferably both displaced from their respective reference positions06;07;08;09;11;12;13;14by the distance ay, then the printing start times for the individual print image elements are different from one another, for example, and additionally or alternatively, the arrival time of the sheet02, preferably of the at least one sheet, in particular the arrival time of the leading edge03of the sheet02, is different, for example, from the arrival time of the printing forme at the respective processing point621of the relevant application mechanism614. Preferably, to adjust, in particular to minimize, the displacement of the at least one application mechanism614in the direction Y by the distance ay, the arrival time of the sheet02, in particular of the leading edge03of the sheet02, and the arrival time of the forward edge of the printing region of the corresponding forme cylinder616are preferably synchronized and/or coordinated with one another. The corresponding forme cylinder616is preferably accelerated and/or decelerated at least briefly by adjusting its rotational speed and/or position while at least part of the non-printing region is located at the processing point621, so that the forward edge of the printing region of the forme cylinder616preferably arrives at the relevant processing point621at the same time as the leading edge03of the sheet02. The corresponding forme cylinder616is preferably accelerated and/or decelerated at least briefly by adjusting its rotational speed and/or position in order to adjust the register in the direction Y, in particular in the circumferential direction of the forme cylinder616, while at least part of the non-printing region is located at the processing point621. If the first register mark16;17;18;19and the respective second register mark21;22;23;24of the same application mechanism614both deviate from their respective reference positions06;07;08;09;11;12;13;14in the direction X, for example, which preferably corresponds to a displacement in the transverse direction A in the processing machine01, then the first register mark16;17;18;19and the respective second register mark21;22;23;24of the same application mechanism614are preferably both displaced from their respective reference positions06;07;08;09;11;12;13;14in the direction X by the distance ax. If, preferably, the first register mark16;17;18;19and the second register mark21;22;23;24of an associated application mechanism614are both displaced from their respective reference positions06;07;08;09;11;12;13;14by the distance ax, then the printing forme and/or the forme cylinder616, for example, of the application mechanism614in question is/are displaced relative to the sheet02in the transverse direction A. Preferably, to adjust, in particular to minimize, the displacement of the at least one application mechanism614in the direction X by the distance ax, the forme cylinder616and/or the printing forme of the forme cylinder616of the application mechanism614in question is preferably shifted relative to the sheet02in the transverse direction A, counter to the direction of the displacement, preferably by the value of the distance ax. Preferably for adjusting the register in the direction X, the forme cylinder616and/or the printing forme of the forme cylinder616of the application mechanism614in question is preferably configured as shiftable relative to the sheet02in the transverse direction A, counter to the direction of the displacement, preferably by the value of the distance ax. The first reference position06;07;08;09and the second reference position11;12;13;14of the same application mechanism614are preferably spaced from one another by a reference length l1, in particular a reference length l1in the form of a reference path. The first register mark16;17;18;19and the second register mark21;22;23;24of the same application mechanism614are preferably spaced from one another by the print length l2, in particular the print length l2in the form of a printing path. If the second register mark21;22;23;24of at least one application mechanism614deviates from its assigned reference position11;12;13;14in the direction Y, for example, which preferably corresponds to a displacement in the direction of transport T in the processing machine01, and if the first register mark16;17;18;19of the same application mechanism614coincides at least partially with the reference position06;07;08;09assigned to it, then the print length l2is different from the reference length l1. If the print length l2deviates from the reference length l1, there has preferably been a change in the length over which the sheet02is printed by the one printing form of the relevant forme cylinder616. This is the case, for example, if upstream of the application unit614in question in the direction of transport T the sheet02has a length in the direction Y, in particular its length in the direction of transport T within the processing machine01, as a result of at least one processing operation and/or the application of printing fluid, which length differs from the original length of the sheet02, preferably the at least one sheet, prior to the at least one processing operation and/or prior to the application of printing fluid. For example, the length of the sheet02in the direction of transport T increases along the transport path as a result of the at least one processing operation and/or the application of printing fluid. Preferably, for adjusting the print length l2relative to the reference length l1, in particular for minimizing the difference between the print length l2and the reference length l1, the forme cylinder616preferably has a speed, in particular circumferential speed, which varies at least to some extent, as long as at least part of the printing region of the lateral surface of the forme cylinder is located at the processing point621. The rotational speed and/or the circumferential speed of the forme cylinder616is adjusted relative to the rotational speed and/or the circumferential speed of the impression cylinder617associated with it. For example, the impression cylinder617has a higher circumferential speed than the forme cylinder616. The print length l2is preferably adjusted relative to the reference length l1by accelerating and/or decelerating the forme cylinder616by means of the individual drive of the forme cylinder616, while the impression cylinder617is operated at a preferably constant circumferential speed. As a result, the print image which is applied to the sheet02is stretched and/or compressed, for example, relative to the printing forme used for printing. For example, a reduced circumferential speed of the forme cylinder616relative to the circumferential speed of the impression cylinder617will result in a lengthening of the printed image on the sheet02. The register can preferably be adjusted with respect to the print length l2in the circumferential direction of the forme cylinder616by accelerating and/or decelerating the forme cylinder616by means of the individual drive of the forme cylinder616, while the impression cylinder617is operated at a preferably constant circumferential speed. The first reference position06;07;08;09is preferably spaced from the second reference position11;12;13;14of the same application mechanism614by the reference path. The first register mark16;17;18;19and the second register mark21;22;23;24of the same application mechanism614are preferably separated from one another by the printing path. For an ideally manufactured sheet02, the printing path is preferably parallel, preferably identical, to the reference path. If the first register mark16;17;18;19deviates from its reference position06;07;08;09or if the second register mark21;22;23;24deviates from its reference position11;12;13;14, for example, the printing path is preferably at an angle w, in particular a tilt angle w, to the reference path. For example, the longitudinal axis of the forme cylinder616and/or the printing forme of the forme cylinder616of the application mechanism614in question is tilted relative to the transverse direction A, preferably relative to the sheet02, by the tilt angle w. Preferably, to adjust the tilt of the longitudinal axis of the forme cylinder616and/or the printing forme of the forme cylinder616of the application mechanism614in question relative to the transverse direction A, preferably relative to the sheet02, the forme cylinder616in question and/or the printing forme of the forme cylinder616in question is preferably tilted counter to the tilt angle w, preferably by the same amount of the tilt angle w, relative to the transverse direction A. For adjusting the register with respect to a skewed position of the print image element, the forme cylinder616in question and/or the printing forme of the forme cylinder616in question is preferably configured as tiltable and/or displaceable counter to the tilt angle w, preferably by the same amount of tilt angle w, relative to the transverse direction A. In a second printing process of the processing machine01, sheets02, in particular a multiplicity of sheets02, are processed by the at least one unit600;900of the processing machine01. In the second printing process, while sheets02are traveling along the transport path through the processing machine01, the corresponding sheet travel sensor622detects each sheet02, preferably the at least one sheet, and thus determines its arrival time at the position of the sheet travel sensor622in question. Each sheet02which passes the position of the sheet travel sensor622in question is preferably detected by the sheet travel sensor622. Each sheet02of the sheets02which passes the position of the at least one sheet sensor622, which is preferably configured as a sheet travel sensor622, is preferably detected by the sheet sensor622. Preferably independently of other values measured for other sheets02by this sheet travel sensor622, the forme cylinder616associated with the sheet sensor622, which is preferably configured as a sheet travel sensor622, is preferably controlled in a closed loop and/or in an open loop based on the arrival time of the one sheet02in question, preferably the at least one sheet, at the position of the sheet travel sensor622, preferably so that the leading edge03of the sheet02, preferably the at least one sheet, will arrive at the processing point621of the application unit600in question at the same time as the forward edge of the printing region of the forme cylinder616. During the second printing process, the inspection device726;728;916, in particular the register monitoring system728, preferably detects the at least one register mark16;17;18;19;21;22;23;24, in particular the respective register marks16;17;18;19;21;22;23;24, of sheets02. The inspection device726;728;916, in particular the register monitoring system728, preferably senses each sheet02that passes it. In a preferred embodiment, the inspection device726;728;916, in particular the register monitoring system728, ascertains the deviation of the at least one register mark16;17;18;19;21;22;23;24from its reference position06;07;08;09;11;12;13;14. In each case, from the ascertained deviations of at least two sheets02, preferably of at least five sheets02, more preferably of at least ten sheets02, the inspection device726;728;916, in particular the register monitoring system728, preferably establishes a mean deviation of the one register mark16;17;18;19;21;22;23;24from its reference position06;07;08;09;11;12;13;14. As soon as the amount of the mean deviation exceeds a threshold value, the inspection device726;728;916emits a signal, in particular a warning signal and/or a closed-loop control signal and/or an open-loop control signal. The inspection device726;728;916preferably controls the forme cylinder616associated with the register mark16;17;18;19;21;22;23;24in a closed loop and/or in an open loop by at least briefly altering its rotational speed and/or speed, with a mean deviation in the direction Y of the register mark16;17;18;19;21;22;23;24from its reference position06;07;08;09;11;12;13;14preferably by an amount that exceeds the threshold value, preferably so that the forward edge of the printing region of the forme cylinder616will arrive at the relevant processing point621at the same time as the leading edge03of the sheet02, preferably the at least one sheet. The inspection device726;728;916preferably controls, in a closed loop and/or an open loop, a deflection of the sheet02in question, preferably of the at least one sheet, from the actual transport path to an alternate transport path, for example, and/or emits at least one signal as soon as the deviation of the at least one register mark16;17;18;19;21;22;23;24from its reference position06;07;08;09;11;12;13;14exceeds the threshold value. In the printing process, in particular the second printing process, the arrival time of the individual sheet02at the processing point621of the application unit600and the arrival time of the forward edge of the printing region of the forme cylinder616of said application unit600are both adjusted and/or will both be adjusted by the signal from the sheet travel sensor622, associated with that application unit600, for the purpose of controlling the forme cylinder616in a closed loop and/or in an open loop. In the printing operating state, in particular in the second printing process, the register in the direction Y, preferably the register in the circumferential direction of the forme cylinder616, is preferably adjustable and/or adjusted in each case by the signal from the sheet sensor622, in particular the sheet travel sensor622associated with the application unit600, for the purpose of controlling the forme cylinder616in a closed loop and/or in an open loop. The closed-loop control and/or open-loop control by the at least one signal from the inspection device726;728;916is preferably configured to correct the mean deviation of the register mark16;17;18;19;21;22;23;24beyond the threshold value from its reference position06;07;08;09;11;12;13;14. In the event of a mean deviation of the register mark16;17;18;19;21;22;23;24beyond the threshold value from its reference position06;07;08;09;11;12;13;14, the at least one signal from the inspection device726;728;916is preferably followed by a manual and/or mechanical closed-loop and/or open-loop control of the register in the circumferential direction. In the second printing process, the closed-loop and/or open-loop control based on the sheet travel sensor622preferably supersedes the closed-loop and/or open-loop control based on the inspection device726;728;916for the purpose of adjusting the register in the direction Y, preferably for adjusting the register in the circumferential direction of the forme cylinder616. Additionally or alternatively, the processing machine01is preferably configured such that the print length l2is and/or can be adjusted by altering the circumferential speed and/or rotational speed of the forme cylinder616relative to the circumferential speed and/or rotational speed of the impression cylinder617associated with said forme cylinder616. Additionally or alternatively, the processing machine01is preferably configured such that the measurement of the print length l2detected by the at least one inspection device726;728;916, in particular the deviation of the print length l2relative to the reference length l1, is and/or can be adjusted by altering the circumferential speed and/or rotational speed of the forme cylinder616relative to the circumferential speed and/or rotational speed of the impression cylinder617associated with said forme cylinder616. The processing machine01comprises the shaping device900having the plate cylinder901with an individual drive and having the processing point909associated with the plate cylinder901. The plate cylinder901of each shaping device900is preferably driven mechanically independently of every other cylinder and/or roller of the shaping device900and/or the processing machine01. The at least one additional sheet sensor922, which is configured for the closed-loop and/or open-loop control of the position and/or rotational speed of the plate cylinder901of the shaping device900, is located upstream of the processing point909of the shaping device900along the transport path for sheets02. The at least one inspection device726;728;916is preferably additionally or alternatively located downstream of the plate cylinder901of the shaping device900along the transport path for sheets02, or the at least one additional inspection device916for inspecting at least part of the sheets02, preferably for inspecting at least part of at least one remaining part of the at least one sheet02which contains at least one multiple-up1101and which has been processed by the shaping device900, is additionally located downstream of the plate cylinder901of the shaping device900along the transport path for sheets02. Preferably, the at least one inspection device916configured at least as a die-cutting monitoring system916for inspecting at least part of sheets02, preferably for inspecting at least part of at least one remaining part of the at least one sheet02, which contains at least one multiple-up1101, preferably at least two multiple-ups1101, and which has been processed by the shaping device900, is positioned along the transport path provided for the transport of sheets02. In particular, the at least one inspection device916, which is preferably configured as a die-cutting monitoring system916, is configured to detect and/or to inspect the at least one remaining part of the at least one sheet02of the sheets02, which contains at least one multiple-up1101, preferably at least two multiple-ups1101, and which has been processed by the shaping device900. The inspection device726;728;916preferably in the form of a die-cutting monitoring system916is preferably configured to inspect at least part of the contour of at least one offcut piece, in particular scrap piece, which has been removed upstream of the die-cutting monitoring system916along the transport path, on the at least one sheet02, in particular on the at least one multiple-up1101and/or the at least one sheet opening1102. Preferably, the inspection device726;728;916in the form of a die-cutting monitoring system916is configured to inspect, to ascertain if at least part of the contour of at least one offcut piece, in particular a scrap piece, which was removed upstream of the die-cutting monitoring system916on the transport path, on the remaining sheet02, in particular on the at least one multiple-up1101and/or the at least one sheet opening1102is missing. The contour of the remaining sheet02preferably emerges downstream of the separation device903on the transport path or after the sheet02has passed through the sheet processing machine01, for example, as a result of the removal of the at least one offcut piece from the sheet02in question. Preferably, the sheet processing machine01having a shaping device900for processing sheets02preferably comprises the at least one separation device903and the at least one delivery unit1000, the separation device903being configured to remove at least one offcut piece from the at least one sheet02. Downstream of the at least one separation device903in the direction of transport T of sheets02, the at least one die-cutting monitoring system916for inspecting at least part of at least one remaining part of the at least one sheet02, which contains the at least one multiple-up1101and which has been processed by the shaping device900. The sheet02, preferably the at least one sheet, preferably contains at least one multiple-up1101, which has at least one printed image and at least one sheet opening1102. Preferably, the sheet02contains at least one multiple-up1101and at least one sheet opening1102, with the sheet02being made of paper or cardboard or paperboard. The die-cutting monitoring system916is preferably configured to detect at least part of the at least one sheet opening1102. The die-cutting monitoring system916, preferably the evaluation means, is preferably configured to compare at least the at least one sheet opening1102with a reference for the at least one sheet opening1102. The reference for the at least one sheet opening1102preferably contains at least a portion of the information, and preferably all of the information, that is required for an unequivocal identification of a required target state of the sheet opening1102in question. The reference for the at least one sheet opening1102is preferably in the form of a digital and/or taught-in reference. The digital reference is preferably in the form of a digital image template. The digital reference is preferably in pdf or tif or jpg file format. The taught-in reference is preferably a sheet02in the form of a sample sheet and having at least one sheet opening1102, which corresponds to the sheet opening1102to be inspected and/or which is detected, for example, by the die-cutting monitoring system916and/or is stored in the evaluation means as a basis for comparison. The inspection device916embodied as a die-cutting monitoring system916preferably comprises at least one image sensing device, preferably at least one optical image sensing device. The at least one image sensing device is preferably configured as a camera, more preferably as a color camera, more preferably as a line camera, more preferably as a CMOS sensor and/or a CCD sensor. In addition to the at least one image sensing device, the die-cutting monitoring system916comprises, for example, at least one light source, for example at least one LED light source. The die-cutting monitoring system916preferably comprises at least one optical device, which is preferably located between the at least one image sensing device and the transport path provided for the transport of sheets02. The die-cutting monitoring system916, in particular the at least one image sensing device, is preferably configured to capture data over at least part of the working width, more preferably the entire working width, of the sheet processing machine01. One image sensing device may cover only part of the working width, for example, in which case the die-cutting monitoring system916preferably comprises at least two image sensing devices, each of which is configured to cover a region of the working width which is at least partially different from the region covered by the other. If present, the at least two image sensing devices of the die-cutting monitoring system916are preferably arranged side by side in the direction of transport T and/or one behind the other in the transverse direction A. The die-cutting monitoring system is preferably located downstream of the shaping device900in the direction of transport T. In a preferred embodiment, the die-cutting monitoring system916is located immediately downstream of the separation device903in the direction of transport T. The die-cutting monitoring system916is preferably located immediately following the separation device903in the direction of transport T, without any possible other processing device therebetween and/or without any possible other processing stage, such as gluing a multiple-up1101and/or separating individual multiple-ups1101from one another, arranged therebetween. More preferably, the die-cutting monitoring system916is located upstream of any possible other processing device, for example a gluing device and/or a multiple-up separation device, for possible further processing of the at least one sheet02immediately following the separation device903. The die-cutting monitoring system916is preferably located upstream of the delivery unit1000and downstream of the separation device903in the direction of transport T. Additionally or alternatively, the sheet processing machine01is preferably characterized in that the die-cutting monitoring system916is preferably arranged orthogonally to the transport path of the at least one sheet02, provided for the transport of sheets02, and is directed toward the transport path of the at least one sheet02. Preferably, the die-cutting monitoring system916is arranged orthogonally to the transport plane of the at least one sheet02and directed toward the transport plane of the at least one sheet02. In the foregoing and in the following, the transport plane preferably refers to a plane of the transport path which is spanned by the direction of transport T and the transverse direction A, in particular at the position along the transport path to which reference is made. The die-cutting monitoring system916is preferably arranged outside of the transport path and directed toward the transport path and/or the transport plane. The die-cutting monitoring system916is preferably directed perpendicularly onto the transport path and/or the transport plane. Preferably, the die-cutting monitoring system916is arranged in the vertical direction V, upstream and/or downstream of the transport path. The die-cutting monitoring system916is preferably configured to inspect the sheet02from the side of the main surface of the sheet02on which the at least one printed image is applied to the sheet02. When sheet02is guided lying flat, for example, the die-cutting monitoring system916is preferably positioned above the transport path and/or the transport plane, in particular in the vertical direction V, downstream of the transport path and/or the transport plane. Thus, the die-cutting monitoring system916can inspect the sheet02from above. When sheets02are guided lying flat, the at least one printed image is preferably arranged on the main surface of sheet02, facing upward. Therefore, in this embodiment the inspection device916configured as a die-cutting monitoring system916is likewise configured to detect the at least one printed image of the sheet02. Preferably, with a hanging guidance of sheets02, the die-cutting monitoring system916is preferably positioned below the transport path and/or the transport plane, in particular in the vertical direction V, upstream of the transport path and/or upstream of the transport plane. Thus, the die-cutting monitoring system916is preferably configured to inspect the sheet02from below. With the hanging guidance of sheets02, the at least one printed image is preferably arranged on the main surface of sheet02, facing downward. Thus, at least in this embodiment, the die-cutting monitoring system916is preferably additionally or alternatively configured to inspect the at least one printed image of the sheet02from below, preferably in the vertical direction V, from upstream of the transport path and/or from upstream of the transport plane. Additionally or alternatively, the die-cutting monitoring system916is preferably configured to inspect the at least one remaining part of the at least one sheet02, which has been processed by the shaping device900, while at least one other sheet02is undergoing at least one shaping process. Thus, each die-cutting monitoring system916is preferably configured to sense each sheet02, and is preferably configured to sense each sheet02individually, which passes the die-cutting monitoring system916on the transport path in the direction of transport T. For example, as one sheet02, preferably the at least one sheet, is being sensed by the die-cutting monitoring system916, additional sheets02are already being processed in at least one shaping process of the at least one shaping device900and/or are traveling through at least one unit100;300;600;700;900of the sheet processing machine01which is located upstream of the inspection device916in the direction of transport T. In a preferred embodiment, the die-cutting monitoring system916, in particular the image sensing device of the die-cutting monitoring system916, is configured at least to detect at least part of one sheet opening1102, for example at least one sheet gap1102, of the at least one sheet02, and/or to detect at least one inner contour of the at least one sheet02, preferably defined by at least one sheet opening1102, and/or to detect at least one outer contour of the at least one sheet02, preferably defined by at least one outer edge of said sheet02. Alternatively, in a further preferred embodiment, the die-cutting monitoring system916, in particular the image sensing device of the die-cutting monitoring system916, is preferably configured at least to detect at least part of the at least one multiple-up1101and/or of the contour, in particular the margins, of said multiple-up1101, preferably of the at least one multiple-up1101of the multiple-ups1101. In the foregoing and in the following, the contour of a sheet02preferably describes the shape of that sheet02, in particular the outer and/or inner margins of the at least one multiple-up1101on said sheet02. The outer contour of the sheet02is preferably defined by at least one outer edge of the sheet02, in particular by at least one outer edge of the at least one multiple-up1101. The inner contour of the sheet02is preferably defined by at least one sheet opening1102and/or sheet gap1102, preferably within the outer contour of said sheet02, more preferably within the main area in the region of the at least one multiple-up1101on said sheet02. The die-cutting monitoring system916, in particular the image sensing device of the inspection device916, is preferably configured to sense at least part of the main surface of the sheet02. The die-cutting monitoring system916, in particular the image sensing device of the inspection device916, is preferably configured to sense at least part of the region of the at least one offcut piece and/or of the at least one sheet opening1102of sheet02. The inner contour of the at least one sheet02preferably corresponds to the contour of the at least one offcut piece of the sheet02in question, in particular after the at least one offcut piece has been removed from the sheet02in question. The die-cutting monitoring system916, in particular the evaluation means, is preferably configured for determining the measure of a deviation of the at least one sheet opening1102and/or the at least one inner contour and/or the at least one outer contour of the sheet02, preferably the at least one sheet, from the target state of said sheet02. For example, if a sheet opening1102has at least one part of the at least one offcut piece remaining in it, then the actual state of the sheet02in question deviates from the target state of the sheet02in question. If the part of the offcut piece that remains has an area of less than 25 mm2(twenty-five square millimeters), for example, preferably less than 20 mm2(twenty square millimeters), more preferably less than 15 mm2(fifteen square millimeters), then the measure of the deviation is preferably within the tolerance range for the target state of the sheet02, and the at least one “good” signal is emitted. If the at least one part of the offcut piece that remains has an area of at least 25 mm2(twenty-five square millimeters), preferably at least 30 mm2(thirty square millimeters), more preferably 35 mm2(thirty-five square millimeters), for example, the at least one “bad” signal is preferably emitted. Additionally or alternatively, the inspection device916configured as a die-cutting monitoring system916, in particular, is preferably configured at least to evaluate the at least one register of the at least one printed image of the at least one sheet02and/or at least to compare the at least one printed image of the at least one sheet02with the at least one sheet opening1102and/or the at least one inner contour and/or the at least one outer contour of that sheet02. Preferably, the inspection device726;728;916is configured to evaluate the at least one register of the at least one printed image of the at least one sheet02and/or at least to compare the at least one printed image of the at least one sheet02with the at least one sheet opening1102and/or the at least one inner contour and/or the at least one outer contour of that sheet02. The inspection device726;728;916is preferably configured to detect and/or evaluate at least part of the at least one printed image of sheet02, which was applied by the at least one application mechanism614. The inspection device726;728;916is preferably configured to detect the at least one printed image of the sheet02in question as at least one piece of information about the actual state of that sheet02, and to compare this actual state, for example using the evaluation means, preferably with the target state of the sheet02in question. Alternatively or additionally, the inspection device726;728;916is preferably configured to detect at least part of the at least one printed image and to detect at least part of the at least one sheet opening1102and/or the at least one inner contour and/or the at least one outer contour of sheet02. Preferably, the inspection device726;728;916, in particular the evaluation means, is configured to compare the at least one printed image of the sheet02, preferably the at least one sheet, at least with the contour of said sheet02, preferably the at least one sheet, for example by comparing the actual state of said sheet02with its target state. Additionally or alternatively, the processing machine01is preferably characterized in that the die-cutting monitoring system916is configured to determine a measure of tool wear of the at least one tool of the at least one shaping device900. The shaping device900, in particular the shaping mechanism914and/or the plate cylinder901, preferably comprises the at least one tool for processing sheets02, preferably at least one cutting tool and/or at least one creasing tool and/or at least one perforating tool and/or at least one embossing tool and/or at least one die-cutting tool. Processing sheets02subjects the tool to wear. The die-cutting monitoring system916is preferably configured to determine the measure of wear of the at least one tool of the shaping device900, in particular of the shaping mechanism914, preferably of the plate cylinder901, by detecting sheets02, in particular by inspecting the at least one remaining part of the at least one sheet02, which contains at least one multiple-up1101and which has been processed by the shaping device900, and/or preferably by comparing the actual state of the sheet02, preferably of the at least one sheet, with the target state of the sheet02in question, preferably of the at least one sheet. As a result of the direct contact of the tool of the shaping device900, in particular the shaping mechanism914, preferably the plate cylinder901, with the counterpressure cylinder902and/or the sheet02, for example, at least one external force acts on the tool, producing wear on the tool and/or on the counterpressure cylinder902, for example. Additionally or alternatively, the processing machine01is preferably characterized in that the die-cutting monitoring system916is configured to determine a measure of wear on at least one surface of the at least one counterpressure cylinder902of the at least one shaping device900. In the case of a rotary die-cutting device900, for example, the at least one counterpressure cylinder902preferably has a surface which is preferably in direct contact with the tool of the shaping device900, in particular the tool of the plate cylinder901. As a result of the direct contact of the surface of the counterpressure cylinder902with the tool of the shaping device900, preferably of the plate cylinder901, for example, at least one external force acts on the surface of the counterpressure cylinder902, producing wear on the counterpressure cylinder902and/or the respective tool, for example. The inspection device726;728;916, in particular the evaluation means, is preferably configured to store and evaluate data about the sheets02being transported and preferably to prepare at least one report regarding the quality of the sheets02. The report preferably includes at least the total number of sheets02processed within at least one unit of time and/or within one order and/or the number and/or percentage of the processed sheets02that have been routed to the delivery pile carrier48and/or that have been routed to the diverted delivery51. Additionally or alternatively, the report preferably includes the total number of multiple-ups1101and/or the number and/or percentage of multiple-ups1101that have been routed to the delivery pile carrier48and/or that have been routed to the diverted delivery51. Preferably, the report additionally or alternatively includes at least one piece of information about the reason for each diversion of the sheets02and/or multiple-ups1101in question to the diverted delivery51. Possible reasons for a diversion to the diverted delivery51include, for example, the measure of the deviation of the at least one sheet opening1102and/or inner contour and/or outer contour of a sheet02from the target state of the sheet02in question, additionally or alternatively the evaluation of the at least one register of the at least one printed image of the sheet02in question and/or the comparison of the at least one printed image with at least one sheet opening1102and/or inner contour and/or outer contour of the sheet02in question. Additionally or alternatively, the report includes, for example, at least one piece of information about the measure of tool wear of the at least one tool of the shaping device900. Additionally or alternatively, the report preferably includes the measure of the position of the at least one multiple-up1101relative to a reference for the position of the at least one multiple-up1101, and additionally or alternatively includes the measure of the color of the at least one printed image of said sheet02and/or multiple-up1101, and additionally or alternatively includes the measure of at least one defect in the at least one processing of said sheet02and/or multiple-up1101and/or of the at least one printed image of said sheet02and/or multiple-up1101. For example, the report includes additional information which preferably is and/or can be detected by the at least one inspection device726;728;916or also by other components of the sheet processing machine01. It is thus possible, for example, to precisely adjust and preferably guarantee a desired and/or required quality of the sheets02preferably processed by the shaping machine900, for example in the delivery pile of the delivery unit1000. Additionally or alternatively, the processing machine01is preferably characterized in that the inspection device726;728;916is configured to determine, preferably by comparing the actual state of the at least one sheet02with the target state of that sheet02, preferably the at least one sheet, a measure of the position of the at least one multiple-up1101relative to a reference for the position of the at least one multiple-up1101, and additionally or alternatively, a measure of the color of at least one printed image of said sheet02, preferably the at least one sheet, and additionally or alternatively, a measure of at least one defect in the processing of said sheet02, preferably the at least one sheet, and/or of a printed image of said sheet02, preferably the at least one sheet, on the basis of missing parts and/or added parts. Additionally or alternatively, the sheet processing machine01is preferably characterized in that the inspection device726;728;916comprises the evaluation means or is connected to the evaluation means, and in that the alteration of the transport path of a relevant sheet02, preferably the at least one sheet, in particular the sheet diverter49, is controlled in a closed loop and/or in an open loop and/or is configured for closed-loop and/or open-loop control based on at least the one signal from the at least one evaluation means. The alteration of the transport path, in particular the sheet diverter49, is preferably controlled in a closed loop and/or in an open loop and/or configured for closed-loop and/or open-loop control, preferably based on the evaluation of the detected sheet02by the evaluation means, preferably by the evaluation means of the inspection device726;728;916. For example, the signal can be transmitted by the evaluation means, in particular by the evaluation means of the inspection device726;728;916, to an open-loop control unit and/or closed-loop control unit of the sheet diverter49, which initiates and/or is configured to initiate a closed-loop control of the sheet diverter49and/or an alteration of the transport path. Additionally or alternatively, the sheet processing machine01is preferably characterized in that the transport path between the inspection device916configured as a die-cutting monitoring system916and the position of the alteration of the transport path of the sheet02in question, preferably of the at least one sheet, in particular the sheet diverter49, is at least 30 cm (thirty centimeters), preferably at least 40 cm (forty centimeters), more preferably at least 50 cm (fifty centimeters). The transport path between the inspection device916and the sheet diverter49preferably has a length which a transported sheet02is preferably configured to travel, depending on the speed of the transported sheets02, in at least 50 ms (fifty milliseconds), preferably in at least 80 ms (eighty milliseconds), more preferably in at least 100 ms (one hundred milliseconds). The transport path between the inspection device916and the sheet diverter49preferably has a length which a transported sheet02is configured to travel, depending on the speed of the sheets02being transported, in no more than 1000 ms (one thousand milliseconds), preferably in no more than 800 ms (eight hundred milliseconds), more preferably in no more than 300 ms (three hundred milliseconds). The sheet02, preferably the at least one sheet, preferably comprises at least one multiple-up1101, preferably at least two multiple-ups1101, more preferably at least four multiple-ups1101, more preferably at least eight multiple-ups1101, more preferably a multiplicity of multiple-ups1101. Each multiple-up1101preferably contains at least one printed image. The sheet02, preferably the at least one sheet, is preferably processed by the at least one application unit600and/or in the at least one shaping device900. Preferably, each sheet02is processed in at least one processing operation by means of at least one device of the sheet processing machine01, for example each sheet is furnished with at least one application fluid and/or is mechanically processed and/or is altered in terms of its shape and/or is die cut. During each processing operation, the sheets02are preferably transported at a processing speed in particular along the transport path provided for the transport of sheets02. Downstream of the shaping device900, preferably the die-cutting device900and/or rotary die-cutting device900, in the direction of transport T of the sheets02, at least one offcut piece is preferably removed from the sheet02, preferably the at least one sheet. The at least one offcut piece is preferably removed from the sheet02, preferably the at least one sheet, as early as during the at least one processing operation and/or during the transport of said sheet02, preferably the at least one sheet, along the transport path, preferably along the transport path between the at least one shaping device900and the at least one separation device903, and/or by the at least one separation device903. The separation device903is preferably configured to remove the at least one offcut piece. More preferably, the separation device903is configured to remove the at least one offcut piece completely from the sheet02, preferably the at least one sheet. The at least one inspection device726;728;916preferably determines the actual state of the sheet02, preferably the at least one sheet. Downstream of the last application mechanism614in the direction of transport T, the printed image monitoring system726and/or the register monitoring system728preferably determines the actual state of the sheet02, preferably the at least one sheet. Downstream of the separation device903in the direction of transport T, the die-cutting monitoring system916preferably determines the actual state of the sheet02, preferably the at least one sheet. The inspection device726;728;916preferably determines the actual state of the sheet02in question, preferably the at least one sheet, which is preferably the state of the sheet02, in particular with respect to printed image and/or register accuracy and/or shape and/or mass and/or contour, which said sheet02, preferably the at least one sheet, has at the time it is detected by the inspection device726;728;916. The actual state of the sheet02in question, preferably of the at least one sheet, is preferably compared with the target state of said sheet02, preferably the at least one sheet. The inspection device726;728;916and/or the evaluation means preferably compares the actual state of the sheet02in question with the target state of said sheet02. More preferably, the evaluation means of the inspection device726;728;916compares the actual state of the sheet02in question with the target state of said sheet02. Preferably, the actual state of the sheet02in question, preferably the at least one sheet, is compared with the target state of said sheet02, preferably the at least one sheet, the target state of the sheet02preferably being the state of the sheet02, in particular with respect to its printed image and/or register accuracy and/or shape and/or mass and/or contour, which an ideally produced sheet02should have and/or has, in particular at the time it is detected by the inspection device726;728;916. Additionally or alternatively, the method is preferably characterized in that the die-cutting monitoring system916preferably detects at least part of the at least one sheet opening1102of the at least one sheet02and/or the at least one inner contour of the at least one sheet02, which is preferably defined by at least one sheet opening1102, and/or the at least one outer contour of the at least one sheet02, which is preferably defined by at least one outer edge of said sheet02. The die-cutting monitoring system916preferably detects the shape of the sheet02and/or of the at least one multiple-up1101, preferably at least the inner and/or outer margins of the at least one multiple-up1101on the sheet02in question. The die-cutting monitoring system916preferably detects the at least one outer edge of the sheet02and additionally or alternatively detects the at least one sheet opening1102of the sheet02in question. Preferably, the die-cutting monitoring system916detects at least the region of the at least one offcut piece and/or at least the region of the at least one sheet opening1102. The inner contour of the at least one sheet02preferably corresponds to the contour of the at least one offcut piece of the sheet02in question, which has preferably been removed from the sheet02in question. Alternatively or additionally, the method is preferably characterized in that the measure of the deviation of the at least one sheet opening1102and/or the at least one inner contour and/or the at least one outer contour of the sheet02from the target state of said sheet02is determined by comparing the actual state of the at least one sheet02with the target state of the sheet02in question. Depending on the result of the determined measure of the deviation of the at least one sheet opening1102and/or the at least one inner contour and/or the at least one outer contour of the sheet02from the target state of said sheet02, the inspection device726;728;916, in particular the evaluation means, preferably emits the at least one signal, for example the optical signal and/or the open-loop control signal and/or the closed-loop control signal. If the measure of the deviation is within the tolerance range for the target state of the sheet02in question, the inspection device726;728;916, in particular the evaluation means, preferably emits the at least one “good” signal. If the measure of the deviation lies outside of the tolerance range for the target state of the sheet02in question, the inspection device726;728;916, in particular the evaluation means, preferably emits the at least one “bad” signal. In addition or as an alternative to the at least one “bad” signal, for example, the inspection device726;728;916, in particular the evaluation means, preferably emits the at least one signal for the closed-loop control and/or the open-loop control of the sheet diverter49. If at least a part of the at least one offcut piece is left in the sheet02in question, preferably the at least one sheet, downstream of the separation device903in the direction of transport T, and if the area of at least one remaining offcut piece, for example, is less than 25 mm2(twenty-five square millimeters), preferably less than 20 mm2(twenty square millimeters), more preferably less than 15 mm2(fifteen square millimeters), then the measure of the deviation is preferably within the tolerance range for the target state of said sheet02and the at least one “good” signal is emitted, for example. If the area of the at least one remaining part of the offcut piece is at least 25 mm2(twenty-five square millimeters), preferably at least 30 mm2(thirty square millimeters), more preferably 35 mm2(thirty-five square millimeters), for example, the at least one “bad” signal is preferably emitted and, additionally or alternatively, the at least one signal for the closed-loop control and/or open-loop control of the sheet diverter49is emitted. Additionally or alternatively, the method is preferably characterized in that the target state of the sheet02in question is determined using the digital and/or taught-in reference as a basis. Additionally or alternatively, the method is preferably characterized in that downstream of the inspection device916configured as the die-cutting monitoring system916and upstream of the delivery unit1000in the direction of transport T, an alteration of the transport path of the sheet02in question, preferably the at least one sheet, provided for the transport of sheets02, in particular the sheet diverter49, is controlled in an open loop and/or a closed loop, on the basis of the comparison of the actual state of the sheet02in question, preferably the at least one sheet, with the target state of the sheet02in question, preferably the at least one sheet. Preferably, the alteration of the transport path provided for the transport of sheets02, in particular the sheet diverter49, is controlled in an open loop and/or a closed loop on the basis of the comparison of the at least one sheet opening1102with the reference for the at least one sheet opening1102and/or on the basis of the comparison of the actual state of the sheet02in question with the target state of said sheet02. The sheet02in question, preferably the at least one sheet, is preferably left on the provided transport path or diverted from the provided transport path onto an alternate transport path depending on the comparison of the actual state of the sheet02in question with the target state of the sheet02in question. To control the alteration of the transport path, in particular the sheet diverter49, in an open and/or a closed loop, the inspection device726;728;916, in particular the evaluation means, preferably emits the at least one signal. The inspection device726;728;916preferably comprises the evaluation means or is connected to the evaluation means, and the alteration of the transport path, in particular the sheet diverter49, is preferably closed-loop controlled and/or open-loop controlled based on the at least one signal from the evaluation means. The inspection device726;728;916, in particular the evaluation means, preferably emits the at least one signal for controlling the alteration of the transport path, in particular the sheet diverter49, in an open loop and/or a closed loop, in particular when the measure of the deviation is outside of the tolerance range for the target state of the sheet02in question. The inspection device726;728;916, in particular the evaluation means, preferably emits the at least one signal for controlling the alteration of the transport path, in particular the sheet diverter49, in an open loop and/or a closed loop, regardless of whether or not the measure of the deviation is outside of the tolerance range of the target state of the sheet02in question. In other words, the inspection device726;728;916, in particular the evaluation means, emits the at least one signal for the open-loop and/or closed-loop control of the alteration of the transport path, in particular the sheet diverter49, preferably during and/or after the inspection of the sheet02in question, for example in addition or as an alternative to the at least one “good” signal or the at least one “bad” signal. Additionally or alternatively, the method is preferably characterized in that the inspection device726;728;916comprises the evaluation means or is connected to the evaluation means and in that the alteration of the transport path of a sheet02in question, in particular the sheet diverter49, is closed-loop controlled and/or open-loop controlled based on the at least one signal from the evaluation means. Additionally or alternatively, the method is preferably characterized in that the response time from the beginning of the process for determining the actual state of the sheet02in question up to the closed-loop control and/or open-loop control of the alteration of the transport path for the purpose of diverting said sheet02, in particular the sheet diverter49, is at least 50 ms (fifty milliseconds), preferably at least 80 ms (eighty milliseconds), more preferably at least 100 ms (one hundred milliseconds). The determination of the actual state of the sheet02in question preferably begins at the leading end in the direction of transport T, more preferably at the forward edge03in the direction of transport T, of the sheet02in question, and/or preferably as soon as the forward edge03, in the direction of transport T, of the sheet02in question reaches the region of the transport path that is detected by the inspection device726;728;916in the direction of transport T. The sheet02in question, in particular the leading edge of the sheet02in question in the direction of transport T, preferably travels the transport path between the inspection device726;728;916and the position for altering the transport path, in particular the sheet diverter49, preferably in at least 50 ms (fifty milliseconds), preferably in at least 80 ms (eighty milliseconds), more preferably in at least 100 ms (one hundred milliseconds), depending on the speed of the transported sheets02. The sheet02in question, in particular the leading edge of the sheet02in question in the direction of transport T, preferably the forward edge03of the sheet02in question in the direction of transport T, preferably traverses the transport path between the inspection device916and the position for altering the transport path, in particular the sheet diverter49, preferably in no more than 1,000 ms (one thousand milliseconds), preferably no more than 800 ms (eight hundred milliseconds), more preferably no more than 300 ms (three hundred milliseconds), depending on the speed of the transported sheets02. Additionally or alternatively, the method is preferably characterized in that the inspection device726;728;916is arranged orthogonally to the transport path of the at least one sheet02, which is provided for the transport of sheets02, and is directed toward the transport path of the at least one sheet02. The inspection device726;728;916preferably captures the at least one part of the transport path and/or the transport plane toward which it is directed. The inspection device726;728;916is preferably directed perpendicularly onto the transport path and/or the transport plane and preferably captures the at least one part of the transport path perpendicularly. Additionally or alternatively, the method is preferably characterized in that the at least one printed image, in particular the at least one printed image of the multiple-up1101, is applied to the at least one sheet02by the at least one application mechanism614of the sheet processing machine01upstream of the shaping device900in the direction of transport T. The at least one printed image is applied to the sheet02in question by the at least one application mechanism614, for example. The sheet processing machine01comprises at least two application mechanisms614, for example, by which two print images and/or print image elements, for example, which differ from one another in terms of at least one property, for example the application fluid used and/or the position of the printed images on the sheet02, are and/or can be applied to the sheet02in question. Additionally or alternatively, the method is preferably characterized in that the inspection device726;728;916comprises the evaluation means or is connected to the evaluation means and in that the inspection device726;728;916and/or the evaluation means detects and/or evaluates the at least one register of the at least one printed image. Preferably, the method is preferably characterized in that the inspection device726;728;916comprises the evaluation means or is connected to the evaluation means and in that the inspection device726;728;916and/or the evaluation means evaluates the at least one register of the at least one printed image of the at least one sheet02and/or compares the at least one printed image of the at least one sheet02with the at least one sheet opening1102and/or the at least one inner contour and/or the at least one outer contour of said sheet02. The inspection device726;728;916, in particular the evaluation means, preferably compares the actual state with the target state of the sheet02in question, wherein to determine the actual state of the sheet02in question, the at least one printed image of the sheet02in question, in particular of the respective multiple-up1101, and/or the at least one sheet opening1102and/or the at least one inner contour and/or the at least one outer contour of the sheet02in question, is preferably determined. Additionally or alternatively, the method is preferably characterized in that the inspection device726;728;916comprises the evaluation means or is connected to the evaluation means and in that the inspection device916configured, in particular, as a die-cutting monitoring system916and/or the evaluation means detects and/or evaluates the position of the at least one multiple-up1101relative to the reference for the position of the at least one multiple-up1101. The reference for the position of the multiple-up1101in question is preferably in the form of at least one additional multiple-up1101and/or the at least one register mark16;17;18;19;21;22;23;24on the sheet02in question and/or at least one edge03;04of the sheet02and/or at least one boundary of said sheet02, in particular the outer contour of said sheet02. Additionally or alternatively, the method is preferably characterized in that the inspection device726;728;916comprises the evaluation means or is connected to the evaluation means and in that the inspection device726;728;916and/or the evaluation means detects and/or evaluates the at least one color of the at least one printed image. The color of the printed image is preferably determined by the at least one application fluid preferably used to produce the printed image and/or preferably corresponds to the application fluid used to produce the printed image, which is preferably dried on the sheet02. Additionally or alternatively, the method is preferably characterized in that the inspection device726;728;916comprises the evaluation means or is connected to the evaluation means and in that the inspection device726;728;916and/or the evaluation means detects and/or evaluates at least one defect in processing of a sheet02and/or at least one defect in the at least one printed image due to missing parts and/or added parts. One example of a defect in the processing of a sheet02is a defect in the material of said sheet02. One example of a defect in the at least one printed image is, for example, an added application applied to the sheet02, for example a grease stain or additionally applied application fluid. Additionally or alternatively, the method is preferably characterized in that the measure of the tool wear of the at least one tool of the at least one shaping device900, in particular of the shaping unit914, preferably of the plate cylinder901, of the sheet processing machine01is determined by comparing the actual state of the at least one sheet02with the target state of said sheet02. The inspection device726;728;916preferably comprises the evaluation means or is connected to the evaluation means and the inspection device726;728;916and/or the evaluation means preferably determines the measure of tool wear of the at least one tool of the at least one shaping device900of the sheet processing machine01for processing the sheet02in question before the sheet02in question is inspected by the inspection device726;728;916. Additionally or alternatively, the method is preferably characterized in that the measure of the wear on the at least one surface of the at least one counterpressure cylinder902of the at least one shaping device900of the sheet processing machine01is preferably determined by comparing the actual state of the at least one sheet02with the target state of said sheet02. Additionally or alternatively, the method is preferably characterized in that the at least one sheet02is transported in a hanging state in the direction of transport T and in that the inspection device726;728;916is positioned below the transport path of the at least one sheet02, which is provided for the transport of sheets02, and is directed toward the transport path. The inspection device726;728;916preferably inspects the sheet02from the side of the main surface of the sheet02on which the at least one printed image is applied to the sheet02. With a hanging guidance of sheets02, the inspection device726;728;916is preferably positioned below the transport path and/or the transport plane, preferably in the vertical direction V, upstream of the transport path and/or the transport plane, and directed toward the transport path and/or the transport plane. Thus, the inspection device726;728;916preferably inspects the sheet02from below. The inspection device726;728;916thus preferably captures at least one part of the transport path and/or at least one part of the transport plane and thus at least one part of the at least one sheet02, which passes the inspection device726;728;916on the transport path in the direction of transport T, at the specific position on the transport path and/or the transport plane toward which the inspection device726;728;916is directed from below. The at least one printed image is preferably applied to the sheet02from below, i.e. in the vertical direction V, upstream of the sheet02. Thus, at least in this embodiment, the inspection device726;728;916preferably additionally or alternatively inspects the at least one printed image of the sheet02from below, preferably in the vertical direction V, from in front of the transport path and/or from in front of the transport plane. Additionally or alternatively, the method is preferably characterized in that the measure of the position of the at least one multiple-up1101relative to a reference for the position of the at least one multiple-up1101, and additionally or alternatively the measure of the color of at least one printed image of a sheet02in question, and additionally or alternatively the measure of at least one defect in the processing of said sheet02and/or the at least one printed image of said sheet02based on missing parts and/or added parts is determined by comparing the actual state of the at least one sheet02with the target state of said sheet02. The sheet02preferably contains the at least one multiple-up1101with the at least one printed image and the at least one sheet opening1102, for example the at least one sheet gap1102. The inspection device726;728;916preferably detects at least part of the at least one sheet opening1102. The inspection device726;728;916, in particular the evaluation means, preferably compares at least the at least one sheet opening1102with the reference for the at least one sheet opening1102. The sheet02preferably contains the at least one multiple-up1101and at least one sheet opening1102. Said sheet02is preferably made of paper or cardboard or paperboard. The inspection device726;728;916preferably detects at least part of the at least one sheet opening1102. The at least one sheet opening1102preferably corresponds to at least one part of an offcut piece removed from the sheet02in question. Additionally or alternatively, the sheet opening1102has preferably been produced by removing the at least one part of the at least one offcut piece from the sheet02in question. Additionally or alternatively, the method is preferably characterized in that the inspection device726;728;916detects at least part of the at least one contour and/or the at least one shape and/or the at least one mass and/or the at least one area of the at least one sheet opening1102. Additionally or alternatively, the method is preferably characterized in that the contour and/or shape and/or mass and/or area of the at least one sheet opening1102corresponds to the contour and/or shape and/or mass and/or area of the at least one offcut piece removed from the sheet02in question. The reference for the at least one sheet opening1102and/or the target state of the sheet02in question preferably is and/or can be determined on the basis of the digital reference and/or the taught-in reference. The reference for the sheet02in question preferably includes the reference for the at least one sheet opening1102of said sheet02. The sheet02is preferably inspected with regard to the processing of said sheet02by the shaping device900and, additionally or alternatively, with regard to the at least one printed image applied to said sheet02and, additionally or alternatively, with regard to the at least one printed image applied to said sheet02relative to the at least one sheet opening1102and/or the at least one inner contour and/or the at least one outer contour of said sheet02. The method is preferably characterized in that the sheets02are modified in terms of their shape in a respective shaping process. The shaping process is preferably a die-cutting process, in which the sheet02is die cut, in particular with parts of the sheet02being removed. Alternatively or additionally, the method is preferably characterized in that in a corresponding separation process the sheets02are freed at least partially from the offcut pieces, for example by jogging. During this process the sheets02are preferably transported by means of the at least one separation transport means904. While preferred embodiments of a processing machine for processing sheets and of a method for processing sheets, in accordance with the present invention, have been set forth fully and completely hereinabove, it will be apparent to one of skill in the art that various changes could be made thereto, without departing from the true spirit and scope of the present invention, which is accordingly to be limited only by the appended claims. | 216,243 |
11858257 | DETAILED DESCRIPTION Identification document personalization systems and methods are described herein. Referring toFIG.1, an example of an identification document personalization system10that can implement the methods described herein includes a DOD print station12with at least one DOD print head that applies radiation curable material, for example UV curable material, to a surface of an identification document. A curing station14is adjacent to the DOD print station. The curing station14includes at least one radiation emitting device, for example a UV light emitting device, that cures the radiation curable material applied to the surface. The curing station14is configured to prevent stray radiation emitted from the radiation emitting device from impinging on the DOD print head(s) and prevent exposure to the operator of the system10and the DOD print station12. The system10is configured to personalize an identification document16. During personalization, the document16generally travels in the direction of the arrow D along a document travel path which may be linear. Transport of the document16along the card travel path between each station and through each station is achieved using suitable transport mechanisms known in the art including rollers, belts, tabbed belts, and combinations thereof. The transport mechanisms may be configured to transport the document16in a single, forward direction, or the transport mechanisms may be reversible to transport the document16in forward and reverse directions. Document transport mechanisms are well known in the art including those disclosed in U.S. Pat. Nos. 6,902,107, 5,837,991, 6,131,817, and 4,995,501 and U.S. Published Application Nos. 2013/0220984 and 2018/0326763, each of which is incorporated herein by reference in its entirety. A person of ordinary skill in the art would readily understand the type(s) of document transport mechanisms that could be used, as well as the construction and operation of such document transport mechanisms. The print station12can be a conventional DOD print station known in the art that includes at least one, for example a plurality of, DOD printheads, one printhead for each ink color and other material, such as varnish, to be printed. The inks and other materials printed by the print station12are curable by radiation, such as ultraviolet (UV) radiation, after being applied to the document16. The print station12further includes a document transport mechanism for transporting the document16along the document transport path within the print station12. The document transport mechanism of the print station12may be reversible to permit transport of the document16in forward and reverse directions in the print station12. Operation of the print station12can be controlled by a suitable controller18which can control the entire system10, or the print station12can have its own dedicated controller. A DOD print station that can be utilized is the DOD printing module available from Entrust Corporation of Shakopee, Minnesota. With continued reference toFIG.1, the radiation curing station14is positioned in the system10so as to be able to apply radiation to radiation curable material that is applied to the surface of the document16by the DOD print station12to fully cure the radiation curable material. For example, the radiation curing station14can be located downstream of the print station12. The radiation curing station14includes a document transport mechanism for transporting the document16along the transport path within the station14. The document transport mechanism of the station14may be reversible to permit transport of the document16in forward and reverse directions in the station14. The station14is configured with one or more radiation emitting devices to emit radiation to cure the radiation curable material. The device(s) may be on or more light emitting diodes, and the radiation may be UV radiation. The radiation emitting device(s) may be configured to apply radiation to the entire document surface in a single pass of the document16and the radiation emitting device(s) relative to one another, or apply radiation only to portions of the document surface containing radiation curable material. Operation of the station14can be controlled by the controller18, or the station14can have its own dedicated controller. A radiation curing station that can be utilized is described in U.S. 2021/0086530, the entire contents of which are incorporated herein by reference, or available from Entrust Corporation of Shakopee, Minnesota. With continued reference toFIG.1, the system10may also optionally include a plasma treatment station20that is positioned in the system10so as to be able to plasma treat the surface of the document16prior to DOD printing. For example, the plasma treatment station20can be located upstream of the print station12. The plasma treatment station14includes a document transport mechanism for transporting the document16along the document transport path within the station20. The document transport mechanism of the station20may be reversible to permit transport of the document16in forward and reverse directions in the station20. The station20may be configured to move a plasma treatment nozzle (also referred to as a plasma treater) and the document16relative to one another during plasma treatment of the document surface. In one embodiment, the document16is held stationary during plasma treatment while the plasma nozzle is moved relative to the document16, with the document transport mechanism of the station20moving the document into treatment position and transporting the document16from the station20after treatment. In another embodiment, the plasma nozzle is stationary while the document16is moved relative to the plasma nozzle during plasma treatment. The plasma nozzle of the station20may be configured to treat only a portion of the document surface in a single pass of the document16and the nozzle relative to one another, or the plasma nozzle may be configured to treat the entire document surface in a single pass of the document16and the nozzle relative to one another. Operation of the station20can be controlled by the controller18, or the station20can have its own dedicated controller. A plasma treatment station that can be utilized is described in U.S. Pat. No. 10,576,769, the entire contents of which are incorporated herein by reference. The system10can also include a document input22and a document output24. The document input22is configured to hold a plurality of documents waiting to be processed and to input each document one-by-one for subsequent processing. The document output24is configured to hold a plurality of the documents16after processing has been completed. The input22and the output24can be positioned in the system10at any locations suitable for performing their input and output functions. For example, the input22can be located at the front end of the system10while the output24can be located at the tail end of the system10as shown inFIG.1. Alternatively, both the input22and the output24can be located at the front end of the system10. Other locations of the input22and the output24in the system10are possible. The system10may also include optional additional document processing station(s)26between the input22and the print station12and/or optional additional document processing station(s)28between the radiation curing station14and the output24. The optional additional processing station(s)26,28can be document processing stations known in the art to perform document processing operations that are known in the art. For example, the optional additional processing stations26,28can include a magnetic stripe read/write system that is configured to read data from and/or write data to a magnetic stripe on a plastic card, and/or an integrated circuit chip programming system that is configured to program an integrated circuit chip on a card or a passport. Magnetic stripe read/write systems and integrated circuit chip programming systems are disclosed, for example, in U.S. Pat. Nos. 6,902,107, 6,695,205 the entire contents of which are incorporated herein by reference, and can be found in the MX family of central issuance systems available from Entrust Corporation of Shakopee, Minnesota. The optional additional processing station(s)26,28can also be configured to perform one or more of embossing; indenting; laminating; laser marking; apply a topcoat; a quality control station that is configured to check the quality of personalization/processing applied to the documents; a security station that is configured to apply a security feature such as a holographic foil patch to the documents; and other document processing operations. The system10may be configured as a large volume batch plastic card production machine, often configured with multiple processing stations or modules, typically referred to as a central issuance system, that processes multiple document at the same time and is designed to personalize documents in relatively large volumes, for example measured in the high hundreds or even thousands per hour. An example of a central issuance system is the MX or MPR-lines of central issuance systems available from Entrust Corporation of Shakopee, Minnesota Additional examples of central issuance systems are disclosed in U.S. Pat. Nos. 4,825,054, 5,266,781, 6,783,067, and 6,902,107, all of which are incorporated herein by reference in their entirety. Alternatively, the system10may be configured as a desktop document printer that has a relatively small footprint intended to permit the desktop document printer to reside on a desktop and that is designed to personalize document in relatively small volumes, for example measured in tens or low hundreds per hour. An example of a desktop document printer is the CD800 Card Printer available from Entrust Corporation of Shakopee, Minnesota Additional examples of desktop printers are disclosed in U.S. Pat. Nos. 7,434,728 and 7,398,972, each of which is incorporated herein by reference in its entirety. Referring toFIGS.2A and2B, the identification document16can be a passport (FIG.2A) or other identification document booklet, or a plastic card (FIG.2B) including, but not limited to, an identification card, a driver's license, a financial card including a credit and debit card, a gift card, and other plastic cards. The passport and the plastic card each include a surface30that is intended to be printed on by the print station12to form personal data. Personal data can include a printed image (i.e. a portrait image) of the intended holder of the passport or plastic card, where the printed image can be a monochromatic image or a multicolor image for example printed from cyan, magenta, yellow and black (CMYK) inks, the name, address and other personal of the document holder, or a document number such as a passport number or an account number. The document16can further include additional personal data provided on the surface30or on an opposite surface such as a CVV number. The additional personal data may be printed onto the document16using the print station12and/or using other known printing techniques, for example direct to document thermal printing, retransfer printing, laser marking, and other printing techniques known in the art of identification document processing. In the case of a plastic card depicted inFIG.2B, the card may also include a magnetic stripe32(often disposed on the surface that is opposite the surface30) that can be magnetically encoded with data. The passport inFIG.2Aand the plastic card inFIG.2Bmay also include an integrated circuit chip34that can be programmed with data. For convenience, the document16may hereinafter be described as being a passport. However, the concepts described herein are applicable to plastic cards as well. As described above, one or more document transport mechanisms are used to transport the document16in the system10.FIGS.3A-3Cillustrate one example of a document transport mechanism in the form of a carrier40onto which a passport booklet is loaded prior to DOD printing in the DOD print station12. The carrier40is configured to hold the passport booklet open in the print station12for printing, as well as in the radiation curing station14during curing of the printed material. In the illustrated example, the carrier40includes a window plate42that defines two windows44a,44b. A spring-biased paddle46a,46bis associated with each window44a,44b, and a spine channel48is defined between the paddles46a,46bthat receives the spine of the passport. The carrier40includes an inlet side50with an input/output slot52between the window plate42and the paddles46a,46bthrough which the passport is inserted into and removed from the carrier40. When the document16is a plastic card, the transport mechanism disclosed in US 2018/0326763 can be used to transport the plastic card. To load the passport onto the carrier40, the passport booklet is opened as shown inFIG.3A. The passport booklet can be mechanically opened using a mechanical opening mechanism known in the art, or the passport booklet can be manually opened and then manually inserted into the system10. With reference toFIG.3B, the opened passport booklet is then slid into the slot52with the spine of the booklet facing downward and positioned in the spine channel48. When the booklet is fully inserted onto the carrier40(FIG.3C), a portion of one-half of the booklet is visible in the window44aand a portion of the other half of the booklet is visible in the window44b. The booklet is held stationary by the carrier40with the portion(s) of the booklet visible in the window(s)44a,44bavailable to be printed on. The carrier40then carries the booklet to and through the print station12(FIG.1), to and through the curing station14, and optionally to and through the plasma treatment station20if present. The booklet may also be held by the carrier in any of the additional processing stations26,28. At the conclusion of processing or earlier, the booklet is removed from the carrier40and ultimately closed and directed into the output24. With reference toFIGS.4-5, a portion of the curing station14is illustrated. The curing station14includes a radiation emitter assembly60mounted on a mounting plate62. The assembly60includes at least one radiation emitting device64such as one or more light emitting diodes (LED) or an LED array. An aperture66is formed in the mounting plate62that allows radiation emitted by the radiation emitting device64to be output toward the document16carried by the carrier40. An optional transparent lens68may be disposed over the aperture66to protect the radiation emitting device64. A reflective surface70of the curing station14is disposed opposite the aperture66. In an embodiment, with reference toFIGS.2A-Band5, the aperture66has a length LAextending in a direction perpendicular to the transport direction of the document16that is approximately equal to or only slightly greater than the length of the document16perpendicular to the transport direction. InFIGS.2A and2B, the length of the document16can be LD1if the document16is transported in an orientation such that edge80is a leading edge and edge82is a trailing edge. Alternatively, the length of the document16can be LD2if the document16is transported in an orientation such that the other edges form the leading edge and the trailing edge. In addition, with continued reference toFIGS.4and5, as discussed in further detail below, a shutter mechanism72is provided to control the emission of radiation through the aperture66. The shutter mechanism72includes a pair of shutters including a first movable shutter74aand a second movable shutter74b. The first movable shutter74ais independently controllably movable separately from the second movable shutter74b. For example, with reference toFIG.6, in one embodiment, the first movable shutter74acan be driven back and forth in the direction of the arrow via dedicated drive motor76aand drive train78a, while the second movable shutter74bcan be driven back and forth in the direction of the arrow via dedicated drive motor76band drive train78b. In another embodiment, with reference toFIG.7, the movable shutters74a,74bcan share a common drive motor76that drives the separate drive trains78a,78bwhich separately and independently drive the movable shutters74a,74b. The drive motors76,76a,76band the drive trains78a,78bcan have any construction suitable for driving the movable shutters74a,74bback and forth in the indicated directions. For example, the drive motors76,76a,76bcan be stepper motors and the drive trains78a,78bcan include elements such as pulleys, drive belts and gears. FIG.11illustrates another embodiment of the shutters74a,74b. In this embodiment, additional movable shutters92a,92bare provided that are movable independently from one another and movable independently from the shutters74a,74b. The shutters92a,92bcan be actuated to move in a manner similar to the shutters74a,74b. The shutters92a,92bcan be smaller than the shutters74a,74b, the same size as the shutters74a,74b, or larger than the shutters74a,74b. The use of the additional shutters92a,92bessentially splits the shutters74a,74binto two or more sections that allows for selective curing of portions of the document surface by controlling the appropriate shutter section(s) to block radiation from reaching the document surface in the window44a,44bof the window plate42. Referring toFIG.4, in order to ensure complete curing of the radiation curable material applied to the document16, the radiation emitting device64of the curing station14needs to be switched on before the leading edge of the document16reaches the aperture66and switched off after the trailing edge of the document16clears the aperture66. Since the radiation emitting device64is turned on prior to the document16reaching the aperture66and turned off after the document16clears the aperture66, without the shutter mechanism72radiation emitted by the radiation emitting device64would be emitted through the aperture66and impinge on the bottom of the station14, including the reflective surface70, for a small period of time before and after the document16passes under the aperture66. However, reflections of the radiation from the reflective surface70and other surfaces in the station14can impinge upon the print head(s) in the print station12with enough energy to cure the radiation curable material in the print head(s). This problem is exacerbated the closer the curing station14and the print station12are to one another. To prevent reflections of the emitted radiation, the movable shutters74a,74bof the shutter mechanism72are controlled to prevent emission of the radiation into the interior space of the station14prior to the leading edge of the document16reaching the aperture66and after the trailing edge of the carrier40and the document16pass the aperture66and before the radiation emitting device64is turned off. Accordingly, with reference toFIG.4, as the carrier40with the document16mounted thereon is transported in the transport direction indicated by the arrow through the station14, the radiation emitting device64is controlled so that the radiation emitting device64is actuated to an on-state from an off-state after the radiation curable material is applied to the surface of the document16in the print station and prior to a leading edge of the identification document16reaching the aperture66. As described in further detail below, during this time the shutter74afully covers the aperture66. Once the leading edge of the carrier40or the document16reaches the aperture66, the shutter74abegins to uncover the aperture66. Ultimately, the radiation emitting device64is actuated to the off-state after a trailing edge of the carrier40or the identification document16clears the aperture66. An example sequence of operations of the carrier40, the radiation emitting device64, and the movable shutters74a,74bwill be described with respect toFIGS.8A-G.FIG.8Aillustrates a point in time immediately after printing on the document16in the print station is complete with the carrier40that carries the document16transiting from the print station to the curing station in the direction of the arrow. As the carrier40is transiting, the radiation emitting device is switched on to emit radiation indicated by the arrows. At this time, the shutter74ais stationary and fully covers the aperture66, and the shutter74bis also stationary and spaced from the shutter74a. Referring toFIG.8B, when the leading edge of the window plate42aligns with the upstream edge of the shutter74a, the shutter74abegins moving to the left as indicated by the arrow with the carrier40continuing to move to the left. InFIG.8C, the shutter74aand the carrier40continue to move and the shutter74astarts to uncover the aperture66exposing the surface of the document16to the emitted radiation. At the same time, the shutter74aand the window plate42overlap in the region80to prevent stray radiation. InFIG.8D, the shutter74astops when the aperture66is fully uncovered and the document surface is fully exposed to the emitted radiation as the carrier40continues to move to the left. Referring toFIG.8E, once the downstream edge of the shutter74bis aligned with a trailing edge82of the windows44a,44bof the window plate42, the shutter74bis actuated to start moving to the left as indicated by the arrow inFIG.8Eto keep pace with the carrier40. The shutter74bcontinues to move together with the carrier40and overlaps the window plate42in the region84, with the shutter74bultimately beginning to cover the aperture66to block stray radiation as depicted inFIG.8F. Ultimately, the shutter74bfully covers the aperture66as the carrier40continues to travel to the left as shown inFIG.8Gto the next station. Once the shutter74bfully covers the aperture66, and the trailing edge82of the document16is clear of the aperture66, the radiation emitting device is then shut off. The result of the sequences shown inFIGS.8A-8Gis that the shutter mechanism72is controlled so that: in a first curing segment, the identification document16is being transported by the carrier40and the first movable shutter74ais moving while the second movable shutter is stationary74b(FIGS.8B and8C); in a second curing segment, the first movable shutter74aand the second movable shutter74bare stationary while the identification document16is being transported by the carrier (FIG.8D); and in a third curing segment, the identification document16is being transported by the carrier40and the second movable shutter74bis moving while the first movable shutter74ais stationary (FIGS.88E and8F). FIG.9illustrates another embodiment of controlling radiation emission in the curing station where the radiation emitting device64is controlled so as to be actuated to the on state from the off state after the radiation curable material is applied to the surface of the identification document16and prior to the leading edge of the identification document16reaching the aperture66, and so that the radiation emitting device64is actuated to the off state after the trailing edge of the identification document16clears the aperture66. In this embodiment, the radiation emitting device64is movably mounted so as to be moved across the aperture66as the document16passes by as indicated by the arrow inFIG.9. In operation, the radiation emitting device64is actuated to the on state, and the movement of the radiation emitting device64must be controlled so that the radiation emitting device64begins to clear the edge of the aperture66simultaneously with the leading edge of the carrier40or the leading edge of the document16so that the leading edge of the document16gets a full cure dose of the emitted radiation without exposing the area below the carrier40and/or the document16to stray radiation. Once the radiation emitting device64fully covers the aperture66, movement of the radiation emitting device64stops until the trailing edge of the carrier40and/or the document16approaches the edge of the aperture66and then the radiation emitting device64is actuated to move off of the aperture66before the trailing edge of the carrier40and/or the document16arrives so that no radiation may leak off of the trailing side. The movement of the radiation emitting device64can be used with or without the moveable shutters74a,74binFIGS.4-8G. Referring toFIG.10, to further aid in preventing stray radiation, extendable and retractable wings90a,90bcan be mounted on the carrier40.FIG.10shows the wings90a,90bin an extended or deployed position (solid lines) and in a retracted or non-deployed position (dashed lines). The wings90a,90bare depicted as being pivotally attached to the carrier40for pivoting movement between the extended and retracted positions. However, the wings90a,90bcan be mounted to the carrier40so as to be movable between extended and retracted positions in ways other than pivoting. The wing90bis actuated to the retracted position when loading the document16onto the carrier40to prevent the wing90bfrom interfering with loading the document16onto the carrier40, with the wing90bthen being actuated to the extended position once the document40is loaded to help block stray radiation during curing of the radiation curable material on the document16. When unloading the document16from the carrier40, the wing90ais actuated to the retracted position to prevent interference with document unloading. In an embodiment, both of the wings90a,90bcan simultaneously pivot together between the extended and retracted positions during loading and unloading. In an embodiment, the upper surfaces of the wings90a,90bcan be configured to help trap the emitted radiation. For example, the upper surfaces can be configured with hexagon shaped cavities that serve as light traps to prevent reflection of the emitting radiation. As illustrated inFIG.10, the extendable and retractable wings90a,90bcan be used with the embodiment inFIG.9, or the wings90a,90bcan be used with the embodiment inFIGS.4-8G. The examples disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. | 26,493 |
11858258 | DESCRIPTION OF EXEMPLARY EMBODIMENTS 1. First Embodiment First, a configuration of a recording apparatus10constituting a work system1will be described. The recording apparatus10is a printer that can perform recording on a medium M (for example, fabric or paper). In each drawing below, a direction along an X axis indicates a width direction of the recording apparatus10. A direction along a Y axis indicates a depth direction of the recording apparatus10. A direction along a Z axis indicates a height direction of the recording apparatus10. FIG.1illustrates a configuration of the recording apparatus10installed on an installation surface2of a floor portion of a factory that is one example of an installation location. An exhaust apparatus4as one example of an exhaust facility is installed on the installation surface2. The exhaust apparatus4may be disposed on a ceiling portion, not illustrated, of the factory. The exhaust apparatus4includes an exhaust fan, not illustrated, and is coupled to an exhaust duct6of the recording apparatus10. Exhaust from the recording apparatus10is collected and purified by the exhaust apparatus4through the exhaust duct6and is released outside the factory from the exhaust apparatus4. The recording apparatus10includes a main body frame12, a casing14(main body portion), a transport unit16, a recording portion20, a cleaning unit24, a control unit28, and a flow channel portion30. The main body frame12is configured as a base portion in which each portion of the recording apparatus10is disposed. The casing14is an exterior member that covers each portion of the recording apparatus10. The main body frame12and the casing14are members including a magnetic body. For example, the casing14accommodates the recording portion20. A casing cover19that can be open and closed is disposed in a +Y direction end portion of the casing14. The casing cover19is a part of the casing14. The casing cover19is positioned above a transport belt17(glue belt). The casing cover19extends in the direction along the X axis. A width dimension of the casing cover19in the direction along the X axis is slightly greater than a width dimension of the transport belt17in the direction along the X axis. The casing cover19pivots between a closed state and an open state about a shaft disposed in the direction along the X axis. When the casing cover19is in the closed state, the casing cover19is in the direction along the Z axis in side view. When the casing cover19is in the open state, the casing cover19is positioned to be directed further above from a horizontal direction in side view. A damper, not illustrated, is disposed in the casing cover19, and the casing cover19can be held in the open state. The casing cover19is set to the closed state during a recording process of the recording apparatus10. The casing cover19is set to the open state in a maintenance work, described later, for the transport belt17. The transport unit16includes a drive roller16A, a passive roller16B, the transport belt17, and a winding roller, not illustrated. The transport unit16can transport the medium M in a +Y direction in accordance with movement of the transport belt17by rotation of the drive roller16A. The drive roller16A is arranged downstream in a transport direction, and the passive roller16B is arranged upstream in the transport direction. In addition, both the drive roller16A and the passive roller16B include a rotation shaft in the direction along the X axis. Rotation of the drive roller16A is controlled by the control unit28. The transport belt17is configured with an endless belt obtained by joining both ends of a planar plate having elasticity. In addition, the transport belt17is wound around an outer circumferential surface of the drive roller16A and an outer circumferential surface of the passive roller16B, and the transport belt17can move in a circular manner. An adhesive to which the medium M can be attached is disposed on an outer circumferential surface17A of the transport belt17. The medium M is supported on the transport belt17in a state where the medium M is attached to the adhesive. The medium M is peeled from the adhesive and collected by a winding apparatus, not illustrated. On the outer circumferential surface17A, a planar part positioned in a +Z direction between the drive roller16A and the passive roller16B is a support surface18that supports the medium M. In addition, the transport belt17of this embodiment includes an exposed part90in which a part of the transport belt17is exposed from the casing14. Specifically, the transport belt17protrudes in the +Y direction from the casing14(casing cover19in the closed state). The protruding part corresponds to the exposed part90. Since the transport belt17protrudes from the casing14, a finger of a user is unlikely to intrude into the casing14during the maintenance work, described later, for the transport belt17, for example, during a work in which the user peels off the adhesive on the transport belt17or applies the adhesive. Workability can be improved. The recording portion20performs recording on the transported medium M. Specifically, the recording portion20includes a recording head21that ejects liquid (for example, ink) as a liquid droplet, and a carriage22that supports the recording head21and reciprocates in the direction along the X axis. The recording portion20is arranged to face the support surface18above the transport belt17(+Z direction). Recording on the medium M can be performed by causing the recording head21to eject the liquid droplet to the transported medium M while moving in the direction along the X axis. The cleaning unit24is positioned downstream of the drive roller16A in a direction in which the transport belt17moves in a circular manner, and cleans the outer circumferential surface17A. The control unit28is configured to include a central processing unit (CPU), a read only memory (ROM), a random access memory (RAM), and a storage and controls an operation of each portion of the recording apparatus10. The flow channel portion30is a part, inside the casing14, that includes a space41and functions as a flow channel through which air is forced to flow. In addition, the flow channel portion30includes a feeding portion32and a suction portion42. The feeding portion32is disposed on the −Y direction side (upstream) of the recording portion20. The feeding portion32includes a first fan38, takes in air through an intake port15, and feeds air toward the support surface18. The suction portion42is disposed on the +Y direction side (downstream) of the recording portion20and suctions air flowing from the support surface18. Specifically, the suction portion42includes a circulation portion44and a second fan52. The circulation portion44includes a first duct56and a second duct76arranged above the first duct56. The second duct76is coupled to the exhaust duct6. The second fan52is disposed inside the first duct56. The second fan52suctions air in the circulation portion44. The air suctioned by the second fan52is discharged from the exhaust duct6through the first duct56and the second duct76. A filter78is arranged inside the second duct76. The filter78can capture a foreign object such as mist mixed in the air. Non-woven fabric, glass wool, or mineral wool can be used as the filter78. Next, the maintenance work for the transport belt17will be described. For example, the maintenance work for the transport belt17is a work of replacing the adhesive of the transport belt17. Specifically, when the medium M is attached to the transport belt17, and the recording process is performed while the medium M is transported, for example, ink, lint, or dust clings to the adhesive disposed in the transport belt17. Thus, adhesive strength of the adhesive is gradually decreased, and the medium M is not transported in a state where the medium M is sufficiently attached to the transport belt17. In such a case, an adhesive layer is formed on the transport belt17by removing the adhesive disposed on the outer circumferential surface17A of the transport belt17and applying a new adhesive. Accordingly, the adhesive strength for the medium M is restored. When the recording apparatus10is newly installed in the factory, the maintenance work related to such a work of applying the adhesive is also performed on the new transport belt17in the same manner. Here, in the maintenance work, a solvent for removing the adhesive of the transport belt17or the adhesive may include a volatile organic compound (VOC). In such a case, there is a possibility that an evaporated VOC is diffused around. Furthermore, there is a possibility that the VOC diffused around exerts a chemical action on various mechanical elements or electric parts constituting the recording apparatus10and consequently, affect an operation of the recording apparatus10. Therefore, in this embodiment, the work system1that suppresses diffusion of the evaporated VOC in the maintenance work is configured. Hereinafter, a configuration of the work system1will be described. As illustrated inFIG.2,FIG.3, andFIG.4, the work system1includes the recording apparatus10, a cover100, and a removing portion. The configuration of the recording apparatus10is described above. InFIG.2, the recording apparatus10is illustrated by solid line, and the cover100is illustrated by chain double-dashed line. InFIG.3andFIG.4, a part of the recording apparatus10is illustrated by chain double-dashed line, and the cover100is illustrated by solid line. The cover100is installed in the maintenance work for the transport belt17. The cover100covers at least a part of the exposed part90exposed from the casing14in the transport belt17disposed in the recording apparatus10. In addition, the removing portion of this embodiment is the second fan52(refer toFIG.1) and suctions gas in a space covered with the cover100. The suctioned gas is released outside the factory through the exhaust duct6. Accordingly, the gas, for example, the VOC, in the space covered with the cover100is removed. That is, diffusion of the evaporated VOC can be suppressed. Covering at least a part of the exposed part90of the transport belt17with the cover100indicates that a region in which the exposed part90of the transport belt17overlaps with the cover100is present in plan view, side view (FIG.3), or front view (FIG.4). In this embodiment, the entire exposed part90of the transport belt17overlaps with the cover100in plan view and side view. That is, the exposed part90is covered with the cover100in plan view and side view. Meanwhile, in front view, an opening130is disposed in the cover100, and the cover100does not overlap with the transport belt17in a width direction and a height direction of the transport belt17through the opening130. That is, the opening130is formed to enable the user to directly view the transport belt17in front view. Accordingly, the transport belt17can be directly accessed through the opening130, and the maintenance work for the transport belt17is easily performed. The space covered with the cover100refers to a space, around the exposed part90, that is closed with the cover100, assuming that the opening130is closed. The cover100of this embodiment includes a first cover101and a second cover102. The first cover101is arranged from the casing cover19to be approximately centered at a part (exposed part90) in which the transport belt17in the +Y direction protrudes. The second cover102is arranged from the casing cover19to be approximately centered at a part of the casing14in the −Y direction. The first cover101is installed with the casing cover19set to the open state. Specifically, the first cover101is installed in a state where the first cover101is hung down to a lower portion of the recording apparatus10from an upper surface of the casing cover19in the open state. A lower end portion of the first cover101is approximately in contact with the installation surface2. Accordingly, leakage of gas from the lower portion of the recording apparatus10can be suppressed. The first cover101may be installed such that a part in which an operation panel portion29is arranged is exposed. In this embodiment, a plurality of frames110that are disposed at intervals to each other are disposed. The frames110are formed of an anti-static material. In this embodiment, two rod-shaped frames110are disposed. Specifically, one frame110is disposed between the casing cover19and a part of the casing14positioned in a +X direction of the transport belt17. The other frame110is disposed between the casing cover19and a part of the casing14positioned in a −X direction of the transport belt17. These frames110support the casing cover19. Accordingly, the open state of the casing cover19can be securely held. A +Y direction end portion of the casing cover19in the open state is positioned slightly further in the +Y direction than the transport belt17and the main body frame12. That is, the first cover101is installed in a state where a +Y direction end portion of the first cover101is hung down near a +Y direction end portion of the transport belt17. Accordingly, the first cover101can cover around the exposed part90of the transport belt17with the minimum size. Accordingly, efficiency of removing gas in a space covered with the first cover101can be increased, and ventilation efficiency can be increased. Furthermore, by setting the casing cover19to the open state, a region between the exposed part90and the second fan52is increased, compared to when the casing cover19is in the closed state. Thus, exhaust efficiency of the gas in the space covered with the first cover101can be further increased. The first cover101is formed of an anti-static material. Accordingly, static electrification can be prevented, and electric discharge can be prevented. For example, a fabric material or a vinyl material is used in the first cover101. Particularly, a thin vinyl material that transmits light is preferred for the first cover101. Accordingly, the transport belt17can be visually recognized through the first cover101, and work efficiency can be increased. The first cover101is detachably attached to the recording apparatus10. The first cover101is fixed to the casing14or the main body frame12by at least one fixing portion104. For example, the fixing portion104is a sheet-shaped magnet that can be freely deformed. In this embodiment, a plurality of the fixing portions104(magnets) are disposed in a plurality of locations in the first cover101and stick to the casing14or the main body frame12including a magnetic body. Accordingly, for example, deviation of the first cover101from the casing14or the main body frame12when the second fan52performs suctioning is suppressed, and the space covered with the first cover101can be held. In addition, the fixing portions104(magnets) can be easily detached from the casing14with the finger. Accordingly, when the maintenance work for the transport belt17is not performed, for example, detaching the first cover101from the casing14can suppress hindrance to a work in which the user accesses the exposed part90and sets the medium M. The fixing portions104may fix the first cover101to the casing14or the main body frame12using, for example, a surface fastener. In the same manner, the second cover102is detachably attached to the recording apparatus10and is installed in a state where the second cover102is hung down to the lower portion of the recording apparatus10from an upper portion of the casing14excluding the exhaust duct6. The second cover102is also fixed to the casing14or the main body frame12by the fixing portions104(for example, magnets). In this embodiment, an opening portion is disposed in a +Y direction end portion of the casing14, and a part of the transport belt17is open from the casing14. Thus, by covering including a −Y direction end portion of the recording apparatus10with the second cover102, for example, diffusion of the VOC generated from the adhesive of the transport belt17is suppressed. An anti-static material is used in the second cover102in the same manner as the first cover101. The fixing portions104are fixed such that a part of the first cover101overlaps with a part of the second cover102. Accordingly, a gap between the first cover101and the second cover102does not occur, and leakage of the VOC is suppressed. The cover100may be formed as a single body. According to this embodiment, by including the cover100(the first cover101and the second cover102) that covers at least a part of the exposed part90of the transport belt17, for example, a range in which the evaporated volatile organic compound (VOC) generated from a peeling agent or the adhesive is diffused around the recording apparatus10in the maintenance work for the transport belt17can be restricted. By removing the gas in the space covered with the cover100using the second fan52, the evaporated VOC can be removed. Accordingly, a chemical action on the recording apparatus10is suppressed, and for example, an effect on the operation of the recording apparatus10can be suppressed. The removing portion in the work system1is not limited to the second fan52. For example, the removing portion may be the exhaust apparatus4installed in the factory. In addition, the removing portion may be a wind blowing apparatus, or a porous material that absorbs or adsorbs the gas in the space covered with the cover100may be used in the removing portion. In addition, while the cover100is formed of an anti-static material in this embodiment, the cover100is not limited thereto. For example, a form of stretching the cover100over the plurality of frames110as a stretching member may be configured. In this case, electrical conductivity of the frames110is greater than electrical conductivity of the cover100, and the frames110are electrically coupled to the recording apparatus10directly or indirectly. When the frames110are electrically coupled to the recording apparatus10indirectly, the frames110are coupled to the recording apparatus10through an electrically conductive member such as a wire. The recording apparatus10is grounded. Accordingly, electric potentials of the cover100and the frames110can be set to be approximately equal to an electric potential of the recording apparatus10. Accordingly, electric discharge caused by an electric potential difference between the electric potential of the frames110and the electric potential of the recording apparatus10is suppressed. While the large opening130is disposed in the +Y direction end portion of the first cover101in this embodiment, the opening130is not limited thereto. For example, a plurality of the openings130may be formed, and a total area of the openings130may be decreased. Accordingly, an area covered with the first cover101is increased, and air intake efficiency in the space covered with the first cover101can be increased. In addition, while the opening130is disposed in only the +Y direction end portion of the first cover101in this embodiment, for example, a plurality of openings may be additionally disposed in a +X direction end portion of the first cover101or a −X direction end portion of the first cover101. By doing so, the maintenance work can be performed by a plurality of persons. 2. Second Embodiment Next, a second embodiment will be described. Note that configurations identical to those in the first embodiment will be denoted by the same reference signs and redundant descriptions will be omitted. While a form of disposing the opening130in the first cover101to expose the transport belt17in front view is used in the first embodiment, a lid portion140is disposed in the opening130of the first cover101in this embodiment as illustrated inFIG.5. The entire opening130is covered with the lid portion140. Accordingly, the exposed part90of the transport belt17is covered with the first cover101in all directions. Accordingly, diffusion of the VOC outside the first cover101can be suppressed. InFIG.5, a part of the recording apparatus10is illustrated by chain double-dashed line, and the cover100is illustrated by solid line. In addition, the lid portion140can be displaced to a position at which the space covered with the first cover101communicates with a space outside the first cover101through the opening130. Specifically, as illustrated inFIG.6AandFIG.6B, the lid portion140of this embodiment is configured with a plurality of rectangular members141(141aand141b) having a rectangular shape. The lid portion140of this embodiment is configured into a curtain shape by the rectangular members141. The rectangular members141(141aand141b) are elastic members and, for example, are formed with rubber members that transmit light. Here, +Z direction end portions and −Z direction end portions of the rectangular members141aare fixed to the first cover101. Parts of the rectangular members141aother than the parts fixed to the first cover101can be freely deformed. Each rectangular member141ais arranged at predetermined intervals in the direction along the X axis. In addition, +Z direction end portions of the rectangular members141bare fixed to the +Z direction end portions of the adjacent rectangular members141a. Similarly, −Z direction end portions of the rectangular members141bare fixed to the −Z direction end portions of the adjacent rectangular members141a. That is, end portions of the rectangular members141ain the X direction and end portions of the rectangular members141bin the X direction are arranged to overlap with each other. Accordingly, the opening130is closed with the lid portion140in front view. Parts of the rectangular members141bother than the fixed parts can be freely deformed. The rectangular members141are formed of an anti-static material. Accordingly, the rectangular members141can be easily deformed (displaced). When the finger or an arm of the user enters toward the transport belt17from the lid portion140, the lid portion140is easily deformed, and the space inside the first cover101communicates with the space outside the first cover101. The space covered with the first cover101can be easily accessed, and the work can be performed. In addition, when the finger or the arm recedes from the lid portion140, elasticity of the rectangular members141causes the shapes of the rectangular members141to return to a state before the finger or the arm enters. Accordingly, when the user does not perform the work, closing the opening130can reduce diffusion of the VOC. In addition, the lid portion140may be configured to be attachable to and detachable from the first cover101. In this case, for example, the VOC in the space covered with the first cover101may be removed by performing air intake for a predetermined period using the second fan52in a state where the lid portion140is attached to the first cover101(state where the opening130is closed). Then, the lid portion140may be detached to perform the maintenance work. In addition, while the lid portion140is configured with the rectangular members141in this embodiment, the lid portion140is not limited thereto. For example, the lid portion140may be configured to be formed with a pair of rubber members and fixed to the first cover101using a line fastener or a surface fastener. Even with this configuration, the lid portion140can be displaced, and similar advantages as described above can be obtained. 3. Third Embodiment Next, a third embodiment will be described. Note that configurations identical to those in the first embodiment will be denoted by the same reference signs and redundant descriptions will be omitted. InFIG.7, the recording apparatus10is illustrated by chain double-dashed line, and a cover100A is illustrated by solid line. The cover100A of this embodiment includes a first cover101A and a second cover102A. The cover100A (the first cover101A and the second cover102A) includes a contact portion105that is in contact with the installation surface2on which the recording apparatus10is installed. As illustrated inFIG.7, the contact portion105includes a contact surface that is in contact with the installation surface2and on which a bottom part in a lower portion of the cover100A extends on the installation surface2. The contact portion105is disposed entirely around the cover100A. A pressing portion150that presses the contact portion105to the installation surface2is arranged. The pressing portion150is a weight such as a chain. The pressing portion150is arranged across the entire contact portion105(entirely around the recording apparatus10). Accordingly, close contact between the installation surface2and the cover100A can be improved. Accordingly, airtightness of a space covered with the cover100A is improved, and diffusion of the VOC from a gap in the lower portion of the cover100A can be reduced. For example, the pressing portion150may be a mechanism that applies a wind pressure to the contact portion105. Other configurations of the first cover101A and the second cover102A are the same as the configurations of the first embodiment. 4. Fourth Embodiment Next, a fourth embodiment will be described. Note that configurations identical to those in the first embodiment will be denoted by the same reference signs and redundant descriptions will be omitted. InFIG.8, a part of the recording apparatus10is illustrated by chain double-dashed line, and the cover100is illustrated by solid line. As illustrated inFIG.8, in a work system1A of this embodiment, an outside air intake portion160that takes outside air into the space covered with the first cover101is disposed. The outside air intake portion160includes a communication portion161that causes the space covered with the first cover101to communicate with the space outside the first cover101, and a wind blowing portion162that blows air to the space covered with the first cover101through the communication portion161. The communication portion161is a pipe and is disposed to pass through the first cover101. The wind blowing portion162is a fan. For example, power is supplied to the wind blowing portion162from a commercial power supply. The wind blowing portion162may be arranged inside the space covered with the first cover101or may be arranged outside the first cover101. For example, the outside air intake portion160is arranged above the user performing the maintenance work. By driving the wind blowing portion162, outside air flows into the space covered with the first cover101through the communication portion161. Accordingly, retention of the VOC in the space covered with the first cover101is suppressed, and density of the VOC can be reduced in a short time period, compared to a configuration in which the outside air intake portion160is not disposed. Accordingly, affecting the operation of the recording apparatus10can be further suppressed. The power supply of the wind blowing portion162may be shared as a power supply of the recording apparatus10. Specifically, the wind blowing portion162is electrically coupled to the recording apparatus10through an electrical cable, and the recording apparatus10is coupled to the commercial power supply. Accordingly, power is supplied to the wind blowing portion162through the recording apparatus10. In addition, the power supply of the wind blowing portion162may be a storage battery. 5. Fifth Embodiment Next, a fifth embodiment will be described. Note that configurations identical to those in the first embodiment will be denoted by the same reference signs and redundant descriptions will be omitted. While the work system1is configured with the recording apparatus10, the cover100, and the removing portion in the first embodiment, all of the recording apparatus10, the cover100, and the removing portion may be configured as the recording apparatus10. That is, the recording apparatus10may include the transport belt17that is provided with an adhesive configured for attachment of a medium, and that can transport the medium M, the casing14in which the recording portion20that can perform recording on the medium M is accommodated, the cover100that covers at least a part of the exposed part90exposed from the casing14in the transport belt17, and the removing portion (for example, the second fan52) that can remove the gas in the space covered with the cover100. Even with this configuration, similar advantages as described above can be obtained. | 28,612 |
11858259 | DETAILED DESCRIPTION For simplicity and illustrative purposes, the present disclosure is described by referring mainly to examples. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be readily apparent however, that the present disclosure may be practiced without limitation to these specific details. In other instances, some methods and structures have not been described in detail so as not to unnecessarily obscure the present disclosure. Throughout the present disclosure, the terms “a” and “an” are intended to denote at least one of a particular element. As used herein, the term “includes” means includes but not limited to, the term “including” means including but not limited to. The term “based on” means based at least in part on. Disclosed herein are examples of media cutter modules, methods and systems to cut a media. Different configurations may be used in order to cut a media. Hence, different examples of modules, methods and systems are described. A cutting module may comprise a carriage and a cutting blade. The carriage may be capable of performing a reciprocating movement along a cutting path, wherein the cutting path is perpendicular to a media path. The carriage may be supported by a support structure, and a cutting blade having a fitting pin may be engaged to the carriage. The fitting pin may have a first portion movable laterally with respect to the media path, so that the position of the fitting pin during movement of the carriage in a first direction along the cutting path provides the cutting blade with a first cutting-edge angle and the position of the fitting pin during a movement of the carriage in a second direction along the cutting path provides a second cutting-edge angle. The second cutting-edge angle may be different than the first cutting-edge angle. The first cutting-edge angle and the second cutting-edge angle may be comprised in a range, for instance between −5 degrees and 5 degrees, i.e., the cutting blade may have an inclination freedom for the cutting-edge angle of about 10 degrees. Both first and second cutting-edge angles may be forced by a contact between the cutting blade and the media. The first cutting-edge angle and the second cutting-edge angle may be different with each other. The fitting pin may be also be movable with a tilt angle in a different plane from that of the cutting-edge angle, for example, a plane orthogonal to that associated to the cutting edge. In particular, the pin may be further movable in a plane having the cutting path direction as normal vector. The tilt angle may be measured in a direction normal to the media, and may be comprised between ranges, e.g., −1 degree and −5 degrees in a first direction and in the range +1 degree and +5 degrees in a second direction. The fitting pin tilt angle may be determined by contact between the cutting blade and the media. The fitting pin may have a second portion attached to a joining element, wherein the joining element biases the fitting pin towards an alignment position substantially parallel to the media path direction. The cutting blade may be a rotary blade, wherein the fitting pin actuates as rotary axis for the rotary blade. In another example, the cutting blade may be a linear blade. The cutting module may further comprise or be able to operate together with a support surface in addition to the carriage and the cutting blade. The support surface may extend parallel to the cutting path. In an example, the support surface may be a stationary blade. According to an example, a media within a media handling apparatus is to be moved by a transport apparatus along a media path direction. The transport apparatus being part of the media handling system. The media transport apparatus may be, for instance, a conveyor to move a media within the media handling system. Once the media reaches a determined cutting position, the movement is halted, and a media cutter module actuates by means of moving a carriage having a cutting blade along a first direction, thereby cutting the media. In a subsequent cutting operation, the media cutter module moves in a second direction, which is opposite to the first cutting direction. A cutting module able to cut in such first and second cutting directions is considered for the purpose of the present disclosure as a bi-directional cutter module. In other examples, the support surface may be replaced for a stationary blade and the cutting blade may be replaced for a rotary blade. According to an example, a media handling system may comprise a conveyor, a support structure, a carriage, a support surface and a cutting blade. The conveyor may be to move a media along a media path. The support structure may be arranged perpendicular to the media path. The carriage may move in a cutting path in a first direction and a second direction, wherein the carriage is supported by the support structure. The support surface may extend parallel to the cutting path, so that the media passes over the support surface. The cutting blade may be provided to the carriage, the cutting blade having a cutting-edge angle defined as a yaw rotation angle measured between the cutting path and the cutting blade. The cutting-edge angle is dynamically determined by contact between the cutting blade and the media on the media path during the movement of the carriage. The reaction forces between the cutting blade and the media may orient the cutting blade with a cutting-edge angle. The cutting blade may cut the media in conjunction with the support surface. According to an example, the cutting-edge angle of the media handling system may be comprised in a range between −5 degrees and 5 degrees in the first direction and the second direction. According to other examples, the media handling system may comprise a tilt angle, the tilt angle being defined as a roll rotation angle between the media normal vector and the cutting blade. The tilt angle in the first direction may be comprised in a range between −5 degrees and −1 degree. The tilt angle in the second direction may be comprised in a range between +1 degree and 5 degrees. In other example, a printer may comprise the media handling system. The media handling system may be one of the media handling systems described in the previous examples. Throughout the description, the carriage movement may be defined as reciprocating or bi-directional, i.e., the carriage moves forward and backwards in a straight line. Additionally, the carriage movement direction may be the X direction and the media direction the Y direction, as shown in the figures. In the examples fromFIG.1toFIG.6, the roll axis is to be an axis in the X direction on the Figures and the yaw axis is to be an axis in the Z direction. In an example, the media cutter module may comprise a support structure, a movable carriage and a cutting blade. The support structure may be parallel and spaced at a first distance to the media. The support structure is to support the carriage. The carriage may be spaced at a second distance of the media that, in an example, is a second distance shorter than the first distance, i.e., the carriage is closer to the media than the support structure. In other example, the support structure is close to the media. The support structure may include a guiding element for the carriage, e.g., a bar or a rail. The above-mentioned distances may be measured, for example, as the minimum distance between the media and the support structure or the carriage. The cutting blade may be provided to the carriage by an engaging element. In an example, the engaging element may be fitted to the carriage by means of joining elements, such as bearings, non-friction elements or fixed unions. Depending on media requirements and the blade lifespan characteristics, the cutting blade may be a consumable. The engaging element may be located in the center of the cutting blade in the case of having a rotary blade as be symmetric, but other locations for the engaging element may be possible. The engaging element may be a fitting pin, an axle, a holding element or the like. The carriage movement may be transmitted by transmission elements which may, for example, be provided as part of the carriage or to the support surface. Examples of carriage body transmission elements may be a motor to move the carriage along a rail of the support structure in the linear movement. An example of transmission element wherein the transmission element is not located in the carriage body may be a transmission belt, in which the carriage receives the motion from a belt and the belt receives the motion from a motor located separated from the carriage. According to some examples, the cutting module may include a support surface to support the media during the cutting operations. The cutting blade in conjunction with the support surface are to cut the media when the media is in the cutting position. However, the support surface may be optional in some cases, as will be described in further detail below in reference to an example. In an example, the cutting module may be included as part of a media handling system, wherein the media handling system is to operations by using the cutting module. The media handling system may include a support surface, for instance a tray, to support the media. This support surface provided by the media handling system may be used to support the media. However, different media types may be possible, and some of them may have enough stiffness to be cut without a support surface. In other example, the media handling system may not include a surface to be used as support, thus, the cutting module may be provided with a support surface. The carriage movement may be defined by two parking positions, e.g., positions and the ends of the reciprocating movement, such parking positions may be referred to as a first and second location. The two locations may be defined, for instance, in opposite sides of the media path width, but alternative locations are possible. The movement from the first location to the second location is defined as a movement in a first direction and the movement from the second location to the first location is defined as a movement in a second direction. When the carriage moves in the first direction, the cutting blade and the media interact and the media exerts a reaction force towards the cutting blade. Such force, while the carriage moves in the first direction, will be referred hereto as a first reacting force. When the carriage moves in the second direction, the cutting blade and the media interact and the media exerts a reaction force towards the cutting blade. Such force while the carriage moves in the second direction will be referred hereto as a second reacting force. In an example, the reaction forces modify the orientation of the cutting blade, defining a cutting-edge angle and, in an example, also a tilt angle with respect to the support surface. The cutting-edge angle may be defined as the angle between the cutting blade and the cutting path. Due to the availability of having different types of cutting blades, the cutting-edge angle may be considered as the attack angle of the cutting blade edge when contacting a media. The tilt angle may be an angle between the cutting blade and the media path direction. Due to the availability of having different types of cutting blades, the tilt angle may be considered as the cutting blade remaining component not defined by the cutting-edge angle, in the case in which the cutting blade has two degrees of freedom. Referring now toFIG.1, there is shown a schematic view of a media cutter module10comprising a support structure13, a carriage14and a cutting blade15. The cutting module10is to cut a media12that is provided over a support surface17. The support structure13extends parallel to a media12and is orthogonal to a media path direction12a. The support surface is to support the carriage14. The carriage14reciprocates or moves alternatively between a first position11aand a second position11bdefined along the media path width18. In another example, the system may lack a support surface17, since an alternative element is available. The carriage movement comprises a cutting path14a. The movement of the carriage14is transmitted by the transmission belt16, but in other examples the transmission methods may be different. The transmission belt16is to receive the motion from a motor not shown inFIG.1. While the carriage14is moving along the cutting path14a, the cutting blade15and the media12are to contact as to cut the media. As explained above, the reaction forces may modify the orientation of the cutting blade15, defining a cutting-edge angle and a tilt angle with the media12. The cutting blade15in the example corresponds to a rotary blade, however, in other examples the cutting blade15may be a linear blade. Further, the position between the cutting blade15and the support surface17may ensure a reduced contact surface between them to increase the pressure at this point to cut the media12. The cutting blade15is provided to the carriage14by an engaging element. In another example, the support surface may be a stationary blade. This stationary blade may extend along the media path width and may have a sharp edge to cut the media in conjunction with the cutting blade. The interaction between the cutting blade and the stationary blade may interact to cut the media when the cutting blade contacts the media during the carriage movement in the first direction or the second direction. When the first or the second contact occurs, the reaction forces may orient the cutting blade relative the stationary blade, defining a cutting-edge angle and a tilt angle. The media is to pass over the stationary blade and the cutting-edge angle and the tilt angle may be defined with the cutting path and/or the media. Nevertheless, the cutting-edge angle and tilt angle may be defined by the orientation of the engaging element with the cutting path and/or the media path direction. In the example ofFIG.2, the media cutter module10comprises a support surface13, a carriage14, a cutting blade15and a stationary blade27. The media12is to move in a media path direction12aover the stationary blade27. The carriage14is supported by the support structure13, parallel to the media12and orthogonal to the media path direction12aand moves between a first position11aand a second position11b(not shown inFIG.2). In the example ofFIG.2, the cutting blade15is a rotary blade, but alternatives such as linear blades may be used. The cutting blade may be attached to the carriage by an engaging element. The cutting blade15in conjunction with the stationary blade27is to cut the media while moving in either one of the first direction and the second direction. The contact between the cutting blade15and the media12forces the orientation of the cutting blade, defining a cutting-edge angle and a tilt angle. As explained in previous examples, the orientation may be defined by the engaging element or the cutting blade15, as will be explained with reference toFIG.3a-3c. The position between the cutting blade15and the stationary blade27may ensure a reduced contact surface between them to increase the pressure at this point to cut the media12. FIG.3ashows an example of cutting blade, a stationary blade and the engaging element, wherein the blade is inclined with by a tilt angle α. The tilt angle α corresponds to a roll rotation of the cutting blade in an angle between the cutting blade15and the vector normal to the media. The vector normal to the media may be defined as a vector perpendicular to the media. The roll axis may depend on the movement direction of the carriage, i.e., the roll axis of the carriage first direction has an opposite direction relative to the roll axis of the carriage second direction. The carriage movement comprises the cutting path. The cutting blade15may include an engaging element31and a body32. The engaging element31inFIG.3ais an axle or fitting pin that in an example comprises different diameters at each side of the blade, a first diameter31aat the cutter side and a second diameter31bat the carriage side. In one side of the engaging element there may be a clearance between the engaging element and the carriage, in the other one there is not. The engaging element side without clearance may be the side with the larger diameter and is to interact with an elastic member, made of an elastic material and designed to ensure the contact between the stationary blade and the rotary blade by allowing the orientation of the engaging element. Elastic members can include, amongst others, springs, gas canisters, or any element capable of recovering size and shape after a deformation, for example, a deformation caused by the process transmitted forces. In another example, the engaging element may have the same diameter both sides of the cutting blade. The cutting blade is provided to the carriage by the engaging element, and, in a first side, the engaging element may have radial clearance relative to the support element. The first side radial clearance enables the engaging to move in the range enabled. The radial clearance may be replaced by suitable elastic members. The engaging element may be a fitting pin, an axle, a holding element or the like. In an example in which the cutting blade is a rotary blade, the body32is traversed by the engaging element31. The body32may contain joining elements such as bearings or be fixed to the engaging element31so that rotary blades are joined with rotation capability to the carriage. InFIG.3b, the cutting-edge angle β is shown. The cutting-edge angle β corresponds to a yaw rotation angle between the cutting blade15and the cutting path14a. The cutting path14ais comprised in the carriage movement direction. A yaw axis is defined by the carriage movement direction, i.e., is the same axis on both cutting path directions. ForFIG.3aandFIG.3b, the cutting-edge angle and the tilt angle may further be referenced to the orientation of the engaging element31with the media path direction12aand/or the cutting path14a, as indicated by the angular dimensions α′ and β′. The engaging element may be enabled to have lateral and/or perpendicular with respect to the media surface plane allowing respectively the orientation of the cutting blade with a cutting-edge angle and/or a tilt angle. The media surface plane may be defined as the plane defined by the media path width and the media path direction. The orientation of the engaging element may also be defined relative to the media when the media cutter module is to cut, i.e., as the angle between the engaging element and the cutting path, the angle being measured in a plane parallel to the media surface plane. The tilt angle may be defined as the angle between the engaging element and the media path direction, the angle being measured in a plane having the carriage movement direction as normal vector. In another example, in a first cutting path direction the cutting-edge angle is comprised in a range between −5 degrees and 0 degrees and in the opposite first cutting path direction in a range between 0 degrees and 5 degrees. Hence, the cutting-edge angle is comprised in a range between −5 degrees and 5 degrees. Nevertheless, another example may comprise a range between −3 degrees and 0 degrees in a first cutting path direction and in a range between 0 degrees and 3 degrees in the opposite first cutting path direction. Hence, the cutting-edge angle is comprised in a range between −3 degrees and 3 degrees. In another example, in a first cutting path direction the tilt angle is comprised in a range between 1 degree and 5 degrees and in the opposite first cutting path direction in a range between −5 degrees and −1 degree. Nevertheless, another example may comprise a range between 2 degrees and 4 degrees in a first cutting path direction and in a range between −2 degrees and −4 degrees in the opposite first cutting path direction. The relationship between the range definition of the cutting-edge angle and the tilt angle may depend on the engaging element characteristics. For simplicity reasons, previous examples are applicable for a cutting blade being orthogonal to the engaging element, in which the angles can be measured with different references. Nevertheless, when replacing the engaging element for elements that may not join the cutting blade orthogonally, other relationships between the ranges in the joining element cutting blade may be provided. Referring now toFIG.4, the media cutter module10comprises a support structure13, a carriage14and a cutting blade15. The joining element41is elastic and may allow the skew of the cutting blade15. The joining element41may be used to balance the opposite side of the engaging element side provided with radial clearance. The cutting blade15may be a rotary blade having an engaging element to be provided to the carriage14. A media (not shown inFIG.4) is to move over the stationary blade27. The cutting blade15in conjunction with the stationary blade27are to cut the media. The cutting blade15has availability to have a cutting-edge angle and a tilt angle. The cutting-edge angle may be a yaw rotation angle between the cutting path and the cutting blade. The tilt angle may be a roll rotation angle measured between the media normal vector and the cutting blade15. Let the roll and yaw axis be defined by the carriage movement, i.e., the roll axis has opposite directions in the first direction and the second direction. The yaw axis in both directions is the same. The structural design of the cutting module10may define the ranges of the cutting blade15cutting-edge angle and tilt angle. The engaging element radial clearance may actuate as structural constrain but other alternatives may be possible. The deformation of the joining element41may enable the orientation of the engaging element The stationary blade27may be replaced for a support surface. The engaging element may be a fitting pin, an axle, a holding element or the like. The cutting-edge angle and the tilt angle during the first direction and during the second direction may be different in terms of sign. In any case when a contact occurs, the engaging element is oriented. FIG.5shows examples of cross-sections which may be obtained during the media cutter module performance. The cross-sections show a carriage14including a cutting blade15and a stationary blade27. The cutting blade15corresponds to a rotary blade in this example, but other alternatives are possible. The stationary blade27corresponds to a linear blade, however, other alternatives such as a support surface may be possible. The engaging element31has two sides with different diameters: first diameter31aat the cutter side and a second diameter31bat the carriage side. In theFIG.5examples, carriage side diameter is smaller than the cutter side diameter, but other alternatives may be possible. The first diameter31ais contacting with the joining element41, having availability to rotate. The joining element41is attached to the carriage14and may be elastic. In the opposite side of the engaging element31, the second diameter31bhas a radial clearance to fit in the carriage14. The radial clearance may be replaced for alternatives, such as elastic members. The radial clearance may not be uniform in all the perimeter of the second diameter31b, since it may determine the ranges for the cutting-edge and tilt angles along the clearance perimeter. The position between the cutting blade15and the stationary blade27may ensure a reduced contact surface between them to increase the pressure at this point to cut the media. In other examples, the engaging element31may be replaced for a fitting pin, an axle, a holding element or the like. InFIG.5ait is shown an example of the cutting blade15being oriented while the cutting blade is contacting with a media in its left-side while moving in a first direction51. When contacting a media, the engaging element31receives a reaction force from the media and the orientation of the cutting blade is obtained. The engaging element31may move laterally with respect to the media path, thereby moving a second portion of the engaging element31(which correspond to the second diameter31b) within the radial clearance. The orientation of the engaging element31orientation is enabled by the carriage side radial clearance and by the joining element41in the first portion of the engaging element (which corresponds to the first diameter31a). The orientation of the cutting bade is measured by the cutting-edge angle and the tilt angle. The orientation may be measured either from the cutting blade15or the engaging element, as explained in other examples previously. InFIG.5bit is shown an example of how the cutting blade15is oriented when the cutting blade15is not contacting with a media. While not contacting a media the cutting blade15is on the same orientation as on the rest position, for example, the orientation may be forced to the rest position by the joining element. The orientation may be measured either from the cutting blade15or the engaging element, as explained previously in other examples. InFIG.5cit is shown an example of how the cutting blade15is oriented when the cutting blade15is contacting with a media in its right-side while moving in a second direction52. When contacting a media, the engaging element31receives a reaction force from the media and an orientation of the cutting blade is obtained. The engaging element31may move laterally with respect to the media path, thereby moving a second portion of the engaging element31(which correspond to the second diameter31b) within the radial clearance. The orientation of the engaging element31is enabled by the carriage side radial clearance and by the joining element41in the first portion of the engaging element (which corresponds to the first diameter31a). The orientation of the cutting blade15is measured by the cutting-edge and tilt angles, described previously in the description. The orientation may be measured either from the cutting blade15or the engaging element, as explained previously in other examples. In another example, the cutting module may be included as a part of a media handling system. The media handling system may be part of a printing system and may comprise several modules, such as conveying modules, scanning modules, cutting modules or the like. The cutting module may comprise a carriage to move in a cutting path, wherein the carriage may include a cutting blade to cut a media. In order to provide a support for the media, the media handling system may have a support structure perpendicular to the media path, wherein the media is to pass over the support surface. The media may be moved by a movement module, the movement module being comprised in the media handling system. When the desired actions may have been performed over the media, the media may be cut by the cutting blade of the cutting module. The carriage of the cutting module may move while the media is halted. The cutting blade is to cut the media, the cutting blade having a cutting-edge angle measured as a yaw rotation angle between the cutting path and the cutting blade. The cutting-edge angle is the measurement of the reaction forces exerted between the cutting blade and the media. Further, the cutting blade may have a tilt angle, wherein the tilt angle is a roll rotation measured between the cutting blade and the cutting path. InFIG.6it is shown an example of a media handling system60. The media handling system60comprises a cutting module, a conveyor to move a media12in a media path direction12aand a stationary blade27. The cutting module comprises a carriage (not shown inFIG.6) that moves between in a first direction movement51a first location11aand a second location11bin a cutting path14a. The carriage is supported by a support structure which is perpendicular to the media path12a, the support structure not being shown inFIG.6. The cutting blade15is supported by the carriage and may define a cutting-edge angle and a tilt angle. The cutting blade15′ depicts another scenario in which the cutting blade15′ may be forced towards a cutting-edge angle and, optionally, towards a tilt angle as a result of the reaction forces during a movement of the carriage in a second direction movement52. For illustrative purposes, the cutting blade15and the cutting blade15′ are shown in the figure but relate to the same cutting blade in different locations between the first location11aand the second location11b. The ranges of the cutting-edge angle and the tilt angle may depend on the structural design of the engaging element. In other examples the stationary blade27may be replaced for a support surface. The cutting-edge angle and the tilt angle may be measured following the criteria of clockwise (CW inFIG.6) for positive angular values and counterclockwise (CCW inFIG.6) for negative angular values, the clockwise/counterclockwise reference being taken from the roll axis and yaw axis relative to the carriage movement. The angles may be measured in the shortest angular path from the cutting path to the cutting blade for the case of the cutting-edge angle and in the shortest angular path from the media normal vector to the cutting blade in the case of the tilt angle. The cutting path may be decomposed in the carriage first direction and the carriage second direction. In an example, a carriage moves in a first direction. When contacting a media. the reaction forces may have an effect on the cutting blade as to provide a tilt angle in the X direction, the angle being measured by the angular rotation of the roll axis, e.g., counterclockwise and clockwise. Also, the reaction forces in the first direction forces the cutting blade to have a cutting-edge angle in the Z direction, the angle being measured by the angular rotation of the yaw axis. For the carriage second direction, the reaction forces orient the cutting blade likewise. In another example, the cutting-edge angle and the tilt angle may be measured from the engaging element instead the cutting blade. The followed criteria defines clockwise for the positive angular values and counterclockwise for the negative angular values, the clockwise/counterclockwise reference being taken from the roll axis and yaw axis relative to the carriage movement. The angles may be measured in the shortest path from the media path direction to the engaging element for the case of the cutting-edge angle and in the shortest path from the media path direction to the engaging element in the case of the tilt angle. While the cutting-edge angle may be measured in a plane parallel to the media, the tilt angle is to be measured in a plane having the cutting path as normal vector. The cutting path may be decomposed in the carriage first direction and the carriage second direction. For the cutting-edge angle measurement, the yaw axis is the same whether going in a first direction or an opposite direction. Therefore, a cutting-edge angle defined clockwise in a carriage first direction is opposite to a cutting-edge angle defined counterclockwise in a carriage opposite direction. For the tilt angle, let be noted that the roll axis may be different whether the carriage is moving in a direction or an opposite direction. Therefore, a tilt angle defined clockwise in a carriage first direction has the negative values the cutting-edge angle defined counterclockwise in a carriage opposite direction. Since the cutting blade is to cut the media, the cutting blade may contact the media, causing the cutting blade orientation against the media. In other examples, the engaging element may be replaced for a fitting pin, an axle, a holding element or the like. In other example, the cutting blade of the media cutter module may be a linear blade. The linear blade may be attached to the carriage as to ensure the contact between the linear blade sharp edge and the media. The linear blade may be provided to a carriage moving in a cutting path. When a contact occurs, the reaction forces orient the linear blade with a cutting-edge angle and a tilt angle, as defined in previous examples. The linear blade may interact with the support surface to cut the media. What has been described and illustrated herein are examples of the disclosure along with some variations. The terms, descriptions and figures used herein are set forth by way of illustration only and are not meant as limitations. Many variations are possible within the scope of the disclosure, which is intended to be defined by the following claims (and their equivalents) in which all terms are meant in their broadest reasonable sense unless otherwise indicated. | 33,038 |
11858260 | DETAILED DESCRIPTION Certain examples described herein allow for increased flexibility in media processing devices such as printing and web handling devices. In particular, certain examples allow a greater variety of media types and supply formats by decoupling media management from a media processing operation. This is achieved through the use of a media management device that may be provided as an interface between an external source of continuous print media and a media processing zone of a media processing device. Example media management devices, and associated media processing devices, as described herein, allow media control in the media processing device to be isolated from conditions at the external media source. For example, this may allow a printing operation to be isolated from a roll supply. This then provides greater freedom of choice for media source configurations, e.g. large or “jumbo” rolls may be supported by certain printing devices. Example media management devices may be incorporated into new media processing devices and/or supplied as an upgrade kit to expand the capabilities of existing media processing devices. Also media processing devices couplable to example media management devices are described. The examples described herein may be used for large format printing with solvent-free inks, including inks that dry to have a protective polymer film on an upper surface. Certain examples described herein may be used to improve existing printing devices that incorporate a roll of media within the printing device. These examples may allow for the printing device to use an external roll of media in place of a previous internal roll of media. Certain examples may improve media transport and simplify media control within a media processing device in an efficient manner without complex additions or modifications to the media processing device. Certain examples may also allow new media types, such as heavy vinyl sheets for use in flooring, laminates for decal and synthetic leather. FIG.1Ashows an example100of a media processing device105. In this example, the media processing device105comprises a printing device. However, the features described herein may also be incorporated into other media processing devices, such as folding devices, cutting devices, devices to apply glosses and varnishes, devices to apply undercoats and perform media preprocessing, and the like. For example, the features described herein may be used in any web handling device, e.g. any device that forms part of a printing system that prints on long stretches of substrate. InFIG.1A, the printing device105is shown schematically from the side. Certain features are omitted for clarity and ease of explanation. The printing device105comprises a printzone110for deposit of printing fluid, e.g. as shown schematically using arrow115, onto continuous print media120. In other examples, this area may take the form of any media processing zone for processing a portion of media, e.g. the area where other printing fluids are applied or where media handling is performed. Continuous print media comprises a substrate for printing where consecutive sheets for printing are coupled, e.g. via a web of media. The continuous print media may be supplied in many different configurations, including single-roll configurations, multi-roll configurations (i.e. where two or more separate substrate webs are used) and free-fall configurations (e.g. where a leading or trailing edge is not rolled up). The continuous print media may comprise porous media (such as textiles or non-standard formats such as window blinds). InFIG.1A, the continuous print media is supplied from an external media source. This may be, for example, a roll or a stack of folded media. It may also comprise an output of a previous media processing device, e.g. where the printing device105forms part of a chain of processing devices. A roll may comprise a spindle around which is wound layers of print media. The continuous print media may be a continuous sheet having a width and a length, where the length is much greater than the width (e.g. by one or two orders of magnitude). Returning toFIG.1A, the printzone110may comprise a section of a media transport system where one or more printheads of the printing device105are arranged to deposit printing fluid. The one or more printheads may be mounted within a moveable carriage that is translated above the continuous print media120. InFIG.1A, a scan axis of such a moveable carriage may be into the figure. The one or more printheads may be removable and replaceable, e.g. may be loaded into the moveable carriage to allow printing and removed when a printing fluid supply is exhausted. In other cases, one or more printheads may form part of a page-wide array, e.g. that extends over the continuous print media120along an axis that is perpendicular to the plane of the figure. The printing device105and printzone110may take a number of different forms depending on the implementation. In the example ofFIG.1A, the printing device105further comprises a motorized drive roller125to receive the continuous print media120for transport through the printzone110. In other examples, this may comprise a motorized drive roller to transport the continuous print media through a media processing zone of a media processing device. The motorized driver roller125may extend along an axis that is perpendicular to the plane of the figure. The motorized driver roller125may comprise a material with a predefined coefficient of friction relative to a set of media types. In certain cases, the motorized driver roller125may comprise a rubber roller wherein the continuous print media120passes over the top of the roller. The motorized drive roller125may be directly or indirectly driven by a motor. In the latter case, the motorized drive roller125may be coupled to a gear and/or belt system to provide a torque. This torque may be controlled by control circuitry of the printing device105. At least the motorized drive roller125propels the continuous print media120through the printzone110, allowing for the deposit of printing fluid at arrow115, wherein, following printing, the print media is output from the printing device105in direction130. The output may be configured in a “free-to-floor” configuration, or be arranged to be received by a further device. FIG.1Aalso shows a media management device140, which may be used with, or form part of, the printing device105. In the example ofFIG.1A, the media management device140comprises a roll management device as media is supplied from an external media source in the form of a roll. Even though the phrase “roll management device” is used in relation to this example, in other examples, the media management device140may be used with other forms of external media source. References to “roll” in this example should be understood as also applying to other media sources. In the side view ofFIG.1A, the printzone110of the printing device105is spatially separated from the roll management device140; however, in other examples, the roll management device140may be spatially integrated into a closed body of the printing device105. In the example ofFIG.1A, the roll management device140is located below the printzone110. For example, the roll management device140may be self-supported and reside on a floor in an installation. The printing device105may then be arranged in relation to the roll management device140such that the printzone110is above the roll management device140. In one set of cases, the roll management device140may be integrated into a structure of the printing device105; in another set of cases, the roll management device140may be structurally couplable to the printing device105; in yet another set of cases, the roll management device140may be detached from the printing device105while being fixedly aligned with the printzone110. In other examples, the roll management device140may be arranged in other locations relative to the printzone110, e.g. to the rear (right inFIG.1A) and/or above the printing device105. The roll management device140is configured to enable a roll of continuous print media150to be managed, e.g. to be handled and/or controlled, independently of the printing device105, e.g. independently of media transport provided in the printzone110. This may be compared to comparative printing devices where a roll of continuous print media is mounted within the printing device and supplied directly to the motorized drive roller125. The roll150inFIG.1Amay be a large or “jumbo” roll that is located in an inline external device and/or mounting. In these comparative cases, conditions at the roll150, may affect image quality by affecting printing in the printzone110. InFIG.1A, the roll management device140receives the continuous print media120from the input roll150. InFIG.1A, the continuous print media120is received by the roll management device140at an input media interface155. In certain implementations, this may comprise an opening to receive the continuous print media120; in other implementations, this may comprise one or more of, for example, rollers, guidance surfaces and apertures to receive the continuous print media120. In these other implementations, a leading edge of the continuous print media120may be fed into the input media interface155during loading of a new roll. InFIG.1A, the continuous print media120passes through the roll management device140and is output at an output media interface160. As above, the output media interface160may comprise a variety of forms depending on implementation, from an opening in the roll management device140to more complex media transport mechanisms. The output media interface160supplies the continuous print media120to the motorized drive roller125of the printing device105. The roll management device140then controls a tension of the continuous print media120within the device such that it is isolated from any tension experienced in the roll150. In more detail, the roll management device140ofFIG.1Acomprises a nip165defined in relation to a motorized nip roller170of the roll management device140. The nip165comprises a point in a media transport path where a force is applied to the continuous print media120to control the tension therein. This force may be applied across the width of the continuous print media120(e.g. along an axis that is perpendicular to the plane ofFIG.1A). This force may be applied uniformly or differentially along the width of the continuous print media120, depending on the complexity of tension control for the implementation. The nip165may comprise a gap or pinch-point between the motorized nip roller170and an additional roller, such as a smaller idle or undriven roller. The motorized nip roller170may extend across at least a width of the continuous print media120or may comprise a plurality of rollers, such as a set of independently driven rollers, aligned on a common axis. In one case, one or more of the motorized driver roller125and the motorized nip roller170may extend across at least a portion of the width of the printing device105. InFIG.1A, the continuous print media120is received by the nip165from the roll150and is supplied from the nip165to the motorized drive roller125of the printing device105. The roll management device140is thus arranged to isolate a tension in the continuous print media120at the motorized drive roller125from a tension in the continuous print media at the input roll150. In certain cases, the nip165may comprise multiple nips. For example, the nip165may comprise a plurality of independent assemblies (e.g. 5, 10 or 20 etc.) that are spaced along the length of one or more nip rollers such as motorized nip roller170(i.e. along a width of the continuous print media). Each assembly may comprise at least one nip roller that is arranged to apply a force to the continuous print media within the nip165. The at least one nip roller may be an idle, e.g. undriven, roller. This force may be applied by an urging mechanism, such as a spring, that urges the at least one nip roller towards the motorized nip roller170. In one implementation, each assembly may comprise two short parallel nip rollers and a spring-loaded mechanism which, in use, presses the two rollers against the motorized nip roller170. In this case, the continuous print media120passes between the motorized nip roller170and the two short nip rollers of each assembly. In one implementation, the motorized nip roller170may control a tension in the continuous print media by running in a torque control mode, where it acts a slave roller to the motorized drive roller125of the printing device105. Torque control may be applied via a closed-loop motion control system, where a winding current consumption of a driver of the motorized nip roller170(such as an electric motor) is controlled in a closed loop to maintain a particular torque at an output shaft of the driver regardless of the speed or position of the shaft. In this case, when the motorized drive roller125of the printing device105advances the continuous print media120, a controller for the driver sees a spike in the driver winding current, e.g. as caused by excess tension in the media, and adjusts the driver accordingly to let the media pass at a controlled tension level. As such, in the example ofFIG.1A, at least one level of tension control is provided by the motorized nip roller170, to which a torque is applied by a driver such as a motor under the control of a controller. The controller may form part of the printing device105or part of the roll management device140. The tension of the continuous print media120may be set via a torque of the motorized nip roller170as applied by a motor or servo and a radius of the roller. If the controller forms part of the printing device105, the motorized nip roller170may be controlled by the printing device105, e.g. control circuitry of the printing device105may be electrically coupled to a motor or servo used to rotate the motorized nip roller170. In certain cases, tension may be controlled by differentially controlling the motorized nip roller170and the motorized drive roller125. Control may be applied such that a tension in the continuous print media120between the roll management device140and the printzone110is independent of, i.e. isolated from, a tension in the continuous print media120between the input roll150and the roll management device140. This is useful where input rolls have different (i.e. varying) radii, and/or where different media types have different weights. In these cases, when a roll and/or media type is changed, the tension in the continuous print media120between the printing device105and the roll150also changes; as such in comparative approaches, the printing device105needs to compensate for the changes. Furthermore, it may be difficult to control and/or predict the tensions between the printing device105and the roll150for large rolls and/or heavy media types. In these cases, without the roll management device140, it may be difficult to control the tension in the continuous print media120, leading to poor image quality due to perturbations in the printzone110. By isolating the roll150from the printing zone110, the roll management device140allows the printing device105to apply media control routines based on a predefined tension in the continuous print media120. In certain cases, the motorized nip roller170has a lower coefficient of friction with respect to the continuous print media than the motorized drive roller125of the printing device. For example, both rollers may comprise an outer rubber layer but with different surface configurations. This feature may help any slippage of the print media to occur with respect to the roll management device140, as opposed to occurring in relation to the motorized drive roller125and thus influencing the position of the print media in the printzone110. FIG.1Bshows a front view of the printing device105. It should be noted that this front configuration is provided for example and may vary between implementations. As can be seen in this figure, the printzone110, the motorized drive roller125, the nip165, and the motorized nip roller170extend across a width of the printing device105, which is greater than a width of the continuous print media120. A leading edge of the continuous print media120is shown emerging from the printing device105at arrow130inFIG.1B. InFIG.1B, the printing device105and the roll management device140are rigidly mounted in relation to each other via housing180. As such, the printing device105may be considered to comprise the housing180and the roll management device140. In other cases, these may be provided separately, e.g. as couplable or independent modular structures. For example, in certain cases, the roll management device140may be provided as a separate module or kit to allow for the upgrade of existing printing devices105. In these cases, an existing roll spindle may be removed and replaced with the roll management device140. The input roll150is mounted within a separate housing185, which in this example is located behind the printing device105. In other cases, the roll150may be mounted in a structure that forms part of the printing device105. Numerous configurations are possible. FIG.2is a schematic side view showing an alternative configuration of the printing device105. In this example, the printing device105also comprises an output media management device240. In this case, the output media management device240is provided in addition to the roll management device140. The roll management device140is shown with a similar configuration to that shown inFIG.1A. The output media management device240may be arranged to function in a similar manner to the roll management device140on an output of the printing device105, e.g. to handle continuous print media120that contains printed images. For example, in addition to, or as an alternative to, a “fall-to-floor” configuration and/or an “internal take-up-reel” configuration, the output media management device240may enable the continuous print media120to be re-rolled following deposit of printing fluids. In certain cases, the printing device105is configured to allow a printed image to dry and/or cure before being re-rolled. This may be performed by way of one or more heating devices and/or lengths of media transport. The output media management device240comprises an input media interface255to receive the continuous print media120from an output roller225of the printzone110. The input media interface255may be configured as per the description of the roll management device interfaces155,160above. The output media management device240comprises a nip265defined in relation to a motorized nip roller270of the output media management device240. The nip265and the motorized nip roller270may be configured in a similar manner to the nip165and motorized nip roller170of the roll management device140, e.g. as described above. In certain cases, the nip265and the motorized nip roller270of the output media management device240may differ from the nip165and motorized nip roller170of the roll management device140, e.g. the components of the output media management device240may be differentially configured to avoid damage to a printed image found upon the continuous print media120. Similarly, the requirements for tension control in the output media management device240may be more relaxed, as the downstream tension control may have less of an effect on perturbations in the printzone110. InFIG.2, the output media management device240also comprises an output media interface260to supply the continuous print media120for storage following the deposit of printing fluid. In the present example, storage is provided via an output roll250; however, other storage means are possible, e.g. the nip265may output a leading edge of the continuous print media120to the floor and/or to a cutting and/or stacking device. In a similar manner to the roll management device140, the output media management device240is arranged to isolate a tension in the continuous print media120at the output roller225of the printzone110from a tension in the continuous print media following the output media interface260. For example, this isolation may avoid re-rolling issues or snags in the output media from affecting a printing operation in the printzone110. In a similar manner to the roll management device140, tension control may be provided via differential control of the output roller225of the printing device105and the motorized nip roller270of the output media management device240, e.g. via the closed-loop control described above. In certain cases, the output media management device240may be supplied independently of a downstream media storage device, such as an output roll. In other cases, the output media management device240may comprises an output roll for storing the continuous print media following deposit of printing fluid, wherein the output media interface260is arranged to supply the continuous print media120to the output roll250. Again, numerous configurations are possible. Use of an input media management device, such as roll management device140, and an output media management device240in combination thus isolates upstream and downstream media perturbations from the media processing zone, e.g. printzone110. This can improve processing, e.g. print or finishing, quality and facilitate the use of a greater range of media supply and storage devices. For example, a modular approach to media supply and/or storage may be taken, wherein devices may be swapped in and out of use depending on the print job specifications. This then provides greater flexibility. It can also aid in providing a consistent loading and/or uploading routine despite the use of different roll configurations and media types. For example, an input media management device and/or an output media management device may have a consistent loading and/or uploading procedure, e.g. to insert media into the input media interface155or255and/or to retrieve media from the output media interface160or260. An input management device and/or an output media management device further allow for input and/or output media source, such as rolls to form part of the media processing device or form part of external equipment. For example, an operator of the printing device105may use large or “jumbo” rolls on the input and/or output for one set of print jobs (e.g. for large textile or vinyl flooring prints), before swapping in smaller rolls for a different set of print jobs (e.g. graphics for boat or van decal). This may be easily managed by the printing device105as the tension control is isolated from the roll and media types. FIG.3shows an example300of a media management device305that may be supplied as an independent component for coupling to a media processing device. The media processing device may be a printing or other web handling device. For example, media management device305may be supplied as an accessory or auxiliary device for an existing media processing device, and/or may be assembled into a new media processing device as a “fit-in” module. The example ofFIG.3comprises both input and output media management. InFIG.3, the media management device305has an input section310and an output section350. The input and output sections310,350may provide functionality similar to the roll management device140and the output media management device240. In certain cases, one of the two sections may be provided, e.g. the input section310may be present but not the output section350(e.g. to implement a device similar to that shown inFIG.1) or vice versa. The input section310of the media management device305comprises an input media interface312to receive continuous print media from an external media source330. The external media source is illustrated inFIG.3as a roll; however, other media source configurations are possible. The continuous print media is shown as portions of dot-dash lines. As described previously, the external media source330may form part of an external device and so is shown using dashed lines. The input section310also comprises an output media interface314to supply the continuous print media to an input roller of a media processing device. The input and output media interfaces312,314may be constructed in a similar manner to input and output media interfaces155,160shown inFIG.1. The input section310further comprises a nip316defined between a first roller318and a second roller320. At least one of the first and second rollers318,320comprises a motorized roller. For example, a larger roller such as the first roller318as shown inFIG.3may be motorized to form a motorized nip roller. The continuous print media is received by the nip316from the input media interface312and is supplied from the nip316to the output media interface314. From the output media interface314, the continuous print media is supplied to a media processing zone of a media processing device, e.g. as indicated by the arrows340. The media processing zone may comprise the printzone of a printing device, such as is shown inFIGS.1A,1B and2. FIG.3also shows an electrical interface322to receive control signals from the media processing device. InFIG.3, the electrical interface322forms part of a larger mechanical interface324for coupling the media management device305to a media processing device. In other cases, the electrical interface322may be separate from the mechanical interface324, e.g. may comprise a plug-and-socket arrangement or the like, with one or more electrical connectors. The electrical interface322may enable the media management device305to be electrically coupled to a systems bus of a mechanically coupled media processing device, and/or may comprise connections to control circuitry of the media processing device. The media management device305may apply passive control via instructions supplied by the media processing device. In other cases, the media management device305may comprise integrated control circuitry to apply active control from within the device. In this case, there may be no electrical coupling with the media processing device, or an electrical coupling may remain and the media processing and media management devices may communicate to control the tension. InFIG.3, both the input section310and the output section350have a mechanical interface component; however, in other examples, the mechanical interface may be independent of any one section and may be provided in one or more portions of the media management device305. The mechanical interface324is used to couple the media management device305to a respective mechanical interface of the media processing device. It may comprise support members on one of the devices that are received in an aperture on one of the other devices. It may also comprise fastening means such as screws and/or clips to secure the devices in relation to each other. InFIG.3, the media management device305is arranged to control the motorized roller, e.g. first roller318. This control may be performed in response to control signals from a media processing device, e.g. as received over the electrical interface322, or in response to internal signals. The control acts to isolate a tension in the continuous print media at an input roller of the media processing device from a tension in the continuous print media at the external media source330. This may be performed as described above with reference toFIGS.1A and1B. This may comprise active and/or passive control. The example media management device305ofFIG.3also comprises a diverter326. The diverter326is provided in the input section310. The diverter326is configured between the input media interface312and the nip316to adjust a wrap angle of the continuous print media around the motorized roller, e.g. the first roller318. The wrap angle is the angle of the sector on the motorized roller where the continuous print media is in contact with the roller. As shown inFIG.3, the diverter326increases the incident angle of the print media as it reaches the motorized roller, so as to increase the wrap angle around the roller. The diverter326may be used to normalize an angle at which the continuous print media is receive at the input media interface312. For example, the diverter326may be useful when using “jumbo” rolls where the angle of receipt is shallower than for other roll types. The diverter326, as described here, may also be used in the other examples. The output section350of the media management device305is configured in a similar manner to the output media management device240ofFIG.2. The output section350comprises an input media interface352to receive, in use, continuous print media from an output roller of a media processing device, e.g. as indicated by the diamond end of the dot-dash line representing the print media. The input media interface352may be configured as per the description of the roll management device interface255above. The output section350comprises a nip356defined in relation to a first roller358. The nip356is formed between the first roller358and a second roller360. The nip356and the first roller358may be configured in a similar manner to the nip265and motorized nip roller270of the output media management device240, e.g. as described above with reference toFIG.2above. In certain cases, the nip356and the first and second rollers358,360of the output section350may differ from the nip316and first and second rollers318,320of the input section310, e.g. as discussed above. Alternatively, they may be mirrored versions of a common set of components. The output section350also comprises an output media interface354to supply the continuous print media for storage on an external media storage device370. InFIG.3, this is shown as an output roll but other devices may alternatively be used. InFIG.3, large “jumbo”-style rolls are shown, but other storage and supply types, as well as other roll sizes, may be used. Although, an output roll is shown, other storage means are possible, e.g. the output media interface354may output a leading edge of the continuous print media to the floor and/or to a cutting and/or stacking device. In the example ofFIG.3, the media management device305is designed to be self-supported on feet328and368. In other examples, the media management device305may be supported by a structure of the media processing device. In the example ofFIG.3, the media management device305may be installed on a floor below the media processing device. In certain cases, the media processing device comprises a printing device. In certain cases, the media management device305may comprise a levered mechanism380(FIG.3A) to increase a separation of at least one of the nips316,356to enable insertion of a leading edge of a new continuous print media. For example, the second rollers may be mounted upon an elongate support member that is rotatably fastened to a housing of the media management device305at a pivot point. In normal use, e.g. while printing, this elongate support member may be locked into a first position where the nip is “closed” (i.e. where there is a first distance between the first and second rollers). When loading and/or unloading the continuous print media, the elongate support member may be unlocked and allowed to pivot and rotate away from the location of the nip. This “opens” the nip, i.e. increases the distance between the first and second rollers such that the sheet of continuous print media may be inserted and/or removed. Once the continuous print media has been inserted and/or removed, the nip may be closed again by pivoting the support member back to the locked position. In certain cases, the media management device305may also comprise one or more spindles to mount rolls of continuous print media. For example, the media management device305may comprise a spindle to mount an input roll and/or a spindle to mount an output roll. This then may allow the rolls to be mounted as part of the media management device305. This may be an option for smaller rolls of print media, or as a backup option for the supply and/or retrieval of print media. For example, these integrated spindles may provide an “internal take-up-reel” and/or an “internal supply-reel” configuration. As shown inFIG.3, the output section350may also comprise a diverter366configured between the output media interface354and the nip356to adjust a wrap angle of the continuous print media around the first roller358. Again, the diverter366may be used and/or mounted to increase a wrap angle around the first roller358, e.g. due to a shallow exit angle of the continuous print media through the output media interface354. In certain cases, the media management device305may comprise a tension monitoring device. For example, this may take the form of a sensor coupled to a roller applied to the continuous print media. Tension may be measured in one or more locations on the continuous print media. Tension measurements may be used by a controller of the media management device305to control tension in the device and/or may be transmitted to a controller of the media handling device (e.g. where control is passive with respect to the media management device). In one case, a tension monitoring device may comprise a load cell installed at one of diverters, e.g. at diverter326and/or diverter366. Measuring tension within the media management device may improve the nip roller's ability to isolate the tension between the external media source and processing zone. In a complementary manner, a media processing device as described herein may be supplied independently of the media management device. For example, a media processing device such as a printing device may be adapted to interface with a media management device as described herein. In this manner, media processing devices may be manufactured such that there operate with, i.e. are couplable to, different media management devices. In this case, the media processing device may comprise a media processing zone for processing a portion of continuous print media and a motorized drive roller to receive the continuous print media for transport through the media processing zone. For example, the media processing device may have features similar to the media processing devices of the previous examples. In this case, the media processing device further comprises a media interface to receive a continuous print media from a media management device, wherein a tension in the continuous print media at the motorized drive roller is isolated from a tension in the continuous print media at an external media source using the media management device. For example, the media processing device may comprise the printing device105ofFIGS.1A,1B and2, in a case where the device is provided independently of the roll management device140. In a similar manner to the previously described media interfaces of the media management device, a media processing device may comprise one or more of a media interface for receiving continuous print media from an input media management device and a media interface for supplying print media to an output media management device. A media interface may comprise a nip defined in relation to a motorized drive roller of the media processing zone. In certain cases, a media interface may comprise an aperture to receive or supply a leading edge of a continuous print media. FIG.4shows an example method400of operating a media processing device. This method may be applied to the printing device105ofFIGS.1A,1B or2, or may be applied to a media processing device that is being used with the media management device305. Alternatively, the method may be applied using a different media management device to that shown in the other Figures. At block410, a media management device is coupled to the media processing device. The media processing device may comprise a printing device or other web handling device, e.g. in a printing system. In certain cases, the media management device may form part of the media processing device and as such may be deemed to be “pre-coupled”, i.e. supply of such a media processing device includes supply of a coupled media management device. In other cases, e.g. when using the media management device305ofFIG.3, the media management device may be physically and electrically coupled to the media processing device. This may involve coupling one or more mechanical interfaces of the media management device, such as mechanical interfaces324,364, to corresponding mechanical interfaces of the media processing device. It may also comprise coupling one or more electrical interfaces, e.g. such as electrical interface322, to corresponding electrical interfaces of the media processing device. In one case, power may also be supplied from the media processing device across the coupled electrical interfaces. In another case, the media management device may have an independent power supply. At block420, a leading edge of continuous print media supplied from an external media source is fed through a nip between two rollers of the media management device to an input roller of the media processing device. For example, this may comprise feeding a leading edge through nip165or316such that it wraps around rollers170or318. In certain cases, as described above, a mechanism may be provided to “open” the nip165or316, i.e. to move a lower roller away to allow the leading edge to be inserted. At block430, the nip is configured to apply a force to the continuous print media. This may comprise applying a torque to a motorized nip roller and/or closing the nip such that the continuous print media wraps around the motorized nip roller. It may also, or alternatively, comprise urging nip rollers towards the motorized nip roller, where the continuous print media is configured between the urged nip rollers and the motorized nip roller. At block440, the media processing device is configured to feed the continuous print media from the media management device through a media processing zone. This may comprise a printzone of a printing device. This may comprise supplying a leading edge to motorized roller125as shown inFIGS.1A and2. The media processing device may also comprise a nip between two rollers that “takes” the leading edge of the continuous print media and feeds it into the media processing device, e.g. such that it may be aligned within the printzone110as shown inFIGS.1A and2. Automated control routines may be applied to configure a media transport of the media processing device to receive the continuous print media. This block may also comprise applying tension control within the media processing device, e.g. by differential control of rollers125and225, to ready the media processing device for media processing, e.g. the deposit of printing fluid such as ink, gloss or varnish. Blocks410to440may be performed to initially configure or “setup” the media processing device. Block450may then be performed to during media processing by the media processing device, e.g. during printing or finishing. This may be a period of time after performing blocks410to440, as indicated by the dashed arrow. Block450may be repeated for each media processing operation, as shown by the dotted arrow inFIG.4. At block450, a tension in the continuous print media is controlled by driving an input roller of the media processing zone, such as roller125inFIGS.1A and2, and at least one of the two rollers of the media management device, e.g. rollers170or318. For example, differential control of these rollers may be used to control a tension in the continuous print media. The tension in the continuous print media at an input to the media processing device is controlled independently of a tension in the continuous print media at the roll. The method400may also comprise operations to change an external media source, e.g. a roll of continuous print media. These operations may comprise, following a media processing operation: configuring the nip to remove a force applied to the continuous print media; removing the continuous print media from the media management device; and repeating the feeding and configuring operations of blocks410to440for a second roll of continuous print media. In a printing case, this allows printing on a second, possibly different, roll without significant change in the configuration of the media processing device. Certain examples described herein enable media control in a media processing device to be applied independently of how the media is supplied. The examples thus isolate an external media source from a media processing device. The examples may be applied to media processing devices in a printing system, such as printing devices, finishing devices, and pre- and post-processing devices. Certain examples allow for a much greater variety of external media sources, e.g. allow for different roll sizes and media types. These examples help decouple the media processing device from the loading forces experienced in external sources of continuous print media. This allows support for “jumbo” rolls, e.g. rolls around 1 m in diameter. The examples described herein are particularly suited to medium-sized, large-format printing devices, e.g. devices that are used for a large variety of different print jobs on different media. The preceding description has been presented only to illustrate and describe examples of the principles described. This description is not intended to be exhaustive or to limit these principles to any precise form disclosed. For example, printing fluid, as described herein, may comprise inks, glosses, varnishes and the like. Media processing may comprise printing, cutting, folding, laminating, stacking, applying glosses and/or varnishes, stitching, etc. Media may be supplied from external media sources such as rolls, stacks, other media processing devices, hand-supplied media etc. Features of individual examples may be combined in different configurations, including those not explicitly set out herein. Many modifications and variations are possible in light of the above teaching. | 42,379 |
11858261 | DESCRIPTION OF EMBODIMENTS FIG.1is a schematic cross-sectional view showing configuration of a printer10. The printer10is an ink jet printer that performs printing by ejecting ink onto a medium M. The printer10includes a printing unit20, a supply unit30that feeds out the medium M, and a medium winding unit40. The printer10corresponds to an example of a recording apparatus. The medium M corresponds to an example of a medium. Some drawings includingFIG.1show an XYZ coordinate system. The X axis, the Y axis, and the Z axis are orthogonal to each other. The X-axis is parallel to the installation surface of the printer10and corresponds to the width of the printer10. The Y axis is parallel to the installation surface of the printer10, and corresponds to the depth of the printer10. The Z axis is perpendicular to the installation surface of the printer10, and corresponds to the height of the printer10. Hereinafter, the +X direction, which is parallel to the X axis, indicates a direction from the supply unit30toward the medium winding unit40, and indicates a direction from the center toward the left inFIG.1. The −X direction of the X axis indicates a direction from the center to the right inFIG.1. The +Y direction, which is parallel to the Y axis, indicates a direction toward the front ofFIG.1. The −Y direction, which is parallel to the Y axis, indicates a direction toward the back ofFIG.1. The +Z direction, which is parallel to the Z axis, indicates a direction directed upward from the center ofFIG.1. The −Z direction, which is parallel to the Z axis, indicates a direction downward from the center ofFIG.1. The printing unit20includes a supply guide frame21, a transport roller pair24including a first transport roller22and a second transport roller23, a platen25, a print head26, a discharge guide frame27, and a control unit50. The supply guide frame21guides the medium M that was fed out from the supply unit30to the transport roller pair24. The supply guide frame21guides the medium M in the +X direction and the +Z direction. The supply guide frame21may be constituted by one member or may be constituted by a plurality of members. The transport roller pair24includes a first transport roller22and a second transport roller23, and is capable of transporting the medium M. The transport roller pair24corresponds to an example of a transport unit. The first transport roller22is disposed at a position in the +Z direction with respect to the medium M. The second transport roller23is disposed at a position in the −Z direction with respect to the medium M. The first transport roller22or the second transport roller23is rotationally driven by a driving force from a driving source such as a motor (not shown). The first transport roller22and the second transport roller23transport the medium M to the print head26by the driving force from the driving source, in a state of sandwiching the medium M by pressing against each other. The platen25is provided at a position in the −Z direction with respect to the print head26. The platen25is a flat plate-shaped member that supports the medium M transported by the transport roller pair24. In a case where a suction fan is provided at a position in the −Z direction with respect to the platen25, a through hole through which an air current flows is provided in the platen25. The medium M is pressed against the platen25by the air flow of the suction fan. The print head26can perform printing by ejecting ink onto the medium M supported by the platen25. The print head26forms an image on the medium M by ejecting ink. The print head26corresponds to an example of a recording unit. The print head26may be supported by a carriage (not shown) and moved in the +Y direction and the −Y direction. The discharge guide frame27guides the medium M printed on by the print head26, to the medium winding unit40. The discharge guide frame27guides the medium M in an oblique direction intersecting the +X direction and the −Z direction. The discharge guide frame27may be formed of one member or may be formed of a plurality of members. A drying unit (not shown) may be provided at a position facing the discharge guide frame27. The drying unit includes, for example, a heater as a heating source. The drying unit heats the medium M on the discharge guide frame27and promotes fixing of the ejected ink to the medium M. The control unit50is a controller that performs various types of control such as transport control of the medium M and print control on the medium M. The controller includes a central processing unit (CPU), read only memory (ROM), random access memory (RAN), and storage, none of which are shown. The control unit50acquires detection results from various sensors (not shown) and performs various controls. The control unit50may acquire print data and perform various controls based on the acquired print data. The control unit50may be composed of one or more units. The supply unit30includes a medium roll support shaft31, a supply guide member32, a supply bar member33, and supply bar support members34. A medium roll60of the medium M wound in a roll shape is supplied to the supply unit30. The medium roll support shaft31supports the medium roll60. The medium roll support shaft31is rotatably supported by a frame or the like (not shown) disposed at an end portion in the +Y direction and an end portion in the −Y direction of the supply unit30. The medium roll support shaft31may be rotated by driving force of a driving source such as a motor (not shown). When the medium roll support shaft31is rotated by the driving force of the driving source, the rotation amount is controlled by the control of the control unit50. The supply guide member32guides the medium M fed out from the medium roll60. The supply guide member32guides the medium M in an oblique direction intersecting the +X direction and the −Z direction. The supply guide member32is, for example, a roll member. The roll member may be supported so as to be rotatable or may be non-rotatably supported. In order to increase the slidability of the medium M, it is desirable that the roll member is rotatably supported. The supply bar member33is supported by the supply bar support members34. The supply bar member33is wrapped around by the medium M guided by the supply guide member32and applies tension to the medium M. The supply bar member33guides the medium M to the transport roller pair24via the supply guide frame21. The supply bar member33guides the medium M substantially in the +Z direction. The supply bar support members34are disposed at a position in the +Y direction and at a position in the −Y direction with respect to the supply bar member33, so as to sandwich the supply bar member33. The supply bar support members34swingably support the supply bar member33. The supply bar support members34swing the supply bar member33about a virtual supply bar swing axis (not shown). In the case ofFIG.1, the supply bar swing axis coincides with the rotation axis (not shown) of the medium roll support shaft31. The supply bar swing axis may not coincide with the rotation axis. The supply bar support members34apply tension to the medium M by swinging the supply bar member33. The supply bar support members34adjust the tension acting on the portion of the medium M from the medium roll60to the transport roller pair24by applying tension to the medium M. The medium winding unit40includes a medium winding member41, a first tension bar43, a second tension bar44, and a tension bar support member46. The medium winding unit40winds the medium M which was printed on by the printing unit20. FIG.1shows a winding member rotation axis42, which is the rotation center of the medium winding member41, and a tension bar swing axis49, which is the swing center of the tension bar support member46. The winding member rotation axis42and the tension bar swing axis49are virtual shafts and are parallel or substantially parallel to the Y axis. The winding member rotation axis42and the tension bar swing axis49may deviate within the range of design error. The winding member rotation axis42corresponds to an example of a rotation axis. The tension bar swing axis49corresponds to an example of a swing axis. The medium winding member41is capable of winding up the printed medium M. The medium winding member41is provided downstream of the transport roller pair24in the transport direction of the medium M. The medium winding member41is rotatable about the winding member rotation axis42. The medium winding member41supports the printing medium roll70on which the medium M printed by the printing unit20is wound. The print medium roll70ofFIG.1shows a virtual state of the medium M being wound up. The medium winding member41is rotatably supported by a frame or the like (not shown) disposed at an end portion in the +Y direction and at an end portion in the −Y direction of the medium winding unit40. The medium winding member41is rotated by a driving force from a driving source such as a motor (not shown), and winds up the medium M. The medium winding member41corresponds to an example of a winding unit. Of the medium M, the printing surface printed by the print head26wraps around the first tension bar43. The printing surface corresponds to an example of a first surface. The first tension bar43is in contact with the printing surface directly or via a cover member161described later. That is, the first tension bar43can directly or indirectly contact the printing surface. The printing surface of the medium M wraps directly or indirectly around the first tension bar43. The first tension bar43presses the printing surface of the medium M by its own weight. The first tension bar43may press against the printing surface of the medium M using the rotation of the medium winding member41as a driving force. The first tension bar43may be pressed against the printing surface of the medium M by swinging of the tension bar support member46. The first tension bar43may have any shape as long as it can be pressed against the printing surface of the medium M, but the shape thereof is preferably a cylinder or a column extending in the direction along the X axis. As the first tension bar43, an extrusion-molded member of a metal material such as aluminum or steel use stainless (SUS), or a pipe-processed member of a metal material such as aluminum or SUS is used. The first tension bar43corresponds to an example of a first bar member. A rear surface of the medium M, which is the opposite surface from the printing surface, wraps around the second tension bar44. The rear surface corresponds to an example of a second surface. The second tension bar44is in contact with the rear surface directly or via the cover member161. That is, the second tension bar44can directly or indirectly contact the rear surface. Further, the rear surface of the medium M directly or indirectly wraps around the second tension bar44. The second tension bar44may have any shape as long as the rear surface of the medium M can wrap around the second tension bar44, but the shape is preferably a cylinder or a column extending in the direction along the X axis. As the second tension bar44, an extrusion-molded member of a metal material such as aluminum or SUS, or a pipe-processed member of a metal material such as aluminum or SUS is used. The second tension bar44corresponds to an example of a second bar member. The tension bar support member46is supported by a frame or the like disposed at a position in the +Y direction and at a position in the −Y direction of the medium winding unit40. The tension bar support member46supports the first tension bar43and the second tension bar44. The tension bar support member46is swingable about the tension bar swing axis49. The tension bar support member46supports the first tension bar43and the second tension bar44such that the second tension bar44is positioned between the tension bar swing axis49and the first tension bar43. The cross-sectional shape of the tension bar support member46inFIG.1is, when viewed from the +Y direction, a rectangle elongated in an axis parallel to the X axis, but is not limited to this. The cross-sectional shape of the tension bar support member46inFIG.1may be a shape, when viewed from the +Y direction, having a portion extending in the +Z direction or in the −Z direction from the tension bar swing axis49and a portion extending in the −X direction from the +Z direction or −Z direction end of the first portion. That is, the cross-sectional shape of the tension bar support member46inFIG.1may be a shape, when viewed from the +Y direction, having a first portion extending in a first direction from the tension bar swing axis49and a second portion extending in a second direction, different from the first direction, from the first portion, which is in the first direction. The tension bar support member46corresponds to an example of an arm member. The first tension bar43, the second tension bar44, and the tension bar support member46correspond to an example of a tension applying unit that applies tension to the medium M. The tension bar support member46may be constituted by two units supported by a frame disposed at a position in the +Y direction and a position in the −Y direction of the medium winding unit40. A sensor (not shown) is provided with respect to the tension bar support member46for detecting a swing position. The tension bar support member46swings in the −Z direction by the weight of the first tension bar43and the second tension bar44, and applies tension to the medium M. When the tension bar support member46swings to a predetermined lower limit position in the −Z direction, the control unit50controls the drive source that rotates the medium winding member41, and causes the medium winding member41to wind the medium M. When the medium M is wound around the medium winding member41, the tension bar support member46swings in the +Z direction. When the tension bar support member46swings to a predetermined upper limit position in the +Z direction, the control unit50controls the drive source that rotates the medium winding member41and stops the winding of the medium M onto the medium winding member41. The control unit50adjusts the degree to which tension is applied to the medium M by the driving operation of the tension bar support member46. The printer10transports the medium M fed out from the medium roll60supplied to the supply unit30through the following path. The medium M unwound from the medium roll60is transported to the printing unit20via the supply guide member32and the supply bar member33. The printing unit20transports the medium M to the medium winding unit40using the supply guide frame21, the transport roller pair24, the platen25, and the discharge guide frame27. The medium winding unit40winds the medium M that has passed by the first tension bar43and the second tension bar44around the printing medium roll70supported on the medium winding member41. A device including the transport roller pair24, the first tension bar43, the second tension bar44, the tension bar support member46, and the medium winding member41corresponds to an example of a transport device. FIGS.2A,2B, and2Cillustrate the operation of the tension bar support member46.FIG.2Ashows a case where the tension bar support member46is positioned at the swing center. The swing center is a position where the longitudinal direction of the tension bar support member46substantially coincides with the direction in which a horizontal line HL (to be described later) extends, and is a reference for when the tension bar support member46swings in the +Z direction or the −Z direction from the center position.FIG.2Bshows a case where the tension bar support member46swings in the +Z direction about the tension bar swing axis49.FIG.2Cshows a case where the tension bar support member46swings in the −Z direction about the tension bar swing axis49. The tension bar support member46is shown in a rod shape to facilitate understanding of the operation. FIGS.2A,2B, and2Cshow the winding start position M1, the separation position M2, the horizontal line HL, and the medium movement line ML. The winding start position M1is a position where the medium M transported from the second tension bar44is wound onto the printing medium roll70. The separation position M2is a position where the medium M wrapping around the second tension bar44separates from the second tension bar44in accordance with movement. The horizontal line HL is a virtual line perpendicular to the tension bar swing axis49and parallel to the X axis. The medium movement line ML is a virtual line connecting the winding start position M1and the separation position M2. FIGS.2B and2Cshow a swing angle α. The swing angle α is an angle between the horizontal line HL and the tension bar support member46. The swing angle α indicates the angle when the tension bar support member46swings. The swing angle α is 0° when the tension bar support member46is at a horizontal position that coincides with the horizontal line HL. InFIGS.2A,2B, and2C, a position where the swing angle α is 0° is set as the swing center of the tension bar support member46. The swing center of the tension bar support member46is not limited to the horizontal position of the tension bar support member46. The swing angle +α inFIG.2Bis “+” because the swinging of the tension bar support member46in the +Z direction is considered as a positive direction. The swing angle −α inFIG.2Cis “−” because the swinging of the tension bar support member46in the −Z direction is considered as the negative direction. InFIGS.2A,2B, and2C, a winding angle θ is shown. The winding angle θ is an angle between the tension bar support member46and the medium movement line ML. The winding angle Go shown inFIG.2Aindicates an angle between the tension bar support member46and the medium movement line ML when the tension bar support member46is positioned in the horizontal position. The winding angle θ+αshown inFIG.2Bindicates the angle between the tension bar support member46and the medium movement line ML when the tension bar support member46is positioned in the position of the swing angle +α. The winding angle θ−αshown inFIG.2Cindicates the angle between the tension bar support member46and the medium movement line ML when the tension bar support member46is positioned in the position of the swing angle −α. As is clear fromFIGS.2A,2B, and2C, when the tension bar support member46swings, the first tension bar43and the second tension bar44move respectively in circular orbits around the tension bar swing axis49. Since the winding member rotation axis42and the tension bar swinging axis49coincide with each other, the first tension bar43and the second tension bar44move in circular orbits concentric with the printing medium roll70. The distance between the second tension bar44and the outer periphery of the print medium roll70is constant or substantially constant. Since the second tension bar44moves in a circular orbit concentric with the printing medium roll70, there is little fluctuation of the winding angle θ due to the swing of the tension bar support member46. That is, it holds that θ≈θ+α≈θ−α≈θ0. In addition, since the medium M wraps around the first tension bar43and the second tension bar44, a change in the winding amount of the medium M on the first tension bar43and the second tension bar44due to the swing of the tension bar support member46is reduced. As described above, the printer10capable of recording on the medium M includes the print head26capable of recording on the medium M, the transport roller pair24capable of transporting the medium M, the medium winding member41that rotates about the winding member rotation axis42and that can wind the medium M transported by the transport roller pair24, the first tension bar43around which the printing surface of the medium M can wrap, the second tension bar44that is disposed between the first tension bar43and the medium winding member41and that the rear surface of the medium M can wrap around, and the tension bar support member46capable of swinging about the tension bar swing axis49, which coincides with the winding member rotation axis42. The tension bar support member46supports the first tension bar43and the second tension bar44. By providing the second tension bar44on the tension bar support member46that can swing coaxially with the winding member rotation axis42of the medium winding member41, fluctuations in the orientation of the medium between the first tension bar43and the printing medium roll70and fluctuations in the wrapping amount of the medium on the first tension bar43and on the second tension bar44are reduced, and fluctuations in the tension on the medium M due to winding of the medium M are suppressed. The transport device includes the transport roller pair24capable of transporting the medium M, the medium winding member41that rotates about the winding member rotation axis42and that can wind up the medium M transported by the transport roller pair24, the first tension bar43around which the printing surface of the medium M can wrap, the second tension bar44that is disposed between the first tension bar43and the medium winding member41and that the rear surface of the medium M can wrap around, and the tension bar support member46that supports the first tension bar43and the second tension bar44and that is capable of swinging about the tension bar swing axis49, which coincides with the winding member rotation axis42. The tension bar support member46supports the first tension bar43and the second tension bar44. By providing the second tension bar44on the tension bar support member46that can swing coaxially with the winding member rotation axis42of the medium winding member41, fluctuations in the orientation of the medium between the first tension bar43and the printing medium roll70and fluctuations in the wrapping amount are reduced, and fluctuations in the tension on the medium M due to winding of the medium M are suppressed. FIGS.3and4show an example of partial configuration of the tension bar support member46. The tension bar support member46inFIG.3shows one of the two tension bar support members46, which are disposed in the +Y direction and in the −Y direction of the medium winding unit40. The wo tension bar support members46may have the same configuration. One of the two tension bar support members46may not be provided with frame fixing members144, a first rotation adjustment member154, or a second rotation adjustment member158, to be described later. FIG.3shows a partial configuration of the tension bar support member46in a state where a first support frame142and a second support frame143are in contact with each other. The tension bar support member46shown inFIG.3includes a guide member141, the first support frame142, the second support frame143, and the frame fixing members144. The guide member141movably supports the first support frame142. The guide member141guides movement of the first support frame142in a direction toward the second support frame143or guides movement of the first support frame142in a direction away from the second support frame143.FIG.3shows a state in which the first support frame142and the second support frame143are in contact with each other. The first support frame142supports the first tension bar43. The first support frame142is movable along the guide member141while supporting the first tension bar43. The first tension bar43has a first tension bar shaft151. The first support frame142supports the first tension bar shaft151via a first bearing152. The first bearing152rotatably supports the first tension bar43. The first support frame142has a first frame hole153. The second support frame143supports the second tension bar44. The second tension bar44has a second tension bar shaft155. The second support frame143supports the second tension bar shaft155via a second bearing156. The second bearing156rotatably supports the second tension bar44. The second support frame143has a second frame hole157. The frame fixing members144fix the position of the first support frame142. The user of the printer10moves the first support frame142along the guide member141to move the first support frame142to a desired position. After moving the first support frame142to a desired position, the user fixes the first support frame142at the desired position using the frame fixing members144. An example of the frame fixing members144is screws. The user fixes the first support frame142to the guide member141by tightening the screws. The user can make the first support frame142movable by loosening the screws.FIG.3shows a state in which the first support frame142is fixed by the frame fixing members144in a state in which the first support frame142is in contact with the second support frame143. In the state ofFIG.3, the distance between the first tension bar43and the second tension bar44is minimized. FIG.4shows a partial configuration of the tension bar support member46in a state where the first support frame142and the second support frame143are separated from each other. The tension bar support member46inFIG.4shows a state in which the first support frame142has slid in the separation direction L. By the first support frame142separating from the second support frame143, the distance between the first tension bar43and the second tension bar44increases. By increasing the distance between the first tension bar43and the second tension bar44, the user can easily perform an operation of inserting the medium M between the first tension bar43and the second tension bar44at the time of medium installation, for example. The user can adjust the distance between the first tension bar43and the second tension bar44by changing the position of the first support frame142. The guide member141and the first support frame142correspond to an example of an interval adjustment mechanism. As shown inFIGS.3and4, the tension bar support member46includes the interval adjustment mechanism for changing the interval between the first tension bar43and the second tension bar44. Work is facilitated when the user performs an operation of winding the medium M around the first tension bar43and the second tension bar44. FIG.5shows support configuration of the first tension bar43and the second tension bar44by the tension bar support member46.FIG.5shows an example of a tension applying unit.FIG.5is a schematic view of the tension applying unit viewed from the +Z direction. Two tension bar supporting members46support the first tension bar43and the second tension bar44. The first tension bar43is rotatably supported by the first bearing152shown inFIG.3. The first tension bar43rotates when the medium M is transported. The second tension bar44is rotatably supported by the second bearing156shown inFIG.3. The second tension bar44rotates when the medium M is transported. Each of the two first support frames142shown inFIG.5includes two frame fixing members144, but are not limited to this. The frame fixing members144may be one, or may be three or more. FIG.6shows a cross-sectional configuration of the first tension bar43and the second tension bar44supported by the tension bar support member46. The tension bar support member46ofFIG.6includes the first rotation adjustment member154and the second rotation adjustment member158. Although the tension bar support member46inFIG.6shows a state in which the first support frame142and the second support frame143are separated from each other, it is not limited to this configuration. The first rotation adjustment member154disables rotation of the first tension bar43. The first rotation adjustment member154is inserted through the first frame hole153shown inFIG.3provided in the first support frame142and through a through hole (not shown) provided in the guide member141, into a first screw hole (not shown) provided in the first tension bar43. The first rotation adjustment member154makes the first tension bar43non-rotatable when inserted into the first screw hole. The first rotation adjustment member154makes the first tension bar43non-rotatable, when the medium M is transported. When the user removes the first rotation adjustment member154from the first screw hole, the first tension bar43becomes rotatable. An example of the first rotation adjustment member154is a screw. The first rotation adjustment member154and the first screw hole correspond to an example of a first adjustment mechanism. In other words, when a first state is a state in which the first tension bar43rotates while the medium M is being transported and a second state is a state in which the rotation of the first tension bar43is more restricted than the first state, the printer10comprises the first rotation adjustment member154and the first screw hole as the first adjustment mechanism for switching the state of the first tension bar43between the first state and the second state. Note that, the first adjustment mechanism may be configuration including at least one of a brake member or a torque limiter for restricting the rotation of the first tension bar43. The second rotation adjustment member158disables rotation of the second tension bar44. The second rotation adjustment member158is inserted through the second frame hole157shown inFIG.3provided in the second support frame143and a through hole (not shown) provided in the guide member141, into a second screw hole (not shown) provided in the second tension bar44. When the second rotation adjustment member158is inserted into the second screw hole, the second tension bar44is made non-rotatable. The second rotation adjustment member158makes the second tension bar44non-rotatable, when the medium M is transported. When the user removes the second rotation adjustment member158from the second screw hole, the second tension bar44becomes rotatable. An example of the second rotation adjustment member158is a screw. The second rotation adjustment member158and the second screw hole correspond to an example of a second adjustment mechanism. In other words, when a third state is a state in which the second tension bar44rotates while the medium M is being transported and a fourth state is a state in which the rotation of the second tension bar44is more restricted than the third state, the printer10comprises the second rotation adjustment member158and the second screw hole as the second adjustment mechanism for switching the state of the second tension bar44between the third state and the fourth state. Note that, the second adjustment mechanism may be configuration including at least one of the brake member or the torque limiter for restricting the rotation of the second tension bar44. The first rotation adjustment member154and the second rotation adjustment member158can be attached to and detached from the tension bar support member46. The user can reduce the tension applied to the medium M by making the first tension bar43and the second tension bar44rotatable. The user can increase the tension applied to the medium M by making the first tension bar43and the second tension bar44non-rotatable. The user can adjust the tension applied to the medium M by making one of the first tension bar43or the second tension bar44rotatable. As shown inFIGS.5and6, the first tension bar43is rotatable, and the second tension bar44is rotatable. The printer10includes a first adjustment mechanism that enables or disables rotation of the first tension bar43while the medium M is being transported, and a second adjustment mechanism that enables or disables rotation of the second tension bar44while the medium M is being transported. It is possible to individually adjust the slidability of the medium M with respect to the first tension bar43and the slidability of the medium M with respect to the second tension bar44, which facilitates adjustment of tension on or transportability of the medium M. The first adjustment mechanism and the second adjustment mechanism are not limited to the configuration shown inFIG.6. The first adjustment mechanism may be any configuration capable of adjusting the rotation of the first tension bar43. The second adjustment mechanism may be any configuration capable of adjusting the rotation of the second tension bar44. As an example, the first adjustment mechanism may be configured by a brake member that applies a braking force by pressing the first tension bar shaft151and a drive mechanism that moves the brake member into contact with and away from the first tension bar shaft151. The second adjustment mechanism may include a brake member that presses the second tension bar shaft155to apply a braking force, and a drive mechanism that moves the brake member into contact with and away from the second tension bar shaft155. FIGS.7and8show configuration in which the cover member161is provided on the second tension bar44.FIG.7is a view of the second tension bar44viewed from the axial direction.FIG.8is a view of the second tension bar44seen from a direction perpendicular to the axis. The second tension bar44ofFIG.8shows the medium M wrapped around it. The cover member161is wrapped around the second tension bar44. The cover member161is fixed to the surface of the second tension bar44by cover fixing members163. As the cover member161, a rubber member made of, for example, silicon resin is used. The rubber member has a higher coefficient of friction than the metal material used for the first tension bar43and the second tension bar44. The frictional resistance of the surface of the rubber member is higher than the frictional resistance of the surface of the first tension bar43and the frictional resistance of the surface of the second tension bar44. By using the cover member161, the user can reduce slidability against the medium M and reduce fluctuations in tension of the medium M. The material of the cover member161is not limited to a rubber member. The cover member161may be made of any material as long as it has a frictional resistance higher than the surface frictional resistance of the second tension bar44. The cover member161corresponds to an example of a friction member. The width of the cover member161in the axial direction is wider than the width of the medium M in the axial direction. Since the width of the cover member161is wider than the width of the medium M, it is possible to prevent the medium M from directly contacting the second tension bar44. As shown inFIG.8, the cover fixing members163fix the cover member161at positions outside of the transport region of the medium M. Since the cover fixing members163are positioned to the outside of the transport region of the medium M, it is possible to prevent interference with the medium M. InFIGS.7and8, the cover member161is fixed to the second tension bar44, but it is not limited to this. The cover member161may be provided on the first tension bar43. The cover member161may be provided on the first tension bar43and the second tension bar44. The cover member161, which has a surface with a coefficient of friction higher than that of the surface of the first tension bar43and of the surface of the second tension bar44, is attachable and detachable to at least one of the first tension bar43or the second tension bar44. The cover member161can be attached and detached by removing the cover fixing members163. The user can set transport conditions desirable for transporting the medium M by attaching and detaching the cover member161according to the type of the medium M used in the printer10. In the printer10, the cover member161, which has a surface with a coefficient of friction higher than that of the surface of the first tension bar43and of the surface of the second tension bar44, is attachable and detachable with respect to at least one of the first tension bar43or the second tension bar44. By attaching and detaching the cover member161, the user can adjust the slidability of the medium M and can increase the degree of freedom of adjustment of the frictional force between at least one of the first tension bar43or the second tension bar44and the medium M. | 36,251 |
11858262 | DETAILED DESCRIPTION Embodiments of the invention provide a new technique for dispensing discrete quantities of fluids of various flow properties, such as viscosities. For greater understanding, a new fluid ejector, its variations and operation thereof, and associated methods are now described with reference toFIGS.1a,1b,1c,2,3a,3b,4,5a,5b,5c,6,7a,7b,8,9,10, and11. FIG.1ashows schematically a cross-section of an apparatus100(also referred to as a device, a fluid ejector, and an ejector) for ejecting therefrom a pattern of discrete volumes of ejectant. The apparatus100includes a body110, an ejectant supply assembly130, a gas supply head150, and translation means (not shown) for translating the body110relative to the ejectant supply assembly130and/or gas supply head150, for example, for translating the body110in the general direction of arrow140shown inFIG.1a. The body110has a first surface111and a second surface112, opposite the first surface111, which are separated by a thickness113—shown as ‘t’. The body110is perforated to form a pattern120of nozzles114,115, and116within the body110. In particular, each nozzle is defined by a conduit extending through the thickness113of the body110and connecting corresponding orifices defined at the first surface111and the second surface112of the body110. For example, the nozzle115is defined by a conduit117connecting a first orifice118defined at the first surface111and a second orifice119defined at the second surface112. Other nozzles defined within the body110, such as nozzles115and116shown inFIG.1a, are similarly structured. The ejectant supply assembly130includes a holder131and a resilient seal member132(e.g., a wiper blade seal) that extends from the holder131. As can be seen inFIGS.1ato1c, the holder131is configured to be placed proximate to second surface112of the body110so as to provide for a pressure-bearing contact between the resilient seal member132and the second surface112. In use, an ejectant133ais deposited between the resilient seal member132and the second surface112such that as the holder131along with the resilient seal member132travels relative to the body110, the ejectant133atravels along the second surface112, for example, in the direction opposite of the direction indicated by the arrow140. Thus, in use the ejectant133ais in contact with the resilient seal member132and a portion of the second surface112that has not yet passed the resilient seal member132in the direction140. In some example embodiments, a single-use volume of the ejectant133ais deposited between the resilient seal member132and the second surface112so as to enable refill of the nozzles114,115, and116of the nozzle pattern120via their second (supply) orifices during a single pass of the body110relative to the ejectant supply assembly130. In some example embodiments however a multiple-use (e.g., on-demand) ejectant supply is provided, for example, as discussed in greater detail with reference toFIGS.5aand5bandFIGS.10aand10b. The relative translation (movement) of the body110to the ejectant supply assembly130in the direction140causes resilient seal member132to move the ejectant133aover the second surface112of body110. This movement, together with the drag force between the ejectant133aand the body110(for example, the viscous drag force if the ejectant is a fluid), causes a pressure gradient to be generated in the ejectant volume such that the pressure in that portion of the ejectant133aadjacent to the resilient seal member132rises above ambient pressure. Consequently, as that portion of the ejectant133apasses over the second orifices of the nozzles114,115, and116, it is pushed into the nozzles114,115, and116, such as shown inFIG.1bat133b. The relative translation of the body110also leaves the portion of the second surface112, which has passed the resilient seal member132, substantially free from the ejectant. In this manner, the ejectant supply assembly130partially or wholly fills the nozzles114,115, and116with a discrete quantity of the ejectant133a. The degree to which the nozzles114,115, and116are filled generally depends on the material of the resilient seal member132, the angle between the resilient seal member132and the second surface112, the relative speed of the second surface112to the resilient seal member132, the geometry of the nozzles114,115, and116, and the properties of the ejectant133a, such as, in the case of liquid ejectants, viscosity and surface tension. For example, the nozzles114,115, and116can be completely filled with the ejectant133aunder the following conditions: the resilient seal member132is made of Polyvinyl Chloride (PVC) and has thickness of 0.5 mm and a length of 20 mm. The resilient seal member is placed at an angle of 20 degrees or less in relation to the second surface112, the relative speed of the second surface112to the resilient seal member132is 3 cm/s, the ejectant133ahas viscosity of 107mPas at shear rate 0.001 s−1and viscosity of 103mPas at shear rate of 10 s−1, the diameter of the nozzles114,115, and116at the second surface112is 0.5 mm, and the thickness113of the body110is 1.4 mm. To fill the nozzles114,115, and116only partially, the angle between the resilient seal member132and the second surface112needs to be increased. The apparatus100further includes a gas supply head150that in use is positioned adjacent to the first surface111of the body110. The gas supply head150is formed of solid walls151, which define a gas outlet153and a gas inlet152. Generally, the gas supply head150receives gas through the gas inlet152and outputs the gas through the gas outlet153. The gas outlet153is defined at an end portion157of the gas supply head150that is adjacent to the body110whilst the gas inlet152can substantially be defined at any portion of the gas supply head150, other than the gas outlet itself. InFIG.1a, the gas inlet152is shown to be formed at an end portion of the gas supply head150that is opposite the end portion157. The gas outlet153may take different shapes. However, its dimensions in a plane substantially corresponding (e.g., parallel) to the plane of the first surface111, such as its width155identified as ‘a’ and length, and/or a diameter, should preferably be greater than those of the largest first orifice within the pattern120of the nozzles114,115, and116, so as to encompass the largest orifice when the gas outlet and the orifice are aligned. Further translation of the body110relative to the ejectant supply assembly130in the direction140also provides translation of the body110relative to the gas supply head150. Such translation results in one or more of the nozzles114,115, and116passing under the gas outlet153, and thus being exposed to the pressure of gas at the gas outlet153, as shown inFIG.1c. The time set for this further translation is selected to be sufficiently short so as to retain the ejectant133bwithin the nozzles114,115, and116. The flow properties, such as, in the case of liquid ejectants, the viscosity and/or surface tension of the ejectant133b, allow the nozzles114,115, and116to retain the ejectant133btherein. In use, an external supply of gas (not shown) supplies gas into the gas inlet152at a pressure sufficiently above ambient pressure. When one or more of the nozzles114,115, and116become exposed to the pressure of gas at the gas outlet153, that pressure causes ejection of the ejectant133bfrom the nozzles114,115, and116. In particular, the ejection is caused by the pressure difference created between respective orifices of each nozzle due to the pressurised gas supplied from the gas outlet153. The time duration of exposure to the gas pressure required to cause ejection of the ejectant from a nozzle may differ depending on, for the example, the pressure of the supplied gas (pressurised gas), dimensions of the nozzle, and/or the flow characteristics and volume of the ejectant. As stated above, the pressure within the gas supply head150may be achieved by the supply of gas at a pressure above ambient pressure to the gas supply head150. That pressure may be continuous (not varying with time) or pulsatile (time-varying). In the apparatus100with a pulsatile pressurisation of gas, the pressure pulses are timed to coincide with the times at which the nozzles are exposed to the gas at the gas outlet153. The gas is supplied at a pressure above ambient during each pulse and at a pressure above the gas pressure between successive pulses. Such gas pressure pulses may for example be provided using a supply of continuously pressurised gas in combination with an electrically controllable gas valve (not shown) positioned between the gas inlet152and an external gas supply (not shown), preferably adjacent to the gas inlet152. Such a gas valve should be capable of rapid opening and closing (for example, opening within 100 milliseconds and closing within a further 100 milliseconds). Spool valves operated by solenoid actuators are suitable for this purpose. The apparatus100with continuous and/or pulsatile supply of gas under pressure can deposit thereby a pattern of discrete volumes of ejectant upon a substrate. For uniform ejection of the ejectant from all nozzles, it is preferable to keep the gas pressure (whether continuous or pulsatile) substantially uniform at the gas outlet153(where the nozzles114,115, and116are exposed to that pressure). For many applications, the gas outlet153has a rather small width ‘a’ (for example 2 mm), whilst its length may extend substantially (for example 100 mm), in the perpendicular direction (i.e., normal to the cross-section shown inFIGS.1a,1band1c). Adequately uniform pressure can be obtained in this configuration whilst operating using continuous pressure, by using multiple gas inlets (not shown) distributed along a path corresponding to the length of the gas outlet153and connected to a common pressurised gas supply. If pulsatile pressure is used instead, then additionally, it is preferable to maintain the frequency of pressure pulses at frequencies lower than that frequency at which half the wavelength of sound in the gas within gas supply head150equals the smallest cross-sectional (width) dimension of gas supply head150. In some embodiments, to minimise gas consumption by the apparatus100, the gas outlet153and the first surface111of the body110are maintained in close proximity. In particular, a gap ‘g1’, shown at156, between the gas outlet153and the first surface111is characterised by a small value, whenever gas is supplied under pressure to the gas supply head150. Preferably, the small value is selected such that the flow of gas through the gap ‘g1’ is smaller than the flow of gas through the nozzles when the nozzles are empty. Further preferably, the small value is selected such that the flow of gas through the gap ‘g1’ is smaller than the flow of gas through the nozzles when ejecting ejectant. By surrounding the gas outlet153with a sliding seal (not shown) between the gas supply head150and first surface111, the gap ‘g1’ may be set to zero. In a general case, however, the gap ‘g1’ is non-zero, and thus the pressure versus flow rate characteristic of the gas supply is selected to ensure that the gas pressure at the gas outlet153remains sufficiently above ambient pressure to eject the ejectant133bfrom the nozzles114,115, and116. The gas may be any compound that is in gaseous phase at the operating temperature of the apparatus and which does not have deleterious reaction with the ejectant133bor materials of the gas supply head150. In many practical applications, the gas can include for example compressed air, nitrogen, or pressurised steam. Further, for some applications, it is preferable to keep the gas pressure inside the gas supply head150constant and uniform throughout the inner volume of the gas supply head150. This can for example be achieved by making the physical dimensions of the interior of the gas supply head smaller than a half of the wavelength of sound where the wavelength is calculated at frequency of the pulsing operation of the gas supply. Referring toFIG.1c, in an example scenario, the ejectant133bis a liquid of high viscosity (e.g., in the range 100 mPas to 108mPas). The gas pressure inside the gas supply head lies in the range 7×103N/m2to 1×108N/m2. The first and second orifices118and119of the nozzles at the first and second surfaces111and112respectively are both chosen to have diameter 500 micrometres. The ejectant is exposed to the ejecting gas pressure for a time period in the range of 1 ms to 100 ms. The thickness ‘t’ of the body110is 1.5 mm. Under these conditions, the ejectant133bwould typically be ejected from the nozzles114,115, and116, through the orifices at the second surface112. In the apparatus shown inFIG.1c, the nozzles114,115, and116direct ejections of the ejectant in a substantially common direction184as shown at181,182, and183. However, certain applications may require the nozzles114,115, and116to have different directionalities (e.g., different inclines within the body110with reference to the first and second surfaces) such that the ejections from the nozzles114,115, and116will not follow the common direction. Although as describedFIGS.1ato1cshow an ejector which has the gas supply head and the body movable relative to each other, in some embodiments, the position of the gas supply head is fixed (stationary) in relation to the body. This arrangement is particularly suitable for ejecting ejectants onto a conveyer system with a substrate, web, or the like continuously or intermittently moving in relation to the nozzles defined within a body of the ejector, thereby enabling the ejector to deposit the ejectant onto new sections of the substrate, web, or the like. FIG.2shows schematically a body210suitable for use in the apparatus100discussed in respect ofFIGS.1ato1c, in accordance with some embodiments. Similar to the body110, the body210is perforated to form a pattern of nozzles, within the body210, such as nozzles214,215, and216. In particular, each nozzle is defined by a conduit extending through the thickness of the body210to connect corresponding orifices defined at a first surface211and a second surface212of the body210. However, unlike the body110, the body210also defines a number of side conduits formed therein for supplying ejectant into the nozzles214,215, and216. For example, as shown inFIG.2, a side conduit285is defined within the body210and connects to an auxiliary orifice288formed in a sidewall of the conduit of the nozzle214. The nozzles215and216have similar auxiliary orifices to which side conduits286and287respectively connect. Each of the side conduits285,286, and287then can be used to fill each of the nozzles214,215, and216respectively via their respective auxiliary (supply) orifices. The ejectant133bcan for example be supplied to the side conduits285,286, and287using a metering device such as a syringe pump (not shown). This arrangement is most practical when using liquid ejectants. An example of a device suitable for refilling the nozzles214,215, and216via their respective side conduits is discussed in greater detail with reference toFIG.9. This approach to filling the nozzles is particularly suited for applications that require highly accurate reproducibility of liquid ejectant volume. Further, using the body210instead of the body110in the apparatus100and the respective ejectant supply method to fill in the nozzles provides for a variation of the apparatus100that does not require the ejectant supply assembly130. The gas supply head150and ejection method described in relation toFIGS.1ato1chowever can still be used in the variation of the apparatus100ofFIGS.1ato1cusing the body210ofFIG.2. FIGS.3aand3bshow a gas supply head350suitable for use in the apparatus100discussed with reference toFIGS.1ato1c, in accordance with some embodiments. Generally, unlike the gas supply head150shown inFIGS.1ato1c, the size of the gas supply head350is dynamically adjustable, such as whilst the apparatus100is being used. More specifically, the gas supply head350is formed of a composite assembly of an elongated solid body363having a gas inlet352defined therein, compressible bodies351aand351b, and piston elements361aand361b. The compressible bodies351aand351bare adapted to cooperate with each other and the body363so as to form an internal cavity of the gas supply head350having the gas inlet352and defining a gas outlet353. The compressible bodies351aand351bare bonded to the piston elements361aand361brespectively, one side, forming corresponding bonds366aand366b, and to the solid body363on the other side, forming bonds367aand367brespectively. In the gas supply head350ofFIG.3, the bonds367aand367bare adjacent to the gas inlet352. There is no other bond between the compressible bodies351aand351band the solid body363in the gas supply head ofFIGS.3aand3b. The piston elements361aand361bare displaceable by actuation means (not shown) towards each other and away from each other, shown inFIGS.3aand3bas directions365aand365bfor the piston elements361aand361brespectively, thereby compressing and expanding the compressible bodies351aand352b. The compressible bodies351aand352bare formed of material(s) having a desired level of compressibility, which include but are not limited to, closed-cell elastic foam and/or flexible structures in the form of bellows. To enable controlled displacement of the piston elements361aand361b, the solid body363may be provided with guides (not shown) to link the piston elements361aand361bto the body363and guide their displacement along the body363. As shown inFIG.3b, actuation of the actuation means to displace the piston elements361aand361btowards each other causes compression of the compressible bodies351aand352b, thereby reducing the width ‘a’ (shown at355), and consequently the inner volume of the gas outlet353. The width ‘a’ of the gas outlet353can be adjusted dynamically in response to the speed of the relative translation between the gas outlet353and the body110of the apparatus100, as discussed with reference toFIGS.1ato1c. In this manner, it is possible to achieve, within a range of such relative speeds (e.g., from 0.1 m/s to 10 m/s), substantially constant time duration of exposure of ejectant within a nozzle to the pressure of the supply gas, independent from the relative speed of the gas outlet353to the body110while supplying gas to the gas supply head350at constant pressure. Thus, consistent ejection behaviour of the ejectant can be provided (e.g. consistent ejection speed and/or, in case of liquid ejectant, consistent ejection as a single droplet of ejectant, rather than as a spray of droplets) substantially independently of the speed of the relative motion and without the need to use sources of gas capable of providing variable pressure or pressure pulses. This approach can be particularly beneficial in scenarios where ejectant patterns are deposited onto substrate(s) moving with a variable speed, e.g., during the speed-up and slow-down of a web on a production line. Width ‘a’ of the gas outlet353can be controlled using a control circuit that uses the speed of the web on a production line derived from an encoder or similar measuring device to control a motor that moves the piston elements361aand361b. In this way, the width ‘a’ of the gas outlet353can be continuously controlled in response to the web speed on a production line. InFIGS.3aand3b, the compressible gas supply head350is shown to comprise two compressible bodies351aand351b. However, the compressible gas supply head may comprise a single compressible body or instead comprise more than two compressible bodies, e.g., 3 or 4 compressible bodies. Furthermore, fewer or more than two pistons361aand361bmay be employed to compress the gas supply head350. FIG.4ashows schematically a cross-section of another apparatus400for ejecting a pattern of discrete volumes of ejectant, according to some embodiments. Generally, the apparatus400is a variation of the apparatus100described with reference toFIGS.1ato1cthat includes many of the functional components described in respect ofFIGS.1ato1c. More specifically, similar to the apparatus100, the apparatus400has a body, an ejectant supply assembly, and a gas supply head identified respectively as410,430, and450, and translation means (not shown) for translating the ejectant supply assembly430and the body410relative to each other. Similar to the body110of the apparatus100, the body410has a first surface411and a second surface412, opposite the first surface411, which are separated by a thickness413—shown as ‘t’. The body410is perforated to form a pattern420of nozzles414,415, and416within the body410. Each nozzle is defined by a conduit extending through the thickness413to connect corresponding orifices defined at the first surface411and the second surface412of the body410. For example, the nozzle415is defined by a conduit417connecting a first orifice418defined at the first surface411and a second orifice419defined at the second surface412. The other nozzles defined within the body410, such as nozzles414and416shown inFIG.4, are similarly structured. Similar to the ejectant supply assembly130of the apparatus100, the ejectant supply assembly430comprises an ejectant supply body431configured to hold ejectant433a, such as an ejectant liquid, and a resilient seal member432that extends from the ejectant supply body431. As can be seen inFIG.4a, the ejectant supply assembly430is configured to be placed adjacent to the body410so as to provide for a pressure-bearing contact between the resilient seal member432and the second surface412of the body410. However, unlike the apparatus100, in the apparatus400, a further component of an aperture member is provided for use in combination with the gas supply head450, together forming a gas supply head system460. InFIG.4a, this further component is shown in the form of a translatable aperture plate471having opposite surfaces477and478and an aperture472defined therethrough. The plate471is positioned between the gas supply head450and the body410. In the apparatus400, the body410and solid walls451, which form the gas supply head450, are held in relation to each other such that when the aperture472of the aperture plate471is positioned at (below) the gas outlet453of the gas supply head450, one or more of the nozzles414,415, and416are exposed to the gas pressure from gas outlet453defined by the gas supply head450. Such an alignment between the gas outlet453and the aperture plate471is referred herein as an open position. The dimensions of the gas outlet453and of the aperture472(such as the width dimensions of the gas outlet453, shown as ‘a’ at455, and of the aperture472, shown as ‘b’ at473, and the respective length dimensions, not shown), in a plane substantially corresponding (e.g., parallel) to the plane of the first surface411of the body410are preferably greater than those of the largest orifice of the nozzles414,415, and416defined at the first surface411of the body410. However, when the aperture plate471is displaced in relation to the gas supply head such that the aperture472is moved away from the gas outlet453in either direction, the aperture plate471prevents pressure of gas admitted into the gas supply head450from being communicated into the nozzle pattern420via the gas outlet453. This shift of the aperture472in relation to the gas outlet453is referred herein as a closed position and its example may be seen inFIG.4a. Whilst the aperture plate471is in this closed position, the ejectant supply assembly430can be translated (by any of a number of known translation means, not shown) relative to the body410towards and past the nozzles414,415, and416. InFIG.4a, such translation is indicated by arrow435. At the same time, the ejectant433atravels from the ejectant supply body431towards the body410by the way of the resilient seal member432. Thus, translation of the ejectant supply assembly430relative to the body410, past the nozzles414,415, and416, whilst under pressure exerted by the resilient seal member432, results in quantities of the ejectant433abeing supplied from the ejectant supply body431into the nozzles414,415, and416. This translation also leaves the portion of the second surface412passed by the resilient seal member432substantially free from the ejectant. Once the nozzles414,415, and416have been filled, the aperture plate471is translated (moved) through the open position so as to temporarily align the aperture472with the gas outlet453to allow the pressure of gas admitted into the gas supply head450to be briefly communicated via the gas outlet453and through the aperture472to the nozzle pattern420. InFIG.4a, such translation is indicated by arrow474. In some embodiments, to minimise gas consumption by the apparatus400, whenever gas is supplied under pressure to the gas supply head450, close proximity is maintained between a portion457of the walls451that defines the gas outlet453and the surface477of the aperture plate471. Close proximity may also be maintained between the surface478of the aperture plate471and the first surface411of the body110whenever the aperture plate471is in the open position. In this open position, the aperture472allows the pressure of the gas exiting the gas supply head450through the gas outlet453to reach one or more of the nozzles414,415, and416through the aperture472of the aperture plate471. The close proximity of the gas supply head450, the aperture plate471, and the body410is characterised by small values of a gap ‘g2’ shown at475between the body410and the aperture plate471and a gap ‘g3’ shown at476between the aperture plate471and the gas outlet453. The gaps ‘g2’ and ‘g3’ can be set to zero by providing a sliding seal (not shown) between the aperture plate471and each of the gas supply head450and the body410. In some embodiments, the sliding seal is realised by incorporating a layer of solid lubricant or low-friction material, such as high density polyethylene, into or onto the surfaces477and478of the aperture plate471. In use, an external supply of gas (not shown) supplies gas into the gas inlet452at a pressure sufficiently above ambient pressure to cause the ejectant to eject from the nozzles414,415and416within that time during which the aperture472passes the gas outlet453to expose those nozzles to the gas pressure at the gas outlet453. The gas may be supplied to the gas supply head450with continuous or pulsatile pressure by means and methods similar to those described with reference toFIGS.1ato1c. In a general scenario with either or both gaps ‘g2’ and ‘g3’, shown at475and476respectively, being non-zero, the pressure versus flow rate characteristic of the gas supply is selected to ensure that the gas pressure at the gas outlet453remains sufficiently above ambient pressure to eject the ejectant from the nozzles414,415, and416. By providing the aperture plate471and positioning the aperture plate471in the closed position whilst filling the nozzles414,415, and416, the repeatability of volume of ejectant433afilled into those nozzles can be improved and the over-filling of the nozzles can be more easily prevented. In addition, whether gas is supplied to the apparatus400with continuous or pulsatile pressure, such an apparatus is particularly useful in ejecting patterns of ejectant onto a stationary substrate. In some embodiments, a composite aperture plate configured to provide an aperture of a variable width ‘d’ is used instead of the aperture plate471in the apparatus400. An example of a composite aperture plate480is shown schematically inFIG.4b. The composite aperture plate480includes plates481and491that cooperate to form an aperture482of a variable width ‘d’. The plate491incorporates slidably cooperating plate members493aand493bsuch that sliding of the plate member493brelative to the plate member493avaries the width ‘d’ of the aperture482. As shown inFIG.4b, the plate member493ahas a recess for slidably receiving the plate member493bsuch that a top surface494bof the plate member493band a recess surface494aof the plate member493aare held (by a number of known means, not shown) in sliding contact with little or no gas leakage therebetween. In the composite aperture plate480shown inFIG.4b, a bottom surface495bof the plate member493band a top surface495aof the plate member493aare arranged to be substantially coplanar. In use, translation of the plate member493brelative to the plate member493ain the direction of an arrow484, whilst maintaining a sliding, low-leakage contact, is achieved by a number of means (not shown) and provides the aperture482of the variable width ‘d’. This dynamic variation in the width ‘d’ enables control of the time duration of exposure of the ejectant within a nozzle to the pressure of the supply gas according to the needs of a particular ejectant (e.g., a liquid of high or low viscosity), whilst using gas supply means that supply gas at constant pressure. FIGS.5aand5bshow cross-sectional views of an apparatus500with a cylindrical body510(also referred to as a roller or a drum) for ejecting discrete quantities of ejectant, according to some embodiments. The roller510has a number of nozzles514,515, and516penetrating through the thickness of the roller from a first, inner surface511of the roller510to a second, outer surface512of the roller510. The nozzles514,515, and516form a nozzle pattern5201. As shown, the roller510may include a number of similar nozzle patterns5201,5202,5203, and5204penetrating through the thickness of the roller510from the first surface511to the second surface512. Each of the nozzles514,515, and516within these patterns is defined by a conduit517having a first orifice518at the first surface511and a second orifice519at the second surface512, as shown by way of example for one of the nozzles in the pattern5203. In use, the roller510is rotated about its axis by auxiliary means (not shown), for example, in the anticlockwise direction shown by a directional arrow540. As the roller510rotates, so does each of the nozzle patterns5201-5204, and thus each of these nozzle patterns successively passes an ejectant supply assembly530, which thereby supplies ejectant533into nozzles within these patterns. In the embodiments ofFIGS.5aand5b, the ejectant supply assembly530includes a housing531, which is adjacent to and extends along but not beyond the axial length of the roller510. The housing531holds ejectant533for supplying such ejectant into the nozzle patterns of the roller510. A resilient seal member532(e.g., a wiper blade seal) extends from at least one side of the housing531, along the length of the housing, and forms a pressure-bearing sliding contact seal against the second surface512of the roller510. Peripheral (or end) seals (not shown) are provided between the ends of the housing531and the roller510. The ejectant supply assembly530further includes an ejectant feed pipe534for transporting the ejectant533from a remote ejectant supply into the housing531, as shown by arrow535. The housing531, the resilient seal member532, the end-seals (not shown), and the second surface512of the roller510create an ejectant supply assembly530. This ejectant supply assembly530can be filled and maintained filled with the ejectant533which is supplied to the ejectant supply assembly530via the feed pipe534from the remote ejectant supply, as indicated by arrow535. In use, the ejectant supply assembly530is maintained filled with the ejectant533, whilst rotation of the roller510causes each of the nozzle patterns5201,5202,5203, and5204to successively pass the ejectant supply assembly530. As the nozzles of the nozzle patterns (the nozzle pattern5203, inFIGS.5aand5b) pass the ejectant supply assembly530, the ejectant supply assembly530fills such nozzles with the ejectant533partially or fully, depending on desired settings and requirements. The resilient seal member532both contributes to such filling in a manner similar to that described above with reference toFIGS.1ato1c, and also removes the ejectant from the second surface512of the roller510as the roller510passes the pressure-bearing contact seal between the resilient seal member532and the roller510. In consequence, the nozzles within each nozzle pattern (for example, the pattern5203) are successively partially- or fully-filled with a discrete quantity533bof the ejectant533. FIGS.5aand5bshow that the continued rotation of the roller510in the direction540brings each nozzle pattern5201,5202,5203, and5204successively underneath the gas supply head550formed with solid walls551.FIG.5bshows the nozzle pattern5203in such a position. The first orifice518of each of the nozzles514,515, and516within the nozzle pattern5203is thereby exposed to the pressure of gas at the gas outlet553of the gas supply head550. A substantially gas-tight seal is formed between a surface558of the walls551proximate to the first surface511and the first surface511of the roller510. This seal may for example be achieved by minimising the gap between those surfaces or, alternatively, by providing a sliding seal (not shown) between those surfaces. In use, the gas supply head550admits gas supplied to the gas supply head550via a conduit559(e.g., a drilling) formed within the walls551. The conduit559may be formed of a number of connected conduits, such as conduits559aand559bshown inFIG.5b. There, the conduit559adirects gas from one end of the roller510towards the inner cavity of the gas supply head, whilst the conduit559bredirects the gas downwards to a gas inlet552of the gas supply head550. In this manner, the gas is directed to the gas outlet553. The pressurised gas supply (not shown) is arranged to provide a pressure sufficiently above ambient pressure so as to eject the ejectant533bfrom the nozzles514,515, and516of the nozzle pattern5203, for at least that time duration needed for ejection to occur. As discussed above, the ejection is caused by the pressure difference created between respective orifices of each nozzle due to the pressurised gas supplied from the gas outlet553. Exposure of one or more of the nozzles in nozzle pattern5203to that pressure for that time (i.e., the combination of time and pressure) thereby ejects the ejectant533bfrom those nozzles. In this manner, a pattern of ejectant according to the pattern of nozzles may be deposited onto a nearby substrate. Example Implementations FIG.5cshows schematically a body510csuitable for use in an apparatus500for ejecting discrete quantities of ejectant, such as the apparatus500discussed with reference toFIGS.5aand5b, according to some embodiments. As shown in the figure, the body510cis a roller or drum that has a number of nozzles, such as nozzles514c,515c, and516cpenetrating through the thickness of the roller from a first, inner surface511cof the roller510cto a second, outer surface512cof the roller510c. The nozzles514c,515c, and516cform a nozzle pattern520c. The nozzle pattern520cshown inFIG.5cis a 4-by-4 array of nozzles. However, nozzle patterns, their symmetry or lack thereof, and how many nozzles form a particular pattern can vary, for example depending on the intended use of the apparatus500. For example, a drum designed to jet bonding adhesive onto a medical dressing may have a nozzle pattern that prints a line of closely spaced dots around the edge of the dressing and a relatively sparse density of dots within the dressing. FIG.6shows a body610suitable for use in a device for ejecting discrete quantities of ejectant, such as the apparatus100discussed with reference toFIGS.1ato1c, according to some embodiments. The body610has a number of nozzles614,615, and616defined therein. In particular, each nozzle is defined by a conduit extending through the body610between corresponding orifices defined at a first surface611of the body610and a second surface612of the body610. The nozzles614,615, and616form a nozzle pattern620. InFIG.6, the nozzle pattern620includes109nozzles. The body610may further include guides defined therein for guiding the motion of a gas supply head across the nozzle pattern620(discussed further with reference toFIG.7). Such guides may for example take a form of slots621aand621bshown inFIG.6. In some example implementations, the body610is made of brass and has thickness of 3 mm and overall dimensions of 76 mm by 150 mm. Further, the nozzle pattern620is disposed within an area 10 mm by 100 mm, the nozzles are about 0.4 mm in diameter, with a centre-to-centre spacing of about 2 mm. The nozzles614,615, and616can for example be formed using a drill to drill the body610in order to create the nozzles614,615, and616. FIGS.7aand7bshow a gas supply head750suitable for use in combination with the body610, according to some embodiments. More specifically,FIG.7ashows an isometric view of the gas supply head andFIG.7bshows a cross-sectional view of the gas supply head750. Similar to the gas supply head150discussed with reference toFIGS.1ato1c, the gas supply head750is formed of solid walls751, which define a gas outlet753and a gas inlet752. The gas outlet753is defined at an end portion757of the gas supply head750that is can be positioned adjacent to the body610whilst the gas inlet752is formed at an end portion of the gas supply head750opposite the end portion757. However, unlike the gas supply head150ofFIGS.1ato1c, which is stationary, the gas supply head150is movable relative to the stationary body610(shown inFIGS.6and8). That is, in the example implementations discussed with reference toFIGS.6to8, the relative movement of the gas supply head and the body is caused by translational movements of the gas supply head, instead of the translational movement of the body as discussed with reference toFIGS.1ato1c. Further, fixing points758aand758b(e.g., drillings) are provided on two opposite sides of the gas supply head750to allow for various components, such as rails (not shown), to be attached to the gas supply head750. Such rails may, for example, be configured to fit into the slots621aand621bso as to guide the motion of the gas supply head750relative to the body610. In some example implementations, the gas supply head750has dimensions of 32 mm in length, 5 mm in width, and 10 mm in height. The gas outlet753has dimensions of 16 mm in length and 2 mm in width in the plane that substantially corresponds (shown inFIG.8as being parallel) to the plane of the first surface611of the body610, when in use. FIG.8depicts a device800for ejecting discrete quantities of ejectant that incorporates the gas supply head750ofFIGS.7aand7band the body610ofFIG.6. As shown inFIG.8, in the device800, whilst it is in use, the body610is positioned below the gas supply head750and in movable relation with the body610so as to move across the nozzle pattern620. To provide for supply of pressurised gas, the gas supply head750of the device800is connected to a gas supply system880. The gas supply system880includes a valve881, which connects the gas supply system880to the gas inlet752of the gas supply head750. In the gas supply system880, the valve881is connected to a pressure regulator883via a pipe882. The pressure regulator883is connected to a reservoir of compressed gas, such as air (not shown), which is maintained by a compressor (not shown) at pressure (e.g., greater than 800 kN/m2). The pressure in the pipe882is monitored using a pressure meter884. The pressure regulator883is set such that when the valve881is closed, the pressure in the pipe882is in the range 10 kN/m2to 1000 kN/m2above ambient pressure, for example 70 kN/m2above ambient pressure, as measured by the pressure meter884. Once the nozzles have been filled or part-filled, for example in the manner discussed with reference toFIGS.1ato1c, the valve881is opened and the gas supply head750is applied, manually or by means of automation hardware, to the first surface611of the body610and then is swept across the body610, traversing the nozzle pattern620. In a number of experiments with the device800, the gas supply head750was moved at a velocity of between 0.05 m/s and 5 m/s relative to the body610. As the area of the gas outlet753crossed the nozzles within nozzle pattern620in turn, the nozzles became exposed to the pressure of the gas supply, which has caused ejection of the ejectant from the nozzles. If the substrate onto which the ejectant is being ejected is stationary relative to the body610, then the ejectant forms a pattern on the substrate that replicates the nozzle pattern620. If however the substrate is moved relative to the body610during the ejection, then the pattern on the substrate is transformed from the nozzle pattern620by either stretching or compression in the direction of the relative motion. Motion control of the substrate relative to the body610can be achieved by a combination of motors, stages and electronic control circuits, such as those used to control the motion of the gas supply head750relative to the body610. A range of materials, including various paints and inks were ejected in this manner using these devices and other test devices built similar to the device800. These devices were made from acrylic and the nozzles were laser-machined. The number of nozzles varied and was in the range 10 to 50 nozzles. Their diameters were in the range of 0.3 mm to 0.5 mm and the thickness of the body was in the range of 0.5 mm to 3 mm. The gas supply heads were made from acrylonitrile butadiene styrene using 3D printing. The dimension of the gas outlet in a direction normal to the motion of the gas supply head relative to body varied in the range 10 mm to 50 mm and the dimension of the gas outlet in the direction parallel to the motion of the gas supply head relative to the body varied in the range of 1 mm to 5 mm. In a number of conducted experiments, such devices were used to eject water-based paint (Multi-Surface Paint supplied by Bedec Products Ltd). The paint had a viscosity of 107mPas at a shear rate of 0.001 s−1and a viscosity of 103mPas at a shear rate of 10 s−1. The nozzles were fully or partially filled by applying a drop of paint measuring 5 mm in diameter to the second surface of the body at one end of the body and wiping the paint across the second surface and the nozzle pattern using a resilient seal member, for example, in the manner described with reference toFIGS.1ato1c. The resilient seal members used were in the form of a polyvinylchloride sheet 5 mm in thickness, a stainless steel blade 0.4 mm in thickness, and a neoprene sheet 3 mm in thickness. The resilient seal member's width was sufficient to span the width of the nozzle pattern in the particular device (1 mm-5 mm) and its length was in the range 15-30 mm. The degree to which the nozzles were filled was influenced by the material properties of the ejectant used, the material properties of the resilient seal member, the angle between the resilient seal member and the body, and the relative speed of the resilient seal member to the body. In a number of further conducted experiments, devices built according to principles and techniques described herein were used to eject adhesives (including hot melt adhesives), inks, glazes, varnishes, and other coating materials. These devices were made of brass and the nozzles were drilled. The number of nozzles varied and was in the range of 100 to 1000 nozzles. The nozzle diameters were in the range of 0.3 mm to 0.5 mm and the thickness of the body was 2 mm. The gas supply heads were made from brass, using machining processes. The dimension of the gas outlet in a direction normal to the motion of the gas supply head relative to the body was 22 mm and the dimension of the gas outlet in the direction parallel to the motion of the gas supply head relative to the body was 2 mm. The nozzles were fully or partially filled by applying 0.2 ml-2 ml of ejectant on the second surface of the body at one end of the body and wiping the ejectant across the second surface and the nozzle pattern using a resilient seal member, for example, in the manner described with reference toFIGS.1ato1c. The resilient seal members used were in the form of a stainless steel blade 0.4 mm in thickness or a rubber sheet 3.5 mm in thickness. The resilient seal member's width was sufficient to span the width of the nozzle pattern in the particular device (10 mm-20 mm) and its length was in the range of 15-30 mm. The degree to which the nozzles were filled was influenced by the material properties of the ejectant used, the material properties of the resilient seal member, the angle between the resilient seal member and the body, and the relative speed of the resilient seal member to the body. When using hot melt adhesive, the body was heated to 150° C. prior to applying the adhesive. In addition, an air heater, placed between the source of compressed air and the gas supply head, was used to heat the air so that the passage of air through the body did not result in cooling of the body. FIG.9shows a cross-sectional view of a system900, in accordance with some embodiments, for supplying ejectant, preferably liquid ejectant, into nozzles of an ejector through the auxiliary orifices defined in the sidewall of their conduits, such as described with reference toFIG.2. The ejector includes a solid body910containing one or more nozzles920(only one nozzle is shown inFIG.9). The nozzle920has a first orifice921and a second orifice922connected by a conduit924. The solid body910further defines a side conduit930, one end of which terminates at a side orifice923of the conduit924of the nozzle920. The other end of the side conduit930is connected to a side pipe940through which ejectant952is supplied into the conduit924of the nozzle920, for example, using a syringe950. As described with reference toFIGS.1ato1c, ejection of the ejectant952from the nozzle920can be effected using a gas supply nozzle applied to the first orifice921so as to apply gas at pressure sufficient to cause ejection of the ejectant952through the second orifice922. In an example embodiment of the system900, the conduit924is about 13 mm long, the first and second orifices have a diameter between 0.3 mm and 1.3 mm, and the side conduit930is a cross-drilling of diameter about 0.5 mm and length about 8 mm. The syringe950is a standard medical syringe of 10 millilitre (10 ml) capacity with Luer fitting driven by a syringe pump, model MS16A, made by Graseby Smiths Medical (not shown) to meter 200 nanolitre (200 nl) of the ejectant952into the conduit924. In this example embodiment, gas pressures in the range 10 kN/m2to 100 kN/m2applied to orifice921were found to be adequate to eject a wide range of materials, including water-based dyes, paints, creams, and gels. FIGS.10aand10bshow another form of an ejectant supply assembly, according to some embodiments. More specifically, an ejectant supply assembly1030includes an ejectant supply body1031and two resilient seal members1032aand1032bthat extend from the ejectant supply body1031. As can be seen inFIGS.10aand10b, the ejectant supply assembly1030is configured to be placed adjacent to a body1010so as to provide for a pressure-bearing contact between the resilient seal members1032aand1032band a second surface1012of the body1010. The two resilient seal members1032aand1032band the ejectant supply body1031form a cavity (void, or the like) which holds ejectant shown at1033abetween the ejectant supply body1031and the second surface1012of the body1010. The ejectant1033ais supplied to ejectant supply assembly1030through an ejectant feed conduit1034in direction shown by arrow1035at a pressure above ambient pressure thereby to fill the cavity at a controlled pressure. Such pressure control may be provided, for example, by control of the hydrostatic head of the ejectant supply. The body1010defines a nozzle pattern1020comprising nozzles1014,1015, and1016each defined by a conduit connecting respective orifices at a first surface1011and the second surface1012. Translation of the body1010relative to the ejectant supply assembly1030in the direction1040causes quantities of the ejectant1033ato be supplied from the ejectant supply assembly1030into the nozzles1014,1015, and1016, such as shown inFIG.10bat1017,1018, and1019. The volume of the ejectant introduced into the nozzles1014,1015, and1016is determined by factors such as the flow properties of the ejectant, the dimensions of the nozzles, the pressure at which the ejectant is supplied, the spacing (in the direction of translation) of the resilient seal members1032aand1032bat the second surface1012, and the speed at which the body1010translates relative to the ejectant supply assembly1030. These factors are all known or may be controlled to ensure that the desired volume of ejectant1033aenters the nozzles1014,1015and1016. Further, translation of the body1010past the resilient seal member1032acan be arranged to leave the portion of the second surface1012which the resilient seal member1032ahas passed substantially free from the ejectant. FIG.11shows a flow-diagram of a method1100for methods for dispensing flowable materials (ejectant), for example onto a substrate, according to some embodiment. The method1100is suitable to be performed in an ejector having a plate-based geometry, such as the apparatus100discussed with reference toFIGS.1ato1c, or a drum-based geometry, such as the apparatus500discussed with reference toFIGS.5aand5b. At step1105, the nozzles of the ejector are moved to a start position. The start position is generally a position where the ejectant can neither be supplied to the nozzles nor ejected from the nozzles. At the start position, the nozzles are substantially empty. For example, with reference toFIGS.1ato1c,FIG.1adepicts the apparatus100at what can be considered a start position. As described above, the nozzles are defined in the body of the ejector. As such, movement of the nozzles generally involves motion of the body relative to a gas supply head and/or an ejectant supply assembly of the ejector. That is, the nozzles can be moved by moving the body110of the ejector containing the nozzles, the gas supply head150, and/or the ejectant supply assembly130. At step1110, the nozzles are further moved to a filling position so as to open the nozzles to the ejectant supply assembly and allow it to fill the nozzles, partially or fully. For example, with reference toFIGS.5aand5b,FIG.5ashows the nozzles5203in the filling position. At step1115, the nozzles are filled with the ejectant by the ejectant supply assembly. In particular, as the nozzles are continued to be moved relative to and across the ejectant supply assembly, it fills them with the ejectant, for example, in the manner described above with reference toFIGS.1ato1c,5ato5b, and10ato10b. For example,FIG.1bshows that once the nozzles114,115, and118have passed across the ejectant supply assembly130, they are filled or partially filled with the ejectant133b. At step1120, the excess ejectant is removed. This may for example be achieved using a resilient member of the ejectant supply assembly. As discussed, with reference toFIGS.1ato1c, the resilient seal member132may serve two purposes, i.e., guiding the supply of the ejectant from the ejectant supply assembly into the nozzles and also removing excess ejectant as it passes the nozzles. In this manner, the surface of the body at which the ejectant is supplied remains substantially clean.FIGS.5aand5b, and10aand10band the corresponding description provide further details of how the excess ejectant can be removed. At step1125, the nozzles are moved to an ejecting position. In this position, the gas outlet of the gas supply head is aligned with (covers) the nozzles so as to allow the gas from the gas supply head to be supplied/communicated into the nozzles. At step1130, the ejectant is ejected/dispensed from the nozzles. This may for example be achieved in the manner described with reference toFIGS.1ato1c,3aand3b,4a,5aand5b,8, and10aand10b. Generally, the supply of gas from the gas supply head into the nozzles causes (effectuates) ejection of the ejectant from the nozzles. More specifically, supply of gas to the nozzles at pressure above ambient creates pressure difference between respective orifices of each nozzle, and thus causes ejection of the ejectant from such nozzles. At step1135, the nozzles are returned to the start position, and the steps1110to1135can then be repeated to provide for further refills of and ejections from the nozzles so as, for example, to provide for continuous printing on a web or a substrate that is not moving. As described above, the method1100is applicable in the context of the plate-based and drum-based geometry of the ejector. To repeat the steps of the method1100in the context of the plate-based geometry, such as the ejector shown inFIGS.1ato1c, reciprocating motion is applied. To repeat the steps of the method1100in the context of the drum-based geometry, such as the ejector shown inFIGS.5aand5b, a continuous rotation is used. The method1100is adaptable to embodiments in which there is no relative movement between the nozzles and the ejectant supply assembly or in which there is no relative movement between the nozzles and the gas supply assembly. In these embodiments, step1110moving the nozzles to the ejectant supply assembly or step1125of moving the nozzles to the gas supply assembly are be omitted. For example, in the embodiment described with reference toFIG.2, it may be advantageous to have a fixed ejectant supply connected to the side conduit285, in which case, step1110of the method1100is omitted. Similarly, in the embodiment described with reference toFIG.9, the ejectant supply assembly may take the form of a syringe950permanently fixed to the side pipe940, which in turn is permanently fixed to the side conduit930. It may also be advantageous to fix a gas supply to the first orifice921. In this particular example, then steps1110and1125would be omitted and a pulsatile source of gas can be used at step1130to cause ejection from the nozzles. Thus, as discussed, relative motion of the gas supply head to the body enables ejection of the ejectant from the nozzles defined in the body, whilst the relative motion of the ejectant supply assembly to the body enables refill of the nozzles with the ejectant. Such relative motions can be effectuated for example by translational or rotational motion of the gas supply head, the nozzle-bearing body, and/or the ejectant supply assembly. The translational motion (relative movement) of the gas supply head, the nozzle-bearing body, and/or the ejectant supply assembly can, for example, be realized by one or more motors connected to a linear stage. An electronic control circuit can be used to start, stop, and control the translational motion of the gas supply head, the nozzle-bearing body, and/or the ejectant supply assembly to provide for the relative motion between the three. A motor connected to a linear stage controlled by an electronic circuit is however merely an example of means by which the relative motion of the gas supply head, the nozzle-bearing body, and/or the ejectant supply assembly can be enabled and controlled. Other means can be used instead. As described herein, the ejectant supply means, such as the ejectant supply assembly, can be configured to supply the ejectant to the nozzle(s) of the ejector at a pressure above ambient pressure. The ejectant flows into each of the nozzle(s) in response to the pressure difference between the supply pressure and the ambient pressure at the other, non-supply orifice(s) of the nozzle. Generally, the pressure at which the ejectant is supplied by the ejectant supply means is controlled to affect (control) the rate at which the nozzle(s) fill with ejectant. Such pressure control can be used to reduce ejectant pressure to ambient pressure and thereby halt further supply of ejectant into the nozzle(s) once the desired volume of ejectant has been supplied into the one or more nozzles. For a given pressure of ejectant supply means, the rate at which the nozzle(s) fill with ejectant in practice is also influenced by other parameters, most particularly by the viscosity of the ejectant and the dimensions of the nozzle and the non-supply orifice. Such parameters are generally themselves either fixed by the design of the body and the material of the ejectant. However, the temperature at which the ejectant is supplied in general influences the viscosity of the ejectant. Therefore, in some example embodiments, the ejectant supply means are configured to supply the ejectant to the nozzle(s) at a controlled pressure above ambient pressure and at a controlled temperature. By controlling both the pressure and temperature of the ejectant supply a more precise control of the rate of filling of nozzle(s) with ejectant is enabled, allowing the nozzles to be filled with more precise quantities of ejectant, than when either the temperature or pressure is controlled alone. Control of the volume of ejectant with which the nozzle(s) are filled enables control of the volume of ejectant subsequently ejected from those nozzle(s). This allows, for example, precise dosing of discrete volumes of ejectant onto substrates and economic use of ejectant material according to the intended purpose of depositing the ejectant onto the substrate. This approach is particularly advantageous in applications where it desirable to deposit small precise quantities, such as small precise quantities of adhesive onto printed circuit board with which to affix ‘chip-on-board’ electronic components onto printed circuit board or of pharmaceutical compounds upon the substrates of transdermal patches subsequently used for drug delivery through the skin. To improve efficiency of the ejector, whether it is plate-based, drum-based, or is of some other geometry, in some embodiments, the body of the ejector is made from materials that provide for a stable and reasonably hard (not flexible) body. It is preferable to make the surfaces of the body reasonably smooth (i.e., substantially non-abrasive) so as to allow the gas supply head, and in particular, the ejectant supply assembly to slide in relation to the body without being excessively worn away, and also provide for a seal without excessive gas leakage. In general, the smoother the surface of the body is the better the seal is, and thus the more efficient is the ejector. It is also preferable to use corrosion-stable materials (i.e., stable to oxidation and degradation) to manufacture the components of the ejector, and in particular to manufacture the body of the ejector. What materials are used however may depend, for example, on the intended use of the ejector, such as the nature of the ejectant and volumes to be ejected by the ejector. If the ejector employs a pulsatile gas supply to supply pressurised gas to the gas supply head, in some embodiments, the gas supply head has small inner dimensions and is preferably stiff (in the sense of having very low volumetric compliance). This may be achieved by using materials having a high Young's modulus, e.g., metals, glasses, ceramics, and carbon fibre composites, to manufacture the gas supply head. The described ejectors enable dispensing of discrete quantities of ejectant onto a substrate, web, or other suitable surface. In some embodiments, a gap is maintained between the body of the ejector and the substrate (web, or other suitable surface) onto which the ejectant is to be deposited. Therefore, droplet(s) of the ejectant ejected from the respective nozzle(s) of the body traverse the gap (such as an air gap) before being deposited onto the substrate (web, or other suitable surface). Such a separation gap ensures no contact between the body and the substrate, thereby (i) avoiding wear in use of the second surface of the body that otherwise may arise by such contact, (ii) allows the deposition of ejectant upon delicate substrates (such as cotton) or lightweight substrates (such as fabric gauze) or weak or brittle substrates (such as thin semiconductor wafers of silicon, gallium arsenide or other semiconductor), and/or (iii) allows serial deposition of discrete quantities of ejectants without the need for the prior drying or curing of the previous deposited quantity. This latter benefit accrues whether each subsequent deposited quantity is formed of the same or different ejectant material as prior-deposited quantities, and whether each subsequent deposited quantity is deposited directly onto the previous deposited quantity or onto some other region of the substrate. As described herein, a fluid ejector can have multiple nozzles. In some example embodiments the multiple nozzles are formed within the body in a fixed pattern—‘nozzle template’. A nozzle template allows deposition of discrete quantities of ejectant onto substrates in a fixed pattern corresponding to the pattern of nozzles in the template. This provides a simple means by which complex patterns of ejectant can easily be deposited. For example, a curved or shaped pattern of ejectant can be deposited upon the substrate using a corresponding fixed nozzle template. In some embodiments, the fluid ejector has a body having only a single nozzle. A single nozzle embodiment is particularly useful and advantageous, for example, in the case of compact industrial equipment, in which only individual ‘dots’ of ejectant need to be deposited upon a substrate at various controllable locations. One such an example is a compact fluid ejector located on the end of the arm of an industrial robot that is used to deposit small precise quantities of adhesive onto locations of a printed circuit board. The locations are determined by the movement of the robot arm according to software instructions for adhesive droplet placement. Such adhesive ‘dots’ are used to affix ‘chip-on-board’ electronic components onto printed circuit board before those components are permanently fixed and electrically connected, most typically using ‘flow-soldering’ techniques. The described ejectors and associated methods and their variations extend the practical applications of ejection of discrete quantities of ejectants to a wider range of ejectants than available ejectors and methods. By way of example, such applications include, but are not limited to:depositing glaze on ceramic tiles using the ejector ejecting a carrier liquid suspension of solid glaze particles to make glazed tiles;depositing silver frit on silicon in production of solar panels;depositing solder paste on circuit boards when manufacturing electronic circuits;depositing varnish on printing materials in production of printed packaging, book cover, magazines, and the like;depositing hot melt adhesive for the manufacture of packaging and personal hygiene products;depositing paint, paint mixtures, ultraviolet-curable paint on metal parts in productions of automobiles, ships, and airplanes;depositing adhesive on carbon fibre to produce pre-impregnated carbon fibre; anddepositing latex solution on cardboard or metal packaging to make tactile packaging, e.g., braille packaging for pharmaceutical products. While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. For example, in some of the embodiments described above, an ejectant supply assembly is configured to supply ejectant into nozzles through the same orifices that are subsequently used to eject the ejectant from the nozzles, such as through the second orifices of the device100as described with reference toFIGS.1ato1c. In some of the described embodiments, the ejectant supply assembly is configured to supply the ejectant into the nozzles through auxiliary orifices defined in the sidewalls of the conduits defining the nozzles, for example as described with reference toFIGS.2and9. Yet, in some other embodiments, the ejectant supply assembly is configured to supply the ejectant by other means, for example, through the orifice that becomes exposed to the gas from the gas supply head during the ejection stage of the fluid ejector, such as through the first orifices of the device100as described with reference toFIGS.1ato1c. Therefore, an ejectant supply assembly, for example, of form similar to that of the ejectant supply assembly130shown and described with reference toFIGS.1ato1cwould be disposed on the opposite side of the body110to supply the ejectant133ainto the nozzles114,115and116through their first orifices (as defined by the intersection of the nozzles114,115and116with the first surface111), rather than, as shown, through their second orifices. Similarly, an ejectant supply assembly of form similar to that of the ejectant supply assembly430shown and discussed with reference toFIG.4, may be disposed on the opposite side of the body410thereby to supply the ejectant433ainto the nozzles414,415and416through their first orifices rather than, as shown, through their second orifices. In this case, the ejectant supply assembly may be incorporated within a second aperture within the aperture plate471, or may be separate therefrom. Further, an ejectant supply assembly of form similar to that of the ejectant supply assembly530, shown in and described with reference toFIGS.5aand5b, may be disposed on the interior side of roller510thereby to supply the ejectant into the nozzles of the nozzle pattern5201,5202,5203, and5204through their first orifices rather than, as shown, through their second orifices. In the preferred embodiments, the time interval between the supply of ejectant into the nozzles and the subsequent exposure of that ejectant to the ejecting gas pressure at the gas outlet is sufficiently short that, after supply, the ejectant remains in the nozzles until that exposure. In the case of a plate-like body of 1.4 mm thickness, with nozzles of orifice diameter of 500 μm, that time interval for many practical ejectant liquids can be many minutes. In some applications, it is undesirable to have a short time interval between the supply of ejectant into the nozzles and its subsequent ejection from the nozzles. In such applications the presently described embodiments are particularly suitable for patterned deposition of liquid ejectants having high viscosity and/or high surface tension and/or emergent from nozzles having a small second orifice. Therefore, although the above particular descriptions refer to many embodiments of the invention, it will be understood by those skilled in the art that many other embodiments fall within the scope of the present invention. For example, some implementations of the present invention provide for a fluid ejector for ejecting discrete volumes of ejectant, the ejector comprising: a body having opposing first and second surfaces and a plurality of nozzles defined between the first and second surfaces, each nozzle defined by a conduit extending through the body to connect a first orifice defined at the first surface of the body and a second orifice defined at the second surface of the body; an ejectant supply means for supplying ejectant to each of one or more of a plurality of nozzles via a supply orifice of the nozzle; and a gas supply means for supplying a pressurised gas to the one or more nozzles through the respective one or more first orifices, wherein, in use, the gas supply means supplies gas to the first orifices of the one or more nozzles at a pressure above ambient pressure, thereby causing ejection of the ejectant from the one or more nozzles through the second orifices of the one or more nozzles. This fluid ejector advantageously enables dispensing of discrete quantities of fluids in a manner that is tolerant of varying operating conditions of practical industrial applications. Furthermore, the described fluid ejector extends the practical applications of ejection of discrete quantities of ejectants to a wider range of ejectants, a wider range of ejection rates, and a wider range of volumes of ejected ejectant than those known in the ink-jet art. By using a supply of pressurised gas, greater ejection energies can be provided than is provided by known ink-jet actuation means. Such use of pressurised gas also provides physical displacements of the ejectant that are larger than those provided by known ink-jet actuation means, thereby advantageously increasing the largest ejectant volume that can be ejected. Additionally, for liquid ejectants, no effective removal of dissolved gases from the ejectant is required, whilst for viscous ejectants, the viscous forces opposing ejectant ejection can be minimised by, for example, feeding the ejectant directly into the conduit immediately adjacent the ejection orifice, rather than via long capillary feed tubes, as known in the art. In some example embodiments, the ejectant supply means are configured to supply the ejectant to the one or more nozzles at a pressure above ambient pressure. For liquid ejectants, supply at a pressure above ambient pressure eliminates the reliance of the ‘refill’ of the nozzles after ejection upon the weak force of surface tension. This enables satisfactory supply (i) of liquid ejectants having a greater range of viscosities and/or (ii) of ejectants into a greater range of orifice and nozzle sizes and thereby a greater range of volumes of ejected ejectant and/or (iii) of ejectants at a faster rate than conventionally used. In some example embodiments, the ejectant supply means and the body are configured to translate relative to each other, the fluid ejector further comprising translational means for causing relative translation of the ejectant supply means to the body. This translatable arrangement enables filling of nozzles with the ejectant at one region of the body whilst simultaneously ejecting the ejectant from nozzles at a separate region of the body. This, in turn allows continuous and rapid operation of fluid ejectors. One such example is a fluid ejector having a body in the form of a rotating annular roller together with a fixed gas supply head and a fixed ejectant supply means located at different positions relative to the roller. In some example embodiments, the ejectant supply means comprises: an ejectant supply holder; and at least one resilient member extending from the ejectant supply holder and configured to provide for pressure-bearing contact between the resilient member and one of the first and second surfaces of the body such that, in use, the resilient member guides the ejectant into the one or more nozzles. In the described configuration of the ejectant supply holder with the at least one resilient member, supply of the ejectant into the nozzles under pressure is advantageously induced by the relative motion between the resilient member and the body. In some example embodiments, the at least one resilient member is further configured, in use, to remove an excess of the ejectant from the surface of the body it contacts. By using the at least one resilient member to remove an excess of the ejectant from the surface with which the resilient member is in contact, build-up of the ejectant on the contacted surface is prevented. If the contacted surface is the second surface, an excess of the ejectant remaining on that surface adjacent to the second orifices may, by coming into contact with the ejectant being ejected from the second orifices cause variability in the ejection characteristics (such as speed or direction of ejection) of the ejectant ejected from those orifices. Removal of the excess using the resilient member prevents such problems from arising. If the contacted surface is the first surface, an excess of the ejectant remaining on that surface may fill the gap between the first surface of the body and those surfaces of the solid walls defining the end portion of the gas supply head with the ejectant, and thereby cause a number of drawbacks. For example, relative motion of the gas supply head and the body can be inhibited. As a second example, for ejectants containing or comprising abrasive materials, filling of the gap can result in undesirable wear of those surfaces when the gas supply head and body are translated relative to each other. Removal of the excess allows these drawbacks to be avoided. If the contacted surface is either the first or the second surface, removal of the excess also aids the use of liquid ejectants that contain volatile components and ejectants that, over time, form or deposit solids. Without removal of the excess, many examples of such ejectants, can, over time, partially or completely block orifices by forming a solid layer of material on the contacted surface that encroaches on those orifices. In some example embodiments, the at least one resilient member comprises two resilient members extending from the ejectant supply holder to form a cavity for holding the ejectant, the ejectant supply assembly further defining a feed conduit that allows, in use, supply of the ejectant into the cavity at a pressure above ambient pressure, responsive to the presence of nozzles adjacent to the ejectant holding cavity. The arrangement with the two or more resilient members allows a greater range of ejectant supply pressures to be provided than can be provided using a single resilient member. The two resilient member arrangement thereby enables the satisfactory supply (i) of liquid ejectants having a greater range of viscosities and/or (ii) of ejectants into a greater range of orifice and nozzle sizes and thereby a greater range of volumes of ejected ejectant and/or (iii) of ejectants at a faster rate, thereby enabling faster operation of the fluid ejector, than conventional fluid ejectors can provide. In some example embodiments, for each for each of the one or more nozzles, the supply orifice is the second orifice; and the at least one resilient member is in pressure-bearing contact with the second surface of the body such that, in use, the resilient member guides the ejectant into the one or more nozzles through the respective second orifices. In some example embodiments, for each of the one or more nozzles, the supply orifice of the nozzle is different from the first orifice of the nozzle. By supplying the ejectant and gas through different orifices, the overall configuration of the fluid ejector is simplified and no special arrangement for managing supplies of different materials through the same orifices are needed. In some example embodiments, for each of the one or more nozzles, the supply orifice is defined in a side of the conduit defining the nozzle. This arrangement is particularly helpful if the gas supply head is fixed relative to the body and also to enable provision of an ejectant supply means that is capable of precise metering. In some example embodiments, the ejectant supply means comprises a metering device configured to supply the ejectant to the supply orifice defined in the side of the conduit defining the nozzle. This arrangement is advantageous in applications requiring delivery of precise amounts of ejectant. In some example embodiments, for each of the one or more nozzles, the supply orifice is the second orifice. In some practical applications, filling of the gap between the first surface of the body and those surfaces of the solid walls defining the end portion of the gas supply head with the ejectant can result in a number of drawbacks. For example, for liquid ejectants containing volatile components, relative motion of the gas supply head and the body can be inhibited by evaporation of the volatile components. This is especially likely after extended periods of non-use of the fluid ejector. As a second example, for ejectants containing or comprising abrasive materials, filling of the gap between the first surface and the end portion of the gas supply head can result in undesirable wear of those surfaces when the gas supply head and body are translated relative to each other. By supplying the ejectant via the second orifice, the ejectant can be supplied in such manner that it does not emerge through the first orifice, thus allowing the above drawbacks to be avoided. In some example embodiments, the gas supply means comprise a gas supply head defining a gas outlet for directing the pressurised gas to the first orifices of the one or more nozzles, and wherein the gas supply head and the body are configured to remain stationary relative to each other in use. This arrangement of the gas supply head allows for more efficient use of gas from the supply of pressurised gas. This stationary arrangement allows the gas supply head to be integrated with the body, thereby providing for a simple implementation of a fluid ejector capable of depositing repeated patterns onto a substrate. In some example embodiments, the gas supply means comprise a gas supply head defining a gas outlet for directing the pressurised gas to the first orifices of the one or more nozzles. The gas supply head allows for more efficient use of gas from the supply of pressurised gas. In some example embodiments, the gas supply head and the body are configured to translate relative to each other, the fluid ejector further comprising translational means for causing relative translation of the gas supply head to the body such that, in use, the gas outlet passes over the first orifices of the one or more nozzles. In some example embodiments, the body and/or the gas supply head are movable to cause the relative translation of the gas supply head to the body. These movable configurations enable supply of ejectant to the first orifices at a location different to that of the gas supply head. Therefore, the nozzles can be filled without exposing them, during filling to the gas pressure of the gas supply head. Such an arrangement simplifies repeated supply of ejectant to the orifices of the one or more nozzles. In some example embodiments a dimension of the gas outlet in a direction of the relative translation of the gas supply head to the body is dynamically adjustable such that, in use, the dimension is adjusted to control a time duration of the one or more nozzles being exposed to the pressure of the gas at the gas outlet. This example configuration enables, for a range of speeds of relative motion between the gas supply head and the body, the time duration during which ejectant within the nozzles is exposed to the pressurised gas supplied by the gas supply head to be advantageously held nearly constant, thereby aiding consistent ejection characteristics within that range of speeds. In some example embodiments, a gap between a portion of the gas supply head defining the gas outlet and the first surface of the body is formed. The configuration with the gap between the gas supply head and the first surface of the body provides for a simple implementation of the fluid ejector in which wear between the first surface of the body and those surfaces of the solid walls defining the end portion of the gas supply head is prevented. In some example embodiments, the gap is such that, if the plurality of nozzles is empty, gas flow through the gap is smaller than gas flow through the plurality of nozzles. Such sizing of the gap provides for relatively efficient use of gas supplied by the gas supply head. In some example embodiments, the gap is such that, if the plurality of nozzles is filled with the ejectant, gas flow through the gap is smaller than gas flow through the plurality of nozzles on ejecting the ejectant. Such sizing of the gap provides for still greater efficiency of gas utilisation from the gas supply head. In some example embodiments, the gas supply head is configured to receive pulsatile supply of gas at a pressure above ambient pressure. The pulsatile gas supply configuration allows the timing of gas pressurisation to be synchronised with the timing at which ejectant-filled nozzles are placed at the gas supply head and thereby exposed to that gas pressure. In this manner, wasteful discharge of pressurised gas (either through the nozzles or through a gap between a portion of the gas supply head defining the gas outlet and the first surface of the body) can be minimised, thereby enabling still greater efficiency of gas utilisation from the gas supply head. Further, this configuration simplifies ejectant supply if the gas supply head is fixed with respect to the body. In some example embodiments, the gas supply head is configured to receive continuous supply of gas at a pressure above ambient pressure. The continuous gas supply configuration is a simpler and more straight-forward configuration of the fluid ejector. In some example embodiments, the discrete volumes of the ejected ejectant are limited by the interior volume of the one or more nozzles. Using the interior volume of the one or more nozzles to limit the ejectant in this way provides for efficient use of the ejectant material. In some example embodiments, the body is a rotatable annular roller. The roller configuration facilitates continuous deposition of the ejectant onto substrates that take the form of continuously moving webs. In some example embodiments, the body is a translatable plate. The plate configuration is particularly useful in combination with a pulsatile supply of gas. In some example embodiments, the fluid ejector further comprises an aperture member, defining at least one aperture and positioned between the body and the gas supply means, wherein the aperture member is translatable such that, in use: for supplying of ejectant to the one or more nozzles, the aperture member is translated to a position in which the aperture member prevents exposure of the one or more nozzles to the pressure of the gas from the gas supply means, and for ejecting the ejectant from the one or more nozzles, the aperture member is translated to a position in which the at least one aperture of the aperture member is aligned with the one or more nozzles to expose the one or more nozzles to the pressure of the gas from the gas supply means. The use of a translatable aperture in the fluid ejector advantageously allows using a continuous supply of gas whilst controlling the timing of ejection from the nozzles. Some implementations of the present invention provide for a method for ejecting discrete volumes of ejectant. The method comprises ejecting the ejectant onto a substrate or a web using any of the above-described fluid ejectors. According to some example embodiments, ejecting comprises: supplying the ejectant to the one or more nozzles from the ejectant supply means; and supplying the gas to the one or more nozzles through the respective one or more first orifices at a pressure above ambient to cause the one or more nozzles to eject the ejectant onto the web or the substrate. According to some example embodiments, supplying the ejectant comprises: translating the one or more nozzles relative to the ejectant supply means to expose the first or second orifices of the one or more nozzles to supply of the ejectant from the ejectant supply means when the ejectant supply means pass the orifices. According to some example embodiments, supplying the gas comprises: translating the one or more nozzles relative to the gas supply means to expose the first orifices of the one or more nozzles to the pressure of the gas from the gas supply means when the gas supply means pass the first orifices, thereby causing the nozzles to eject the ejectant from one or more nozzles through the respective second orifices. According to some example embodiments, the method further comprises: repeating the supplying the ejectant and supplying the gas steps at least once. According to some example embodiments, ejecting comprises: supplying the ejectant to the one or more nozzles from the ejectant supply means; and supplying the gas to the one or more nozzles through the respective one or more first orifices at a pressure above ambient to cause the one or more nozzles to eject the ejectant onto the web or substrate. Some other implementations provide for a method for ejecting discrete volumes of ejectant, the method comprising: supplying with ejectant one or more nozzles of a plurality of nozzles defined in a body between opposing first and second surfaces of the body, each nozzle defined by a conduit extending through the body to connect a first orifice defined at the first surface of the body and a second orifice defined at the second surface of the body, wherein the ejectant is supplied at a pressure above ambient pressure to each of the one or more nozzles through a supply orifice of the nozzle; and supplying a gas at a pressure above ambient pressure to the one or more nozzles through the first orifices of the one or more nozzles to cause the one or more nozzles to eject the ejectant through the second orifices. According to some example embodiments, the ejectant is supplied to the one or more nozzles using the ejectant supply assembly and the method further comprising translating the ejectant supply assembly relative to the body to allow supply of the ejectant from the ejectant supply assembly to each of the one or more nozzles through the first or second orifice of the nozzle. According to some example embodiments, translating the ejectant supply assembly relative to the body comprises moving the body to cause the relative translation of the ejectant supply assembly to the body. According to some example embodiments, translating the ejectant supply assembly relative to the body comprises moving the ejectant supply assembly to cause the relative translation of the ejectant supply assembly to the body. According to some example embodiments, the ejectant supply assembly comprises an ejectant supply holder and at least one resilient member extending from the ejectant supply holder and configured to provide for pressure-bearing contact between the resilient member and one of the first and second surfaces of the body; and translating the ejectant supply assembly relative to the body causes the at least one resilient member pass over the orifices at the surface contacted by the at least one resilient member, thereby guiding the ejectant into the one or more nozzles through the orifices at the surface contacted by the at least one resilient member. According to some example embodiments, the method further comprises: removing an excess of the ejectant supplied to the one or more nozzles from the surface of the body contacted by the at least one resilient member using the at least one resilient member. According to some example embodiments, the at least one resilient member comprises two resilient members extending from the ejectant supply holder to form a cavity for holding the ejectant, the ejectant supply assembly further defining a feed conduit, and the method further comprises supplying the ejectant into the cavity at a pressure above ambient pressure, responsive to the presence of nozzles adjacent to the ejectant holding cavity. According to some example embodiments, for each of the one or more nozzles, the supply orifice is the second orifices; the at least on resilient member is in pressure—bearing contact with the second surface of the body; and translating the ejectant supply assembly relative to the body causes the at least one resilient member pass over the second orifices of the one or more nozzles, thereby guiding the ejectant into the one or more nozzles through the second orifices. According to some example embodiments, for each of the one or more nozzles, the supply orifice of the nozzle is different from the first orifice of the nozzle. According to some example embodiments, for each of the one or more nozzles, the supply orifice is defined in a side of the conduit defining the nozzle. According to some example embodiments, wherein supplying one or more nozzles with the ejectant comprises supplying the ejectant to each of the one or more nozzles through the supply orifice of the nozzle using a metering device. According to some example embodiments, for each of the one or more nozzles, the supply orifice is the second orifice; and translating the ejectant supply assembly relative to the body allows supply of the ejectant from the ejectant supply assembly to the one or more nozzles through the second orifices. According to some example embodiments, the gas is supplied to the one or more nozzles by a gas supply head adjacent to the first surface of the body, the gas supply head defining a gas outlet for directing the gas to the first orifices of the one or more nozzles, and the gas supply head remains stationary relative to the body whilst the method is executed. According to some example embodiments, the gas is supplied to the one or more nozzles by a gas supply head adjacent to the first surface of the body, the gas supply head defining a gas outlet for directing the gas to the first orifices of the one or more nozzles. According to some example embodiments, the method further comprises translating the gas supply head relative to the body to cause the gas outlet to pass over the first orifices of the one or more nozzles. According to some example embodiments, translating the gas supply head relative to the body comprises moving the body to cause the relative translation of the gas supply head to the body. According to some example embodiments, translating the gas supply head relative to the body comprises moving the gas supply head to cause the relative translation of the gas supply head to the body. According to some example embodiments, the method further comprises adjusting dynamically, in response to a speed of the relative translation of the gas supply head to the body, a dimension of the gas outlet in a direction of the relative translation of the gas supply head to the body to control a time duration of the one or more nozzles being exposed to the pressure of the gas at the gas outlet. According to some example embodiments, a gap is formed between a portion of the gas supply head defining the gas outlet and the first surface of the body. According to some example embodiments, the gap is such that, if the plurality of nozzles is empty, a gas flow through the gap is smaller than a gas flow through the plurality of nozzles. According to some example embodiments, the gap is such that, if the plurality of nozzles is filled with the ejectant, gas flow through the gap is smaller than a gas flow through the plurality of nozzles on ejecting the ejectant. According to some example embodiments, the method further comprises receiving by the gas supply head pulsatile supply of gas at a pressure above ambient pressure. According to some example embodiments, the method further comprises receiving by the gas supply head continuous supply of gas at a pressure above ambient pressure. According to some example embodiments, the method further comprises repeating the supplying the ejectant and supplying the gas steps at least once. According to some example embodiments, the discrete volumes of the ejectant ejected from the one or more nozzles are limited by the interior volume of the one or more nozzles. According to some example embodiments, the body is a rotatable annular roller, and the method further comprises rotating the annular roller to cause the first orifices of the one or more nozzles to pass in front of the gas supply head. According to some example embodiments, the body is a rotatable annular roller, and the method further comprises rotating the annular roller to allow supply of the one or more nozzles with the ejectant. According to some example embodiments, the body is a translatable plate. According to some example embodiments, an aperture member, having at least one aperture, is disposed between the body and the gas supply head, wherein the aperture member is translatable and the method further comprises: translating the aperture member to a position in which the aperture member prevents exposure of the one or more nozzles to the pressure of the gas from the gas supply means to allow supply of ejectant to the one or more nozzles; and translating the aperture member to a position in which the at least one aperture of the aperture member is aligned with the one or more nozzles to expose the one or more nozzles to the pressure of the gas from the gas supply means to cause ejection of the ejectant from the one or more nozzles. The above described embodiments and implementations enable ejection of defined volumes of ejectant particularly because no further ejectant is introduced into the nozzle as a consequence of the ejection event. Rather, the nozzles are refilled during a subsequent separate operation. This is unlike the conventional arrangements in which further ejectant stored in a chamber in fluid communication with the nozzles flows into the nozzle. Consequently there is no need to maintain careful balance between the timing of pressurisation pulses required for droplet ejection and the time duration required for pressure-reduction of a chamber according to the particular ejectant viscosity, size of the droplet outlet, the flow profile of the valve controlling the sudden gas pressurisation as it opens, the liquid fill level within the chamber, or the ambient temperature. Similarly there is no need to eliminate reverberating pressure pulses within the chamber. The disclosed fluid ejectors and associated ejection methods are therefore more tolerant of varying operating conditions expected in practical industrial application. For example, some of the described embodiments provide for implementations (such as the variations described with reference toFIG.4) in which the volume of ejectant entering any nozzle during the ‘fill’ part of the cycle, and therefore the volume subsequently ejected from that nozzle during the ‘eject’ part of the cycle, may be metered or controlled by closing the first orifice of that nozzle during the fill operation. Further, as described, the disclosed fluid ejectors and associated methods are not limited to gravitational liquid feed to the nozzles, but instead utilise positive-pressure feed into the nozzles. This increases the rate at which the nozzles can be refilled for the next ejection event (for the ‘eject’ part of the cycle), thereby allowing greater ejection rates and corresponding greater productivity in industrial applications. Furthermore, the disclosed fluid ejectors and associated methods enable ejection and deposition onto a target substrate or web of fluid volumes larger than the volumes typically required in an inkjet application. For example, volumes larger than 1 nanolitre (1 nl) of ejectant as droplets can be ejected using the described fluid ejector. Additionally, some of the variations disclosed herein (such as the variation described with reference toFIG.1) allow fluid ejector's implementations that do not require seals contacted by ejectant between relatively moving parts of the fluid ejector without sacrificing the quality of the ejected patterns or efficiency of the fluid ejectors. Furthermore, the described fluid ejectors and associated methods enable the gas pressures, nozzle dimensions and time that the ejectant is exposed to the ejecting gas pressure to be easily varied to enable ejection of a wide range of ejectants as single droplets rather than as sprays. This in turn facilitates depositing of high quality patterns of ejectant upon various substrates and webs. | 95,841 |
11858263 | DETAILED DESCRIPTION OF EMBODIMENTS An embodiment of a printing device according to the present disclosure will be described with reference toFIGS.1to11. The embodiment described below is provided with various limitations technically preferable for carrying out the present disclosure. However, the scope of the present disclosure is not limited to the embodiment below or illustrated examples. Furthermore, in the following embodiment, a case where the printing device is a nail printing device that performs printing on fingernail(s) (including thumbnail(s)) of hand(s) as a printing target will be described as an example. However, the printing target of the printing device in the present disclosure is not limited to the fingernail(s) or the thumbnail(s) of hand(s). For example, toenail(s) of foot (feet) may be the printing target. The printing target may also be targets other than nails, such as nail tips and surfaces of various accessories. FIG.1is a perspective view showing the main part outer configuration of a nail printing device1. In the following embodiment, the up, down, left, right, front and rear refer to the directions shown inFIG.1. Furthermore, the X direction and the Y direction respectively refer to the left-right direction and the front-rear direction. As shown inFIG.1, the nail printing device1includes a housing2which is formed in a nearly box shape. The housing2includes an opening21which is formed over the nearly entire surface in the left-right direction (horizontal direction of nail printing device1, left-right direction inFIG.1, X direction) in the lower section on the front surface side (front surface side of nail printing device1, front side inFIG.1). There is a cut-off portion22continuing to the upper side of the opening21, in the nearly central portion in the left-right direction of the housing2. The cut-off portion22functions as a port when an after-mentioned print head41is attached to and detached from the device. Though not shown in the drawings, the housing2may include a cover member or the like which covers the opening21and the cut-off portion22. The cover member may be a separate member from the housing2, or may be attached to the housing2via a hinge or the like in an openable and closable manner, for example. An operation unit12of the nail printing device1is provided on the upper surface (top plate) of the housing2. The operation unit12is an operation button (power switch button) to turn on/off the power of the nail printing device1, for example. When the operation unit12is operated, the operation signal is output to an after-mentioned control device80, and the control device80performs control in accordance with the operation signal to operate the components of the nail printing device1. For example, when the operation unit12is a power switch button, the power of the nail printing device1is turned on/off according to the button operation. The components of the nail printing device1may operate in accordance with the operation signal which was input from an operation unit91of an after-mentioned control device9instead of the operation unit12. The shapes, arrangement and the like of the components in the housing2are not limited to the illustrated examples, and can be set as needed. For example, the operation unit12may be provided on a lateral surface, a back surface or the like, not on the upper surface of the housing2. The housing2may have other various operation buttons as the operation unit12, and may have various displays, indicators and the like. A device body10is contained inside the housing2. The device body10includes a base11, a printing unit and a finger fixing unit6attached to the base11, for example. The finger fixing unit6is arranged in the nearly central portion in the left-right direction (X direction) on the device front surface side in the base11. The finger fixing unit6fixes, in the region suitable for the printing, the finger (printing finger) having the nail which is the printing target in the present embodiment. The finger fixing unit6has an opening61on the device front surface side. A finger fixing member62is provided inside the finger fixing unit6. The finger fixing member62presses up and supports the finger inserted from the opening61from the lower side. The finger fixing member62is formed of a resin or the like having flexibility, for example. The upper surface of the finger fixing unit6has a window63to expose the nail portion of the finger which was inserted from the opening61and is held by the finger fixing member62. The printing unit40is a printing unit that performs printing on the nail which is the printing target. The printing unit40includes a print head41that performs the printing operation, and a head moving mechanism49for moving a print head unit42including the print head41(seeFIG.2). In the print head41of the present embodiment, the surface facing the nail surface is the ink ejection surface including multiple nozzle tips (none of them shown in the drawings) to eject ink. The print head41is an inkjet type inkjet head that performs printing by making micro droplets of ink and directly spraying, from the ink ejection surface, the ink onto the nail surface which is the printing surface of the printing target (nail). Though the configuration of the print head41is not especially limited, the print head41is a cartridge-integrated head which has the ejection mechanism section such as the ink ejection surface integrated with the ink cartridge (none of them shown in the drawings), for example. For example, the print head41can eject inks of C (CYAN), M (MAGENTA), and Y (YELLOW). The print head41in the present embodiment can also eject the ink of white color as the background paint. By printing a white color background, it is possible to make the colors appear well since the background color greatly influences the color tint in the inkjet printing. The type of inks included in the print head41is not limited to the above type. The head moving mechanism49is configured by including an X-direction moving mechanism (not shown in the drawings) for moving the print head41in the left-right direction (X direction) of the device, and a Y-direction moving mechanism (not shown in the drawings) for moving the print head41in the front-rear direction (Y direction) of the device. The X-direction moving mechanism includes an X-direction moving motor46(seeFIG.2), and moves the print head41in the left-right direction (X direction) of the device by the X-direction moving motor46driving. The Y-direction moving mechanism includes a Y-direction moving motor48(seeFIG.2), and moves the print head41in the front-rear direction (Y direction) of the device by the Y-direction moving motor48driving. At a position above the window63of the finger fixing unit6inside the upper surface (top plate) of the housing2, there is provided a photographing unit50that photographs the nail (finger including the nail) exposed from the window63and obtains an image of the nail (image of the finger including the nail, hereinafter, referred to as a “nail image”). The photographing unit50includes a photographing device51such as a camera and an illuminating device52which illuminates the nail that is the photographing target and includes a white LED, for example (seeFIG.2). The photographing device51is, for example, a small-sized camera configured by including a CCD (Charge Coupled Device) type or CMOS (Complementary Metal Oxide Semiconductor) type solid imaging element which has approximately two million pixels or more and a lens. The photographing device51includes an optical axis Ax along the up-down direction orthogonal to the X-Y plane. A size alignment is adjusted to accurately obtain the size of an object from the image capturing the object that is located on a reference plane L which is at a predetermined distance (seeFIGS.4A and4B). The position of the optical axis Ax on the X-Y plane is fixed, and has the coordinates (CX, CY) in the present embodiment. The present embodiment takes, as an example, a case where the photographing device51and the illuminating device52are arranged to be fixed at positions capable of facing the nail (nail surface) of the finger placed in the finger fixing unit6on the inner side of the top plate of the housing2. However, the specific arrangement is not particularly limited as long as the photographing unit50is provided at a position capable of photographing the nail of the finger placed in the finger fixing unit6. For example, the photographing unit50may be configured to be movable in the X-Y direction by the head moving mechanism49that moves the print head41. FIG.2is a control block diagram showing the schematic control configuration of the nail printing device1and an after-mentioned terminal device9. As shown inFIG.2, the nail printing device1includes a communication unit55and a control device80, in addition to the printing unit40and the photographing unit50described above. The communication unit55is configured to be able to transmit and receive information to and from the after-mentioned terminal device9that operates in cooperation with the nail printing device1. The communication between the nail printing device1and the terminal device9is performed by, for example, a wireless LAN. The communication between the nail printing device1and the terminal device9is not limited to this, and any method may be used. For example, a network line such as the Internet may be used, or wireless communication based on a near field wireless communication standard such as Bluetooth (registered trademark) or Wi-Fi may be performed. Furthermore, this communication is not limited to wireless communication, and various types of data may be transmitted and received between the nail printing device1and the terminal device9by wired connection. The communication unit55includes an antenna chip or the like corresponding to the communication method of the terminal device9. The control device80is a computer that includes: a controller81configured by including a CPU (Central Processing Unit) not shown in the drawings; and a storage82configured by including a ROM (Read Only Memory)821, a RAM (Random Access Memory)822, and the like. The storage82stores various programs and various types of data for operating the nail printing device1. Specifically, the ROM821of the storage82stores various programs such as a printing program for performing printing processing, for example. These programs are executed by the control device80. Thereby, the components of the nail printing device1are controlled in an integrated manner. The controller81includes functional sections such as a photographing controller811, a printing controller813, and a communication controller814. The functions of these respective functional sections are realized by the cooperation of the CPU of the controller81and the program stored in the ROM821of the storage82. The photographing controller811controls the photographing device51and the illuminating device52of the photographing unit50, and causes the photographing device51to photograph an image of the finger (nail image) including an image of the nail of the printing finger fixed to the finger fixing unit6. The image data of the nail image acquired by the photographing unit50is transmitted to the after-mentioned terminal device9via the communication unit55. The image data may be stored in the storage82. The printing controller813outputs a control signal to the printing unit40on the basis of printing data transmitted from the terminal device9, and controls the X-direction moving motor46and the Y-direction moving motor48, the print head41, and the like of the printing unit40so as to perform printing on the nail according to the printing data. The communication controller814controls the operation of the communication unit55. In the present embodiment, the communication controller814controls communication with the terminal device9, to receive printing data or the like when the printing data or the like is transmitted from the terminal device9. The nail printing device1in the present embodiment is configured to be able to communicate with the terminal device9, and executes the printing operation and the like on the basis of the operation instruction from the terminal device9. The terminal device9is, for example, a mobile terminal such as a smartphone or a tablet. However, the terminal device9is not particularly limited as long as the terminal device9can communicate with the nail printing device1. For example, the terminal device9may be a notebook or stationary personal computer, a terminal device for a game, or the like. Specifically, the terminal device9includes an operation unit91, a display92, a communication unit94, a control device95, and the like. The operation unit91can perform various inputs and settings according to user operations. When the operation unit91is operated, an input signal corresponding to the operation is transmitted to the control device95. In the present embodiment, a touch panel is integrally provided on the surface of the display92, and the user can perform various input/setting operations and the like by touch operations on the touch panel. The operation unit91for performing various input/setting operations and the like is not limited to the touch panel. For example, various operation buttons, a keyboard, a pointing device, and the like may be provided as the operation unit91. In the present embodiment, the user can select a nail design to be printed on the nail by operating the operation unit91. The touch panel configured in the display92displays various display screens under the control of a controller96to be described later. In the present embodiment, the display92can display a nail design which was input or selected by the user from the operation unit91, an image which was transmitted from the nail printing device1, and the like. The communication unit94can transmit printing data to the nail printing device1. Furthermore, when data such as a nail image is transmitted from the nail printing device1, the communication unit94receives the transmitted data. The communication unit94includes a wireless communication module that can communicate with the communication unit55of the nail printing device1. The communication unit94may be any communication unit as long as the communication unit can communicate with the nail printing device1, and a communication unit that meets the communication standard of the communication unit55of the nail printing device1is applied as the communication unit94. The control device95is a computer that includes: a controller96configured by including a CPU (Central Processing Unit) not shown in the drawings; and a storage97configured by including a ROM (Read Only Memory) and a RAM (Random Access Memory) not shown in the drawings. The storage97stores various types of data and programs for operating the components of the terminal device9. Specifically, the ROM or the like in the present embodiment stores various programs such as a nail print application program for performing nail printing using the nail printing device1in addition to an operation program for controlling the components of the terminal device9in an integrated manner. The control device95expands these programs in a working area of the RAM and executes the programs, for example, so that the terminal device9is controlled. The data of nail designs, information on nail images and nail shapes, and the like are stored in the storage97of the present embodiment. The controller96controls the operations of respective components of the terminal device9in an integrated manner. The controller96implements various functions for performing printing on the nail in cooperation with a program stored in the storage97. Next, the operation of nail printing device1when executing printing on the nail will be described. FIG.3is a flowchart showing the flow of printing processing of the nail printing device1. Each ofFIGS.4A and4Bis a view for explaining the influence of positional deviation of the nail from the reference plane L of the photographing device51. The nail design to be printed is set in advance in the embodiment. As shown inFIG.3, when the printing processing is executed and the user places a finger (printing finger) in the finger fixing unit6(step S1), the controller81obtains a nail image by photographing the nail of the printing finger with the photographing unit50, recognizes (detects) the nail shape (nail region) from this nail image and stores the recognized nail shape (nail region) in the storage82(step S2). The controller81then executes white color printing of printing the background paint of white color (white ink) on the printing finger placed in the finger fixing unit6(step S3). In the embodiment, the white color printing is executed by the printing unit40on the printing region (region to apply the nail design) which is set in advance in the nail region which was recognized (detected) in step S2. This white color printing (background) is an example of a preceding print according to the present disclosure. The range of background region to apply the white color printing is not particularly limited. The range of background region to apply white color printing may be a part of the nail, may be the entire nail, or may not one-to-one correspond to the detected nail region. The controller81stores, in the storage82, the information on the background region which was actually printed (step S4). In the present embodiment, the X-direction width W0 and the Y-direction length H0 (seeFIG.6) of the circumscribed quadrangle of the background region are stored. The circumscribed quadrangle is formed by the sides along the X direction and the Y direction. Thereafter, the printing finger is removed from the finger fixing unit6by the user, and drying of the white ink and application of an accepting layer for color inks onto the white ink are performed as needed (step S5). When the printing finger is placed in the finger fixing unit6by the user again (step S6), the controller81obtains the nail image by photographing the nail of the printing finger with the photographing unit50(photographing device51), recognizes (detects) the background region of white color from this nail image, and stores the recognized background region in the storage82(step S7). When the position of the nail which was placed again in step S6after the white color printing is vertically deviated from the reference plane L which allows obtaining the accurate size by the photographing device51, the background region (hereinafter, referred to as “recognized region R1”) which was recognized (detected) in step S7is recognized (detected) in the state changed from the actual background region (hereinafter, referred to as “actual region R0”) by the amount of distance deviated from the reference plane L. The actual region R0 is an example of a preceding print setting region according to the present disclosure, and the recognized region R1 is an example of a succeeding print region according to the present disclosure. To be specific, as shown inFIG.4A, when the nail position M (position on the optical axis Ax) is lower than the reference plane L (farther from the photographing device51), the recognized region R1 becomes smaller than the actual region R0. Thus, when printing is performed for the range of the recognized region R1, the white portion is left in end portions of the actual region R0. On the other hand, as shown inFIG.4B, when the nail position M is upper than the reference plane L (closer to the photographing device51), the recognized region R1 becomes larger than the actual region R0. Thus, when printing is performed for the range of the recognized region R1, this printed region protrudes from the actual region R0. The controller81performs correction processing of correcting the position and the size of the background region which was recognized in step S7(step S8). FIG.5is a flowchart showing the flow of this correction processing.FIG.6is a view for explaining this correction processing. FIG.6illustrates a case where the position M of the nail which was placed again in step S6after the white color printing is lower (farther) than the reference line L of the photographing device51. In the following description, except where specifically noted, “distance” indicates the distance along the optical axis Ax, “width” indicates the distance along the X direction, “length” indicates the distance along the Y direction, and “coordinates” indicate the XY coordinates. As shown inFIGS.5and6, when the correction processing is performed, the controller81first obtains the coordinates of the outline of the recognized region R1 and the X-direction width WW and the Y-direction length HW of its circumscribed quadrangle (step S81). The circumscribed quadrangle is formed by the sides along the X direction and the Y direction. Next, the controller81sets the coordinates of a reference point P1 of the recognized region R1 (step S82). The reference point P1 is an example of a succeeding print region reference point according to the present disclosure. In the present embodiment, this reference point P1 is any one vertex (XW, YW) of the circumscribed quadrangle (having respective sides along X and Y) of the recognized region R1 on the X-Y plane. However, the reference point P1 is not limited to the reference point P1 in the present embodiment as long as the reference point P1 is a point (for example, representative point) corresponding to a circumscribed polygon of the recognized region R1. The reference point P1 may be a center of gravity (center of the figure) of the circumscribed polygon of the recognized region R1, for example. Next, the controller81reads out the X-direction width W0 and the Y-direction length H0 of the background region stored in step S4(step S83). The X-direction width W0 and the Y-direction length H0 are equal to the X-direction width and the Y-direction length of the actual region R0 since the X-direction width W0 and the Y-direction length H0 are actual sizes when the white color printing was performed. The controller81then enlarges/reduces the outline of the recognized region R1 such that the X-direction width WW and the Y-direction length HW of the recognized region R1 match the X-direction width W0 and the Y-direction length H0 of the actual region R0 (step S84). That is, in order to obtain the point B on the outline of the actual region R0, for example, the X-direction length BC may be obtained from the following formula: BC=EF×W0/WW The EF is known from the point E on the circumscribed quadrangle of the recognized region R1 and the point F on the optical axis Ax. Similarly, in order to obtain the point J on the outline of the actual region R0, the Y-direction length JC may be obtained from the following formula: JC=HF×H0/HW The HF is known from the point H on the circumscribed quadrangle of the recognized region R1 and the point F on the optical axis Ax. The controller81obtains the reference point P0 of the actual region R0 corresponding to the reference point P1 of the recognized region R1 (step S85). The reference point P0 is an example of a preceding print setting region reference point according to the present disclosure. The coordinates (XW0, YW0) of the reference point P0 of the actual region R0 are calculated by the following formula: XW0=CX−lengthBC =CX−lengthEF×W0/WW =CX−(CX−XW)×W0/WW YW0=CY−lengthJC=CY−lengthHF×W0/WW=CY−(CY−YW)×W0/WW In such a way, the recognized region R1 is corrected to the region having the outline which was enlarged or reduced in step S84and the reference point P0 (XW0, YW0) calculated in step S85, that is, the actual region R0. Thus, it is possible to properly perform design printing to the actual background region. As shown inFIG.3, the controller81generates printing data to execute predetermined design printing to the background region (recognized region R1) which was corrected in step S8(step S9). Thereafter, the controller81executes design printing (printing of decoration) by the printing unit40on the basis of the printing data generated in step S9(step S10), and then ends the printing processing. This design printing (decoration) is an example of a succeeding print according to the present disclosure. As descried above, according to the present embodiment, the background region is recognized from the image obtained by photographing the printing finger, the reference point P1 of this recognized region R1 and the reference point P0 of the actual region R0 are set, and the decoration is printed on the nail region on the basis of the information on the reference points and the actual region R0. Thus, even when the nail position M is deviated from the reference plane L which allows to obtain the accurate size by the photographing device51, the recognized region R1 can be corrected to the region having the reference point P0 and the size corresponding to the actual region R0. Thus, it is possible to make the printing region to apply design printing match the background region, and finish the nail as a nice-looking nail. A first modification example of the above embodiment will be described. The first modification example is mainly different from the above embodiment in the contents of correction processing in step S8correcting the recognized background region. Hereinafter, this difference will be mainly described, and same reference numerals are provided to the same components as those of the above embodiment to omit the explanation thereof. FIG.7is a flowchart showing the flow of correction processing in the first modification example. Each ofFIGS.8A and8Bis a view for explaining this correction processing. In the first modification example, as shown inFIG.8A, the controller81obtains the coordinates of the outline of background region in addition to the X-direction width W0 and the Y-direction length H0 of the circumscribed quadrangle of the background region as the information on the background region which was actually printed (that is, actual region R0), and stores them in the storage82in step S4. Thereafter, when the correction processing is executed, as shown inFIGS.7and8B, the controller81first obtains the coordinates of the outline of the recognized region R1 and the X-direction width WW and the Y-direction length HW of its circumscribed quadrangle, similarly to step S81of the above embodiment (step T81). The controller81sets the coordinates of the reference point P1 of the recognized region R1, similarly to step S82of the above embodiment (step T82). Next, the controller81obtains the reference point P0 of the actual region R0 corresponding to the reference point P1 of the recognized region R1, similarly to step S85of the above embodiment (step T83). The controller81then locates the outline of the background region (that is, actual region R0) obtained in step S4such that the reference position P2 (seeFIG.8A) matches the reference point P0 (step T84). The reference position P2 is a point in the actual region R0, the point being in the positional relationship corresponding to the reference point P1 in the recognized region R1. In the example ofFIG.8A, the reference position P2 is the upper left vertex of the circumscribed quadrangle. The reference position P2 may be obtained in step T84, or may be obtained in step S4in advance. In such a way, the recognized region R1 is corrected to the actual region R0 having the outline obtained in step S4and the reference point P0 calculated in step T83. Thus, it is possible to properly perform design printing on the actual background region. As described above, the effect similar to that of the embodiment is obtained by the first modification example. That is, even when the nail position M is deviated from the reference plane L which allows to obtain the accurate size by the photographing device51, the recognized region R1 can be corrected to the region having the reference point P0 and the size (outline) corresponding to the actual region R0. Thus, it is possible to make the printing region of design printing match the background region and finish the nail as a nice-looking nail. Furthermore, according to the first modification example, the actual region R0 is set by locating the outline of background region while making the reference position P2 match the reference point P0. Accordingly, it is possible to reduce the calculation processing amount compared to the case of setting the actual region R0 by enlarging/reducing the recognized region R1. A second modification example of the above embodiment will be described. The second modification example is mainly different from the above embodiment in the contents of correction processing in step S8correcting the recognized background region. To be specific, in the above embodiment, the decoration is printed by setting the reference point P1 of the recognized region R1 and the reference point P0 of the actual region R0. However, instead of this, in the second modification example, the decoration is printed by setting only the reference point P1 of the recognized region R1, without setting the reference point P0 of the actual region R0. Hereinafter, this difference will be mainly described, and same reference numerals are provided to the same components as those of the above embodiment to omit the explanation thereof. FIG.9is a flowchart showing the flow of correction processing in the second modification example.FIG.10is a view for explaining this correction processing. When the correction processing is executed, as shown inFIGS.9and10, the controller81first obtains the coordinates of the outline of the recognized region R1 and the X-direction width WW and the Y-direction length HW of its circumscribed quadrangle, similarly to step S81of the above embodiment (step U81). The controller81then reads out the X-direction width W0 and the Y-direction length H0 of the background region (that is, actual region R0) which were stored in step S4, similarly to step S83of the above embodiment (step U82). The controller81enlarges/reduces the outline of the recognized region R1 such that the X-direction width WW and the Y-direction length HW of the recognized region R1 match the X-direction width W0 and the Y-direction length H0 of the actual region R0 (step U83). At this time, the controller81sets the point C (CX, CY) on the optical axis Ax, that is, the intersection of the recognized region R1 and the optical axis Ax as a reference point P1, and enlarges/reduces the relative position of the outline of the recognized region R1 with respect to the reference point P1. The enlargement or reduction rate may be W0/WW or H0/HW, may be an average value thereof, or may be W0/WW in the width direction and H0/HW in the length direction. In such a way, the recognized region R1 is corrected to the actual region R0 having the outline which was enlarged or reduced in step U83and the reference point on the optical axis Ax (equal to the reference point P1 since it is the point on the optical axis Ax). Thus, it is possible to properly perform design printing on the actual background region. As described above, the similar effect to that of the embodiment is obtained by the second modification example. That is, the background region is recognized from the image obtained by photographing the printing finger, the reference point P1 of this recognized region R1 is set, and the decoration is printed on the nail region on the basis of the information on this reference point P1 and the actual region R0. Thus, even when the nail position M is deviated from the reference plane L which allows to obtain the accurate size by the photographing device51, the recognized region R1 can be corrected to the region having the reference point and the size (outline) corresponding to the actual region R0. Thus, it is possible to make the printing region of design printing match the background region and finish the nail as a nice-looking nail. Though the embodiment of the present disclosure has been described above, the present disclosure is not limited to the embodiment, and various modifications can be made within the scope of the present disclosure. For example, the embodiment and its modification examples takes, as an example, a case where the nail position M is located lower than the reference plane L in the correction processing of step S8. However, as shown inFIG.11, the correction processing can be executed similarly in a case where the nail position M is upper than the reference plane L (closer to the photographing device51). The background may be in a color other than the white color. In the present embodiment, the nail printing device1performs printing by the inkjet method. However, the method of performing printing by the nail printing device1is not limited to the inkjet method. For example, printing may be performed with a pen by providing a pen holder that holds the pen for printing which performs printing with the pen tip contacting the nail surface. There may be provided both of the inkjet type printing unit as in the present embodiment and the pen holder holding the pen for printing so as to perform printing by using multiple printing units. In the present embodiment, the background is printed as a preceding print, and the decoration is printed as a succeeding print. However, the preceding print and succeeding print according to the present disclosure are not limited to this embodiment. For example, both of the preceding print and the succeeding print may be the background (first background and second background), or both of the preceding print and the succeeding print may be the decoration (first decoration and second decoration). The present embodiment takes, as an example, a case where the printing system is formed in the cooperation between the nail printing device1and the terminal device9, the inputting of the printing start instruction and the like are performed on the terminal device9side, and then the printing operation is executed on the nail printing device1side. However, the nail printing device1is not limited to this case. For example, the operation unit and display to input various instructions, the printing data generating unit to generate printing data and the like may be provided on the nail printing device1side so that the control device of the nail printing device1may perform these processes. In such a case, it is possible to configure such that the nail printing device1can complete the printing operation alone without cooperating with the terminal device. The various types of data such as nail designs, image data obtained by photographing, and printing inclination setting table may be stored in the storage of the terminal device, or may be stored in the storage of the nail printing device1. The various types of data may be stored in a server device or the like which can be connected via a network line or the like so that the terminal device or the nail printing device1can access the server device or the like to refer to this data. By such a configuration, it is possible to select a design to be printed from among more nail designs. Although several embodiments of the present disclosure have been described, the scope of the present disclosure is not limited to the above described embodiments and includes the scope of the present disclosure that is described in the claims and the equivalents thereof. | 35,673 |
11858264 | DESCRIPTION OF EMBODIMENTS Various embodiments will be described more fully hereinafter with reference to the accompanying drawings, in which some embodiments are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this description will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, the sizes and relative sizes of layers and regions may be exaggerated for clarity. Like numerals refer to like elements throughout. It will be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Hereinafter, preferred embodiments of the invention will be described in detail with reference to the accompanying drawings. Like elements or components can be indicated by like reference numerals throughout the drawings, and the repeated explanations of like elements or components may be omitted. FIG.1is schematic diagram illustrating an apparatus for dispensing droplet in accordance with example embodiments of the invention. Referring toFIG.1, an apparatus for dispensing droplet (100) according to example embodiments of the invention may be configured to discharge droplets onto a substrate (10) in manufacturing processes for a display device such as an organic electroluminescence (EL) device, particularly to discharge the droplets onto the substrate (10) for forming a plurality of pixels (11) on the substrate (10). In example embodiments of the invention, each of the plurality of pixels (11) may be formed to have the same size and the plurality of pixels (11) may be formed on the substrate (10) in a first direction and in a second direction perpendicular to the first direction. Further, each of the plurality of pixels (11) may have a rectangular structure including one side having a length of m in the first direction and another side having a length of n in the second direction such that the rectangular structure may have a size of m×n. The apparatus for dispensing droplet (100) according to example embodiments of the invention may include a droplet discharging member (13), a stage (15), a gantry (16), a control member (20), etc. The stage (15) may receive and support the substrate (10) while providing the droplets onto the substrate (10) such that the stage (15) may have a size which may sufficiently receive the substrate (10) and may not affect the transference of the substrate (10). In example embodiments of the invention, the plurality of pixels (11) having the same size may be formed on the substrate (10) placed on the stage (15) wherein the pixels (11) may be disposed on the substrate (10) in the first direction and the second direction. The stage (15) may float the substrate (10) thereover while the droplets are discharged onto the substrate (10) to form the pixels (11), and thus the stage (15) may be a floating stage. In particular, the stage (15) may be disposed in an area of the apparatus for dispensing droplet where the droplets are discharged such that the distance between the stage (15) and the substrate (10) floating over the stage (15) may be precisely adjusted. Thus, the stage (15) may simultaneously provide an air spray and a vacuum suction toward a bottom face of the substrate (10) in order to precisely float the substrate (10) over the stage (15) by spraying the air and by providing the vacuum suction. The droplet discharging member (13) may provide the droplets onto the substrate (10) located over the stage (15). The droplet discharging member (13) may discharge the droplets onto the substrate (10) while transferring the substrate (10) along the stage (15), and may be fixed over the substrate (10) so as to downwardly provide the droplets onto the substrate (10) transferred over the stage (15). In example embodiments of the invention, the droplet discharging member (13) may include a plurality of nozzles arranged in the first direction by constant intervals, and thus the droplet discharging member (13) may be the ink jet head capable of discharging the droplets onto the substrate (10) from a plurality of nozzles thereof. The droplet discharging member (13) may additionally include a plurality of piezoelectric elements disposed adjacent to the plurality of nozzles, respectively. The number of the piezoelectric elements may be the same as the number of the nozzles. The nozzles may discharge the droplets onto the substrate (10) by the operations of the piezoelectric elements. That is, each of the piezoelectric elements may operate to enable each of the nozzles to spray the droplets onto each of regions of the substrate (10). Particularly, the amounts of the droplets provided from the nozzles may be adjusted by controlling voltages applied to the piezoelectric elements, respectively. The gantry (16) may support the droplet discharging member (13) and may move along the stage (15) such that the droplet discharging member (13) may provide the droplets onto the substrate (10) transferred over the stage (15). In example embodiments of the invention, the gantry (16) may be disposed across the stage (15) in the first direction, and also the droplet discharging member (13) may be moved along with the gantry (16) in the first direction so as to discharge the droplets onto the regions of the substrate (10). In the process for discharging the droplets onto the substrate (10) using the apparatus for dispensing droplet (100) according to example embodiments of the invention, the droplets may be sprayed onto the substrate (10) from the nozzles of the droplet discharging member (13) while moving the substrate (10) positioned over the stage (15) along the second direction. FIG.2is a diagram illustrating a transferring member of the apparatus for dispensing droplet shown inFIG.1. Referring toFIG.2, the apparatus for dispensing droplet (100) may additionally include a transferring member (21) wherein the transferring member (21) may move the substrate (10) placed on or over the stage (15) along the second direction in the process for dispensing the droplets onto the substrate (10). The transferring member (21) may include a holding member (23) capable of holding one end portion or two end portions of the substrate (10), a guide rail (27) being disposed in parallel with the stage (15) adjacent to one side of the stage (15), and a driving member (25) capable of applying a driving force to the holding member (23) to move the holding member (23) along with the substrate (10). Alternatively, two guide rails (27) may be disposed adjacent to both sides of the stage (15), respectively. The holding member (23) may be disposed on the guide rail (27) such that the holding member (23) may be transferred along the guide rail (27) by the driving force applied from the driving member (25). The holding member (23) may hold the one end portion or the two end portions of the substrate (10) through a vacuum suction. Alternatively, the holding member (23) may directly grip the one end portion or the two end portions of the substrate (10). As described above, in the process for discharging the droplets onto the substrate (10) using the apparatus for dispensing droplet (100) according to example embodiments of the invention, the droplets may be discharged onto the substrate (10) from the droplet discharging member (13) coupled to the gantry (16) while transferring the substrate (10) positioned on or over the stage (15) such that the droplets may be provided onto the regions of the substrate (10), respectively, for forming the plurality of pixels (11). Meanwhile, the amounts of the droplets may be different at the regions of the substrate (10) for the plurality of pixels (11) because the numbers of nozzles of the droplet discharging member (13) relative to the sides of the regions of the substrate (10) for the plurality of pixels (11) along the first direction. Considering the above mentioned problem, the apparatus for dispensing droplet (100) according to example embodiments of the invention may include the control member (20) to control the droplet discharge member (13) so that the amounts of the droplets sprayed from the nozzles of the droplet discharge member (13) may be substantially identical at the regions of the substrate (10) for the pixels (11) while discharging the droplets onto the substrate (10) even though the numbers of nozzles of the droplet discharging member (13) with respect to the sides of the regions of the substrate (10) for the pixels (11) along the first direction. FIG.3is a diagram illustrating a method of adjusting the amounts of the droplets and the patterns of the discharged droplets in the regions of the substrate for the pixels using the apparatus for dispensing droplet inFIG.1. Referring toFIG.3, the plurality of pixels (11) having the same size may be formed on the regions of the substrate along the first direction and the second direction such that the plurality of pixels (11), for example, a first pixel (11a), a second pixel (11b) and a third pixel (11c) may be formed on the substrate in the first direction. In the example embodiments of the invention, each of the plurality of pixels (11) may include one side having a length of m along the first direction and another side having a length of n along the second direction such that each of the plurality of pixels (11) may have a size of m×n. In the process for discharging the droplets onto the substrate (10) using the apparatus for dispensing droplet (100) according to example embodiments of the invention, the droplets may be discharged onto the substrate (10) from the droplet discharging member (13) including the plurality of nozzles (31) arranged in the first direction while transferring the substrate (10) including the plurality of regions for the plurality of pixels (11) having the first pixel (11a), the second pixel (11b) and the third pixel (11c) along the second direction. Thus, patterns of discharged droplets may be formed at the regions of the substrate (10) for the plurality of pixels (11) having the first pixel (11a), the second pixel (11b) and the third pixel (11c). As described above, the numbers of the nozzles (31) of the droplet discharging member (13) may be different with respect to the sides of the plurality of pixels (11) along the first direction because the distance between adjacent pixels (11) are substantially different from the interval between adjacent nozzles (31) of the droplet discharging member (13). For example, as shown inFIG.3, in the patterns of the discharged droplets in the first pixel (11a), the second pixel (11b) and the third pixel (11c), the first pixel (11a) may include twelve patterns of the discharged droplets therein in addition to four patterns of the discharged droplets at a right boundary thereof. Additionally, the second pixel (11b) may include twelve patterns of the discharged droplets therein and the third pixel (11c) may include sixteen patterns of the discharged droplets therein. Moreover, four patterns of the discharged droplets may be formed between adjacent pixels. In this case, the first pixel (11a) and the third pixel (11c) may be determined as fails if the process for discharging the droplets is decided based on the patterns in the second pixel (11b). Considering the above problems, in the apparatus for dispensing droplet (100) according to example embodiments of the invention, the control member (20) may control the droplet discharging member (13) based on the patterns of the discharged droplets such that the droplet discharge member (13) may adjust the amounts of the droplets in the regions of the substrate (10) for the pixels (11). As a result, the amounts of the droplets may be substantially identical at the pixels (11) formed on the substrate (10) even though the numbers of the nozzles (31) of the droplet discharging member (13) may be different relative to the sides of the pixels (11) along the first direction. In other words, the apparatus for dispensing droplet (100) according to example embodiments of the invention may provide the droplets onto the substrate (10) such that all of the first pixel (11a), the second pixel (11b) and the third pixel (11c) may have twelve patterns therein. Particularly, the control member (20) may control the droplet discharging member (13) such that the nozzles (31) of the droplet discharging member (13) may not spray the droplets at the right boundary of the first pixel (11a) to form twelve patterns in the first pixel (11a), may spray the droplets to form twelve patterns in the second pixel (11b), and may spray the droplets to form twelve patterns in the third pixel (11c). As such, the control member (20) may adjust the amounts of the droplets provided from the nozzles (31) onto the substrate (10) by controlling the droplet discharging member (13) so that the amounts of the droplets may be substantially identical in the regions of the substrate (10) for the pixels (11) even though the patterns of the discharged droplets are substantially different in the regions of the substrate (10). In this case, the control member (20) may control the droplet discharging member (13) such that the discharges of the droplets from the nozzles (31) may be different so as to provide the droplets onto the regions of the substrate (10) for the pixels (11) with the substantially same amount. That is, the control member (20) may adjust the nozzles (31) of the droplet discharging member (13) so that each of the pixels (11) may have substantially the same patterns of the discharged droplet although the distance between adjacent pixels (11) are substantially different from the interval between adjacent nozzles (31) of the droplet discharging member (13). In particular, the control member (20) may determine whether each of the nozzles (31) may spray the droplets onto the substrate (10) or not while the nozzles (31) of the droplet discharging member (13) moves over the substrate (10). Thus, the control member (20) may adjust the amounts of the droplets in the regions of the substrate (10) for the pixels (11) although the patterns of the discharged droplets are substantially different in the regions of the substrate (10) for the pixels (11). In this case, the control member (20) may control the operations of the piezoelectric elements by adjusting the voltage applied to the piezoelectric elements such that the piezoelectric elements may independently control the operations of the nozzles (31). Further, the control member (20) may control the nozzles (31) based on the region of the substrate (10) on which the minimum amount of the droplets is provided from the nozzles (31) such that the amounts of the discharged droplets are substantially identical in the regions of the substrate (10) for the pixels (11). For example, as shown inFIG.3, when the second pixel (11b) has twelve patterns of the discharged droplets, the control member (20) may adjust the amounts of the discharged droplets in the first pixel (11a) and the third pixel (11c) based on the amount of the discharged droplets in the second pixel (11b) by controlling the nozzles (31) of the droplet discharging member (13) so that each of the first pixel (11a) and the third pixel (11c) may also have twelve patterns of the discharged droplets. In this case, the patterns of the discharged droplets may vary in the pixels (11) by controlling the nozzles (31) of the droplet discharging member (13) with the control member (20). Moreover, the control member (20) may adjust the amounts of the droplets discharged from the droplet discharging member (13) by controlling the speed of the substrate (10) transferred over the stage (15) and the discharge frequencies for the spraying of the droplets from the nozzles (31) besides the nozzles (31) of the droplet discharging member (13) such that the amounts of the discharged droplets may be more accurately identical in the regions of the substrate (10) for the pixels (11) although the patterns of the discharged droplets are substantially different in the regions of the substrate (10) for the pixels (11). According to example embodiments of the invention, the apparatus for dispensing droplet (100) may include the control member (20) capable of adjusting the amounts of the droplets discharged from the droplet discharging member (13) onto the substrate (10) for the plurality of pixels (11) such that the amounts of the discharged droplets may be substantially identical in the regions of the substrate (10) for the plurality of pixels (11) even though the distance between adjacent pixels (11) are substantially different from the interval between adjacent nozzles (31) of the droplet discharging member (13). Therefore, the failure of the process for discharging the droplets may be prevented and the pixels (11) formed on the substrate (10) may be uniform. Further, the control member (20) according to example embodiments of the invention may identify the patterns of the discharged droplets in the regions of the substrate (10) for the pixels (11) and may control the droplet discharging member (13) so that the amounts of the discharged droplets may be substantially identical in the regions of the substrate (10) for the pixels (11) although the numbers of nozzles of the droplet discharging member (13) with respect to the sides of the regions of the substrate (10) for the pixels (11) along the first direction. INDUSTRIAL APPLICABILITY According to example embodiments of the invention, the apparatus for dispending droplet may be advantageously used in the processes for manufacturing a display device such as an organic electroluminescent (EL) device because the apparatus for dispending droplet may uniformly provide droplets onto a substrate for forming pixels of the display device. The foregoing is illustrative of embodiments and is not to be construed as limiting thereof. Although a few embodiments have been described, those skilled in the art will readily appreciate that many modifications are possible in the embodiments without materially departing from the novel teachings and advantages of the invention. Accordingly, all such modifications are intended to be included within the scope of the invention as defined in the claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Therefore, it is to be understood that the foregoing is illustrative of various embodiments and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims. DESCRIPTION OF REFERENCE NUMERALS 10: substrate11: pixels13: droplet discharging member15: stage16: gantry20: control member21: transferring member31: nozzles100: apparatus for dispensing droplet | 20,480 |
11858265 | DETAILED DESCRIPTION In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific examples in which the disclosure may be practiced. It is to be understood that other examples may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present disclosure is defined by the appended claims. It is to be understood that features of the various examples described herein may be combined, in part or whole, with each other, unless specifically noted otherwise. There may be advantages to having an integrated circuit (e.g., a semiconductor die) behave differently for various geographic regions, for subscription or non-subscription customers, or for other reasons. Rather than fabricate multiple physical integrated circuits designed to behave differently that may have to be tracked individually or managed separately, it may be easier to write some non-volatile memory bits to an integrated circuit (e.g., during manufacturing) to change the behavior of the integrated circuit. Accordingly, disclosed herein are integrated circuits (e.g., fluid ejection dies) including a plurality of memory cells each storing a customization bit. In one example, the customization bits may be used to modify an address input to the die by summing the customization bits with an address from a nozzle data stream to generate a modified address. The modified address may be used to fire fluid actuation devices or to access memory cells corresponding to the fluid actuation devices based on the modified address. In other examples, the customization bits may be used to configure other operations of the integrated circuit as will be described below. As used herein a “logic high” signal is a logic “1” or “on” signal or a signal having a voltage about equal to the logic power supplied to an integrated circuit (e.g., between about 1.8 V and 15 V, such as 5.6 V). As used herein a “logic low” signal is a logic “0” or “off” signal or a signal having a voltage about equal to a logic power ground return for the logic power supplied to the integrated circuit (e.g., about 0 V). FIG.1Ais a block diagram illustrating one example of an integrated circuit100to drive a plurality of fluid actuation devices. Integrated circuit100includes a plurality of memory cells1020to102N, where “N” is any suitable number of memory cells (e.g., four memory cells). Integrated circuit100also includes control logic106. Control logic106is electrically coupled to each memory cell1020to102Nthrough a signal path1010to101N, respectively. Each first memory cell1020to102Nstores a customization bit. Each first memory cell1020to102Nmay include a non-volatile memory cell (e.g., a floating gate transistor, a programmable fuse, a write-once memory cell, etc.). Control logic106may include a microprocessor, an application-specific integrated circuit (ASIC), or other suitable logic circuitry for controlling the operation of integrated circuit100. Control logic106may prevent external read access to the plurality of memory cells1020to102N. Write access to the plurality of memory cells1020to102Nmay be disabled once the customization bits are written to the memory cells1020to102N, such as by writing a lock bit as will be described below with reference ofFIG.3. Control logic106may configure an operation of the integrated circuit100based on the customization bits. In one example, the operation may be to modify an address input to the integrated circuit100based on the customization bits. In another example, read and/or write access to further memory cells (e.g., memory cells130to be described below with reference toFIG.1B) of the integrated circuit or a subset of the further memory cells may be prevented or allowed based on the customization bits. In yet another example, a data stream (e.g., a nozzle data stream) or at least portions of a data stream received by the integrated circuit100may be inverted based on the customization bits. The data stream or portions of the data stream may be inverted anywhere along the data stream path. Multiple customization bits may be used for multiple inversion points. In yet another example, the behavior of bits stored in a configuration register (not shown) of the integrated circuit100may be modified based on the customization bits. For example, delays bits in the configuration register for setting a delay of a function of the integrated circuit100may be reversed and/or encoded based on the customization bits. In any case, a single customization bit or a subset of the customization bits may be used to configure a single operation of the integrated circuit100. Accordingly, the customization bits may be used to configure multiple operations of the integrated circuit100, where each operation is configured based on different customization bits. FIG.1Bis a block diagram illustrating another example of an integrated circuit120to drive a plurality of fluid actuation devices. Integrated circuit120includes a plurality of first memory cells1020to1023and control logic106. In addition, integrated circuit120includes fluid actuation devices128and a plurality of second memory cells130. In this example, control logic106includes an address modifier122. Address modifier122is electrically coupled to an address signal path124, each first memory cell1020to1023through a signal path1010to1013, respectively, and the fluid actuation devices128and the plurality of second memory cells130through a modified address signal path126. Each of the plurality of second memory cells130includes a non-volatile memory cell (e.g., a floating gate transistor, a programmable fuse, etc.). In one example, fluid actuation devices128include nozzles or fluidic pumps to eject fluid drops. In this example, there are four memory cells1020to1023to store four customization bits. The customization bits define the integrated circuit120as one of 16 unique integrated circuits. Each of the 16 unique integrated circuits operates differently due to the stored customization bits. Address modifier122receives an address through address signal path124. In one example, the address is part of a nozzle data stream input to the integrated circuit120from a host print apparatus, such as fluid ejection system700to be described below with reference toFIG.7. Address modifier122also receives the stored customization bit from each first memory cell1020to1023. Address modifier122modifies the address input to the integrated circuit120based on the customization bits to provide a modified address on signal path126. In one example, control logic106fires fluid actuation devices128based on the modified address. In another example, control logic106accesses a second memory cell130based on the modified address. FIG.2illustrates one example of an address modifier122. In this example, address modifier122is a four bit adder. A first input of four bit adder122receives four address bits (ADDR0, ADDR1, ADDR2, and ADDR3) through signal path124. A second input of four bit adder122receives four customization bits (CUST0, CUST1, CUST2, and CUST3) through signal paths1010to1013, respectively. Four bit adder122sums the four address bits and the four customization bits to generate a modified address including four bits on signal path126. In one example, the most significant bit resulting from the summing is discarded. FIG.3is a block diagram illustrating another example of an integrated circuit200to drive a plurality of fluid actuation devices. Integrated circuit200includes a plurality of first memory cells2020to202N, a plurality of first storage elements2040to204N, and control logic206. In addition, integrated circuit200includes a second memory cell222, a second storage element224, a write circuit230, and a read circuit232. Control logic206is electrically coupled to each first memory cell2020to202Nthrough a signal path2010to201N, respectively, to each first storage element2040to204Nthrough a signal path2030to203N, respectively, and to a reset signal path210. Each first memory cell2020to202Nis electrically coupled to a corresponding first storage element2040to204Nthrough a signal path2080to208N, respectively. Control logic206is also electrically coupled to second memory cell222through a signal path221and to storage element224through a signal path223. The second memory cell222is electrically coupled to the storage element224through a signal path228. Each first memory cell2020to202N, the second memory cell222, the write circuit230, and the read circuit232are electrically coupled to a single interface (e.g., a single wire)234. Read circuit232is electrically coupled to an interface (e.g., sense interface)236. The reset signal path210may be electrically coupled to a reset interface, which may be a contact pad, a pin, a bump, a wire, or another suitable electrical interface for transmitting signals to and/or from integrated circuit200. The reset interface may be electrically coupled to a fluid ejection system (e.g., a host print apparatus such as fluid ejection system700, which will be described below with reference toFIG.7). The sense interface236may be a contact pad, a pin, a bump, a wire, or another suitable electrical interface for transmitting signals to and/or from integrated circuit200. The sense interface236may be electrically coupled to a fluid ejection system (e.g., a host print apparatus such as fluid ejection system700ofFIG.7). Each first memory cell2020to202Nstores a customization bit. Each first memory cell2020to202Nincludes a non-volatile memory cell (e.g., a floating gate transistor, a programmable fuse, etc.). Each first storage element2040to204Nincludes a latch or another suitable circuit that outputs a logic signal (i.e., a logic high signal or a logic low signal) that may be directly used by digital logic. Control logic206may include a microprocessor, an application-specific integrated circuit (ASIC), or other suitable logic circuitry for controlling the operation of integrated circuit200. Control logic206, in response to a reset signal on reset signal path210, reads (e.g., in response to a first edge of the reset signal) the customization bit stored in each first memory cell2020to202Nand latches (e.g., in response to a second edge of the reset signal) each customization bit in a corresponding first storage element2040to204N. In one example, control logic206configures an operation of integrated circuit200based on the latched customization bits. In one example, the operation may modify an address input to the integrated circuit200based on the latched customization bits. In other examples, other operations of integrated circuit200may be modified based on the latched customization bits as previously described above. The second memory cell222stores a lock bit. The second memory cell222includes a non-volatile memory cell (e.g., a floating gate transistor, a programmable fuse, etc.). The second storage element224includes a latch or another suitable circuit that outputs a logic signal (i.e., a logic high signal or a logic low signal) that may be directly used by digital logic. Control logic206, in response to the reset signal, reads (e.g., in response to a first edge of the reset signal) the lock bit stored in the second memory cell222and latches (e.g., in response to a second edge of the reset signal) the lock bit in the second storage element224. In addition, control logic206allows or prevents writing to the plurality of first memory cells2020to202Nbased on the latched lock bit. In one example, control logic206also allows or prevents writing to the second memory cell222based on the latched lock bit. For example, if a “0” lock bit is stored in the second memory cell222, the customization bits stored in first memory cells2020to202Nmay be modified. Once a “1” lock bit is written to second memory cell222, the customization bits stored in first memory cells2020to202Ncannot be modified and the lock bit stored in the second memory cell222cannot be modified. The write circuit230writes the corresponding customization bit to each of the plurality of first memory cells2020to202Nthrough the single interface234. The write circuit230may also write the lock bit to the second memory cell222through the single interface234. In one example, write circuit230may include a voltage regulator and/or other suitable logic circuitry for writing customization bits to first memory cells2020to202Nand the lock bit to second memory cell222. The read circuit232enables external access (e.g., via sense interface236) to read the customization bit of each of the plurality of first memory cells2020to202Nthrough the single interface234. The read circuit232may also enable external access (e.g., via sense interface236) to read the lock bit of the second memory cell222through the single interface234. In one example, read circuit232may include transistor switches or other suitable logic circuitry for enabling external read access to first memory cells2020to202Nand second memory cell222through sense interface236. In one example, control logic206allows or prevents external read access to the plurality of first memory cells2020to202Nand to second memory cell222based on the latched lock bit. For example, if a “0” lock bit is stored in the second memory cell222, the customization bits stored in first memory cells2020to202Nand the lock bit stored in the second memory cell222may be read through read circuit232. Once a “1” lock bit is written to second memory cell222, the customization bits stored in first memory cells2020to202Nand the lock bit stored in the second memory cell222cannot be read through read circuit232. FIG.4Ais a schematic diagram illustrating one example of a circuit300for accessing a memory cell storing a customization bit. In one example, circuit300is part of integrated circuit100ofFIG.1A, integrated circuit120ofFIG.1B, or integrated circuit200ofFIG.3. Circuit300includes a memory cell302, a latch304, an internal (reset) read voltage regulator306, a write voltage regulator308, an inverter310, AND gates312and316, OR gates314and318, transistors320and322, and a sense pad324. Memory cell302includes a floating gate transistor330and transistors332,334, and336. The input of inverter310is electrically coupled to a lock signal path340. The output of inverter310is electrically coupled to a first input of AND gate312through a signal path311. A second input of AND gate312is electrically coupled to a customization bit enable signal path338. A third input of AND gate312is electrically coupled to a select signal (ADDR[X], which corresponds to one of Y address bits from a nozzle data stream, where “Y” is any suitable number of bits (e.g., 4)) path342. The output of AND gate312is electrically coupled to a first input of OR gate314through a signal path313. A second input of OR gate314is electrically coupled to a reset signal path344. The output of OR gate314is electrically coupled to the gate of transistor332of memory cell302and the gate (G) input of latch304through a signal path315. A first input of AND gate316is electrically coupled to a write enable signal path346. A second input of AND gate316is electrically coupled to a fire signal path348. The output of AND gate316is electrically coupled to the gate of transistor334of memory cell302through a signal path317. A first input of OR gate318is electrically coupled to the fire signal path348. A second input of OR gate318is electrically coupled to the reset signal path344. The output of OR gate318is electrically coupled to the gate of transistor336of memory cell302through a signal path319. An input of internal (reset) read voltage regulator306is electrically coupled to the reset signal path344. An output of internal (reset) read voltage regulator306is electrically coupled to one side of the source-drain path of floating gate transistor330of memory cell302through a signal path323. An input of write voltage regulator308is electrically coupled to a memory write signal path350. An output of write voltage regulator308is electrically coupled to one side of the source-drain path of floating gate transistor330of memory cell302through signal path323. Sense pad324is electrically coupled to one side of the source-drain path of transistor320. The gate of transistor320and the gate of transistor322are electrically coupled to a read enable signal path352. The other side of the source-drain path of transistor320is electrically coupled to one side of the source-drain path of transistor322through a signal path321. The other side of the source-drain path of transistor322is electrically coupled to one side of the source-drain path of floating gate transistor330of memory cell302through signal path323. The other side of the source-drain path of floating gate transistor330is electrically coupled to one side of the source-drain path of transistor332and the data (D) input of latch304through a signal path331. Another input of latch304is electrically coupled to a preset signal path354. The output (Q) of latch304is electrically coupled to a customization bit signal path356. The other side of the source-drain path of transistor332is electrically coupled to one side of the source-drain path of transistor334and one side of the source-drain path of transistor336through a signal path333. The other side of the source-drain path of transistor334is electrically coupled to a common or ground node335. The other side of the source-drain path of transistor336is electrically coupled to a common or ground node335. While circuit300includes one memory cell302for storing a customization bit and one corresponding latch304, circuit300may include any suitable number of memory cells302and corresponding latches304for storing a desired number of customization bits. For each customization bit, each memory cell and corresponding latch would be accessed in a similar manner as described for memory cell302and latch304. Circuit300receives a customization enable signal on customization enable signal path338, a lock signal on lock signal path340, an address or select signal on select signal path342, a reset signal on reset signal path344, a write enable signal on write enable signal path346, a fire signal on fire signal path348, a memory write signal on memory write signal path350, a read enable signal on read enable signal path352, and a preset signal on preset signal path354. The preset signal may be used to override latch304during testing to output a desired logic level from latch304. The customization enable signal and the lock signal may be used to enable or disable write access and external read access to the memory cells storing customization bits. The address signal may be used to select one of the memory cells storing a customization bit. The customization enable signal, the write enable signal, the memory write signal, the read enable signal, and the preset signal may be based on data stored in a configuration register (not shown) or based on data received from a host print apparatus. The lock signal is an internal signal output from a latch, such as storage element224ofFIG.3. The address signal is received from a host print apparatus, such as through a data interface. The reset signal may be received from a host print apparatus through a reset interface. The fire signal may be received from a host print apparatus through a fire interface. Each of the data interface, the reset interface, and the fire interface may include a contact pad, a pin, a bump, a wire, or another suitable electrical interface for transmitting signals to and/or from circuit300. Each of the data interface, the reset interface, the fire interface, and the sense pad324may be electrically coupled to a fluid ejection system (e.g., a host print apparatus such as fluid ejection system700ofFIG.7). Inverter310receives the lock signal and outputs an inverted lock signal on signal path311. In response to a logic high customization enable signal, a logic high inverted lock signal, and a logic high select signal, AND gate312outputs a logic high signal on signal path313. In response to a logic low customization enable signal, a logic low inverted lock signal, or a logic low select signal, AND gate312outputs a logic low signal on signal path313. In response to a logic high signal on signal path313or a logic high reset signal, OR gate314outputs a logic high signal on signal path315. In response to a logic low signal on signal path313and a logic low reset signal, OR gate314outputs a logic low signal on signal path315. In response to a logic high write enable signal and a logic high fire signal, AND gate316outputs a logic high signal on signal path317. In response to a logic low write enable signal or a logic low fire signal, AND gate316outputs a logic low signal on signal path317. In response to a logic high fire signal or a logic high reset signal, OR gate318outputs a logic high signal on signal path319. In response to a logic low fire signal and a logic low reset signal, OR gate318outputs a logic low signal on signal path319. In response to a logic high signal on signal path315, transistor332is turned on (i.e., conducting) to enable access to memory cell302. In response to a logic low signal on signal path315, transistor332is turned off to disable access to memory cell302. In response to a logic high signal on signal path317, transistor334is turned on to enable write access to memory cell302. In response to a logic low signal on signal path317, transistor334is turned off to disable write access to memory cell302. In response to a logic high signal on signal path319, transistor336is turned on to enable read access to memory cell302. In response to a logic low signal on signal path319, transistor336is turned off to disable read access to memory cell302. In one example, transistor334is a stronger device and transistor336is a weaker device. Therefore, the stronger device may be used to enable write access and the weaker device may be used to enable read access to improve the margin for latching the voltage on signal path331. In response to a logic high reset signal, internal (reset) read voltage regulator306is enabled to output a read voltage bias to signal path323. In response to logic low reset signal, internal (reset) read voltage regulator306is disabled. Accordingly, in response to the reset signal transitioning from a logic low to a logic high, transistors332and336turn on and internal (reset) read voltage regulator306is enabled to read the state (i.e., resistance representing the stored customization bit) of floating gate transistor330. The state of floating gate transistor330is passed to the data (D) input of latch304(i.e., as a voltage representing the stored customization bit). In response to the reset signal transitioning from logic high to logic low, the customization bit stored in floating gate transistor330is latched by latch304, transistors332and336turn off, and the internal (reset) read voltage regulator306is disabled. As a result, the customization bit is then available on the output (Q) of latch304and therefore on customization bit signal path356for use in other digital logic. In response to a logic high read enable signal, transistors320and322are turned on to enable external access to memory cell302through sense pad324. In response to a logic low read enable signal, transistors320and322are turned off to disable external access to memory cell302through sense pad324. Accordingly, in response to a logic high customization enable signal, a logic low lock signal, a logic high address signal, a logic high read enable signal, and a logic high fire signal, transistors320,322,332and336are turned on to allow floating gate transistor330to be read through sense pad324by an external circuit. In response to a logic high memory write signal, write voltage regulator308is enabled to apply a write voltage to signal path323. In response to a logic low memory write signal, write voltage regulator308is disabled. Accordingly, in response to a logic high customization enable signal, a logic low lock signal, a logic high address signal, a logic high write enable signal, a logic high memory write signal, and a logic high fire signal, transistors332,334, and336are turned on to allow floating gate transistor330to be written by write voltage regulator308. FIG.4Bis a schematic diagram illustrating one example of a circuit370for accessing a memory cell storing a lock bit. In one example, circuit370is part of integrated circuit200ofFIG.3. Circuit370is similar to circuit300previously described and illustrated with reference toFIG.4A, except that in circuit370, memory cell302is replaced with a memory cell372and latch304is replaced with a latch374. Memory cell372stores a lock bit and latch374latches the lock bit in response to the reset signal. Memory cell372is similar to memory cell302previously described. Latch374is similar to latch304previously described, except that latch374does not include a preset signal input. The output (Q) of latch374provides the lock signal on lock signal path340, which is an input to inverter310(see also inverter310ofFIG.4A). In place of a select signal input to AND gate312, a nozzle data lock bit signal is input to AND gate312through a nozzle data lock bit signal path376. The nozzle data lock bit signal may be used to select memory cell372. The nozzle data lock bit signal may be based on data received from a host print apparatus, such as through a data interface. Memory cell372may be enabled for write or read access similarly to memory cell302ofFIG.4Aas previously described. FIG.5illustrates one example of a fluid ejection device500. Fluid ejection device500includes a sense interface502, a first fluid ejection assembly504and a second fluid ejection assembly506. First fluid ejection assembly504includes a carrier508and a plurality of elongate substrates510,512, and514(e.g., fluid ejection dies, which will be described below with reference toFIG.6). Carrier508includes electrical routing516coupled to an interface (e.g., sense interface) of each elongate substrate510,512, and514and to sense interface502. Second fluid ejection assembly506includes a carrier520and an elongate substrate522(e.g., a fluid ejection die). Carrier520includes electrical routing524coupled to an interface (e.g., sense interface) of the elongate substrate522and to sense interface502. In one example, first fluid ejection assembly504is a color (e.g., cyan, magenta, and yellow) inkjet or fluid-jet print cartridge or pen and second fluid ejection assembly506is a black inkjet or fluid-jet print cartridge or pen. In one example, each elongate substrate510,512,514, and522includes an integrated circuit100ofFIG.1A, an integrated circuit120ofFIG.1B, an integrated circuit200ofFIG.3, or circuits300and/or370ofFIGS.4A and4B. Accordingly, sense interface502may be electrically coupled to the sense interface236(FIG.3) or sense pad324(FIGS.4A and4B) of each elongate substrate. Memory cells of each elongate substrate510,512,514, and522may be accessed through sense interface502and electrical routing516and524. In one example, the customization bits of each elongate substrate510,512, and514of first fluid ejection assembly504vary between each elongate substrate. In one example, each elongate substrate510,512,514, and522includes four non-volatile memory cells to store four customization bits. Therefore, the customization bits may define the fluid ejection assembly504as one of 4096 unique fluid ejection devices and the fluid ejection assembly506as one of 16 unique fluid ejection devices. FIG.6Aillustrates one example of a fluid ejection die600andFIG.6Billustrates an enlarged view of the ends of fluid ejection die600. In one example, fluid ejection die600includes integrated circuit100ofFIG.1A, integrated circuit120ofFIG.1B, integrated circuit200ofFIG.3, or circuits300and/or370ofFIGS.4A and4B. Die600includes a first column602of contact pads, a second column604of contact pads, and a column606of fluid actuation devices608. The second column604of contact pads is aligned with the first column602of contact pads and at a distance (i.e., along the Y axis) from the first column602of contact pads. The column606of fluid actuation devices608is disposed longitudinally to the first column602of contact pads and the second column604of contact pads. The column606of fluid actuation devices608is also arranged between the first column602of contact pads and the second column604of contact pads. In one example, fluid actuation devices608are nozzles or fluidic pumps to eject fluid drops. In one example, the first column602of contact pads includes six contact pads. The first column602of contact pads may include the following contact pads in order: a data contact pad610, a clock contact pad612, a logic power ground return contact pad614, a multipurpose input/output contact (e.g., sense) pad616, a first high voltage power supply contact pad618, and a first high voltage power ground return contact pad620. Therefore, the first column602of contact pads includes the data contact pad610at the top of the first column602, the first high voltage power ground return contact pad620at the bottom of the first column602, and the first high voltage power supply contact pad618directly above the first high voltage power ground return contact pad620. While contact pads610,612,614,616,618, and620are illustrated in a particular order, in other examples the contact pads may be arranged in a different order. In one example, the second column604of contact pads includes six contact pads. The second column604of contact pads may include the following contact pads in order: a second high voltage power ground return contact pad622, a second high voltage power supply contact pad624, a logic reset contact pad626, a logic power supply contact pad628, a mode contact pad630, and a fire contact pad632. Therefore, the second column604of contact pads includes the second high voltage power ground return contact pad622at the top of the second column604, the second high voltage power supply contact pad624directly below the second high voltage power ground return contact pad622, and the fire contact pad632at the bottom of the second column604. While contact pads622,624,626,628,630, and632are illustrated in a particular order, in other examples the contact pads may be arranged in a different order. Data contact pad610may be used to input serial data to die600for selecting fluid actuation devices, memory bits, thermal sensors, configuration modes (e.g. via a configuration register), etc. Data contact pad610may also be used to output serial data from die600for reading memory bits, configuration modes, status information (e.g., via a status register), etc. Clock contact pad612may be used to input a clock signal to die600to shift serial data on data contact pad610into the die or to shift serial data out of the die to data contact pad610. Logic power ground return contact pad614provides a ground return path for logic power (e.g., about 0 V) supplied to die600. In one example, logic power ground return contact pad614is electrically coupled to the semiconductor (e.g., silicon) substrate640of die600. Multipurpose input/output contact pad616may be used for analog sensing and/or digital test modes of die600. In one example, multipurpose input/output contact (e.g., sense) pad616may provide sense interface236ofFIG.3or sense pad324ofFIGS.4A and4B. First high voltage power supply contact pad618and second high voltage power supply contact pad624may be used to supply high voltage (e.g., about 32 V) to die600. First high voltage power ground return contact pad620and second high voltage power ground return contact pad622may be used to provide a power ground return (e.g., about 0 V) for the high voltage power supply. The high voltage power ground return contact pads620and622are not directly electrically connected to the semiconductor substrate640of die600. The specific contact pad order with the high voltage power supply contact pads618and624and the high voltage power ground return contact pads620and622as the innermost contact pads may improve power delivery to die600. Having the high voltage power ground return contact pads620and622at the bottom of the first column602and at the top of the second column604, respectively, may improve reliability for manufacturing and may improve ink shorts protection. Logic reset contact pad626may be used as a logic reset input to control the operating state of die600. In one example, logic reset contact pad626may be electrically coupled to reset signal path210ofFIG.3or reset signal path344ofFIGS.4A and4B. Logic power supply contact pad628may be used to supply logic power (e.g., between about 1.8 V and 15 V, such as 5.6 V) to die600. Mode contact pad630may be used as a logic input to control access to enable/disable configuration modes (i.e., functional modes) of die600. Fire contact pad632may be used as a logic input to latch loaded data from data contact pad610and to enable fluid actuation devices or memory elements of die600. In one example, fire contact pad632may be electrically coupled to fire signal path348ofFIGS.4A and4B. Die600includes an elongate substrate640having a length642(along the Y axis), a thickness644(along the Z axis), and a width646(along the X axis). In one example, the length642is at least twenty times the width646. The width646may be 1 mm or less and the thickness644may be less than 500 microns. The fluid actuation devices608(e.g., fluid actuation logic) and contact pads610-632are provided on the elongate substrate640and are arranged along the length642of the elongate substrate. Fluid actuation devices608have a swath length652less than the length642of the elongate substrate640. In one example, the swath length652is at least 1.2 cm. The contact pads610-632may be electrically coupled to the fluid actuation logic. The first column602of contact pads may be arranged near a first longitudinal end648of the elongate substrate640. The second column604of contact pads may be arranged near a second longitudinal end650of the elongate substrate640opposite to the first longitudinal end648. FIG.7is a block diagram illustrating one example of a fluid ejection system700. Fluid ejection system700includes a fluid ejection assembly, such as printhead assembly702, and a fluid supply assembly, such as ink supply assembly710. In the illustrated example, fluid ejection system700also includes a service station assembly704, a carriage assembly716, a print media transport assembly718, and an electronic controller720. While the following description provides examples of systems and assemblies for fluid handling with regard to ink, the disclosed systems and assemblies are also applicable to the handling of fluids other than ink. Printhead assembly702includes at least one printhead or fluid ejection die600previously described and illustrated with reference toFIGS.6A and6B, which ejects drops of ink or fluid through a plurality of orifices or nozzles608. In one example, the drops are directed toward a medium, such as print media724, so as to print onto print media724. In one example, print media724includes any type of suitable sheet material, such as paper, card stock, transparencies, Mylar, fabric, and the like. In another example, print media724includes media for three-dimensional (3D) printing, such as a powder bed, or media for bioprinting and/or drug discovery testing, such as a reservoir or container. In one example, nozzles608are arranged in at least one column or array such that properly sequenced ejection of ink from nozzles608causes characters, symbols, and/or other graphics or images to be printed upon print media724as printhead assembly702and print media724are moved relative to each other. Ink supply assembly710supplies ink to printhead assembly702and includes a reservoir712for storing ink. As such, in one example, ink flows from reservoir712to printhead assembly702. In one example, printhead assembly702and ink supply assembly710are housed together in an inkjet or fluid-jet print cartridge or pen. In another example, ink supply assembly710is separate from printhead assembly702and supplies ink to printhead assembly702through an interface connection713, such as a supply tube and/or valve. Carriage assembly716positions printhead assembly702relative to print media transport assembly718, and print media transport assembly718positions print media724relative to printhead assembly702. Thus, a print zone726is defined adjacent to nozzles608in an area between printhead assembly702and print media724. In one example, printhead assembly702is a scanning type printhead assembly such that carriage assembly716moves printhead assembly702relative to print media transport assembly718. In another example, printhead assembly702is a non-scanning type printhead assembly such that carriage assembly716fixes printhead assembly702at a prescribed position relative to print media transport assembly718. Service station assembly704provides for spitting, wiping, capping, and/or priming of printhead assembly702to maintain the functionality of printhead assembly702and, more specifically, nozzles608. For example, service station assembly704may include a rubber blade or wiper which is periodically passed over printhead assembly702to wipe and clean nozzles608of excess ink. In addition, service station assembly704may include a cap that covers printhead assembly702to protect nozzles608from drying out during periods of non-use. In addition, service station assembly704may include a spittoon into which printhead assembly702ejects ink during spits to ensure that reservoir712maintains an appropriate level of pressure and fluidity, and to ensure that nozzles608do not clog or weep. Functions of service station assembly704may include relative motion between service station assembly704and printhead assembly702. Electronic controller720communicates with printhead assembly702through a communication path703, service station assembly704through a communication path705, carriage assembly716through a communication path717, and print media transport assembly718through a communication path719. In one example, when printhead assembly702is mounted in carriage assembly716, electronic controller720and printhead assembly702may communicate via carriage assembly716through a communication path701. Electronic controller720may also communicate with ink supply assembly710such that, in one implementation, a new (or used) ink supply may be detected. Electronic controller720receives data728from a host system, such as a computer, and may include memory for temporarily storing data728. Data728may be sent to fluid ejection system700along an electronic, infrared, optical or other information transfer path. Data728represent, for example, a document and/or file to be printed. As such, data728form a print job for fluid ejection system700and includes at least one print job command and/or command parameter. In one example, electronic controller720provides control of printhead assembly702including timing control for ejection of ink drops from nozzles608. As such, electronic controller720defines a pattern of ejected ink drops which form characters, symbols, and/or other graphics or images on print media724. Timing control and, therefore, the pattern of ejected ink drops, is determined by the print job commands and/or command parameters. In one example, logic and drive circuitry forming a portion of electronic controller720is located on printhead assembly702. In another example, logic and drive circuitry forming a portion of electronic controller720is located off printhead assembly702. FIGS.8A-8Care flow diagrams illustrating examples of a method800for operating an integrated circuit to drive a plurality of fluid actuation devices. In one example, method800may be implemented by integrated circuit100ofFIG.1A, integrated circuit120ofFIG.1B, integrated circuit200ofFIG.3, circuit300ofFIG.4A, and/or circuit370ofFIG.4B. As illustrated inFIG.8A, at802method800includes reading a plurality of customization bits stored in a corresponding plurality of first non-volatile memory cells. At804, method800includes receiving an address from a nozzle data stream. At806, method800includes summing the customization bits and the address to generate a modified address. In one example, the plurality of customization bits includes four customization bits and the address includes four bits. In this case, summing the customization bits and the address may include summing the customization bits and the address to generate a modified address including four bits where the most significant bit resulting from the summing is discarded. As illustrated inFIG.8B, at808method800may further include firing fluid actuation devices based on the modified address. As illustrated inFIG.8C, at810method800may further include accessing a second non-volatile memory cell of a plurality of second non-volatile memory cells based on the modified address. Although specific examples have been illustrated and described herein, a variety of alternate and/or equivalent implementations may be substituted for the specific examples shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific examples discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof. | 41,776 |
11858266 | DESCRIPTION OF EXEMPLARY EMBODIMENTS 1. First Embodiment Hereinafter, the first embodiment of the liquid ejecting apparatus and the maintenance method of the liquid ejecting apparatus will be described with reference to the drawings. The liquid ejecting apparatus is an ink jet printer that ejects the ink, which is an example of a liquid, onto a medium such as printing paper to print an image such as a character or a photograph. FIG.1is a block diagram showing a configuration of a printer1as a liquid ejecting apparatus according to the first embodiment. A computer120outputs print data corresponding to an image to the printer1in order to cause the printer1to print the image. The printer1is a liquid ejecting apparatus that prints an image on printing paper as a medium, and is communicatively connected to the computer120. The printer1includes an ink supply unit19, a transport unit14, an ink ejecting section15as a liquid ejecting section, an irradiation unit40, a detector group112, and a controller111. The detector group112includes a state detection unit113capable of detecting the state of the ink in the ink ejecting section15. The printer1that has received the print data from the computer120controls the ink supply unit19, the transport unit14, the ink ejecting section15, and the irradiation unit40by the controller111, and prints an image on the printing paper according to the print data. The situation in the printer1is monitored by the detector group112, and the detector group112outputs the detection result to the controller111. The controller111includes an interface unit115, a CPU116, a memory117, a control circuit118, and a drive circuit119. The interface unit115transmits/receives data between the computer120and the printer1. The drive circuit119generates a drive signal for driving an ejection element89included in the ink ejecting section15. The CPU116is an arithmetic processing unit. The memory117is a storage device that secures an area for storing the program of the CPU116or a work area, and has a storage element such as a RAM or an EEPROM. The CPU116controls the ink supply unit19, the transport unit14, the ink ejecting section15, the irradiation unit40, and the like via the control circuit118according to the program stored in the memory117. FIG.2shows an example of a liquid ejecting unit included in the printer1. An ink ejecting unit10as a liquid ejecting unit includes the ink ejecting section15that ejects the ink from a nozzle24and the ink supply unit19. The ink supply unit19is located between an ink cartridge50as a liquid supply source and the ink ejecting section15of the printer1. The ink supply unit19includes a holder52that mounts the ink cartridge50, an ink flow path51, as a supply flow path, capable of supplying the ink to the ink ejecting section15, an ink return path57, as a return flow path, together with the ink flow path51forming an ink circulation path80as a circulation flow path so that the ink supplied to the ink ejecting section15can be returned, a valve53that opens/closes the ink flow path51, a sub tank70as a liquid storage unit, a supply pump54that supplies the ink in the ink cartridge50to the sub tank70, a filter55that filters the ink supplied to the sub tank70, a feed pump82as a flow mechanism, a warming device900as a warming mechanism, a degassing device100as a degassing mechanism, a filter unit81, and a damper unit83. The printer1of the present embodiment includes a plurality of ink ejecting units10so as to correspond to five types of inks: black ink, cyan ink, magenta ink, yellow ink, and white ink. The ink used in the embodiment is an ultraviolet curable ink that is cured when the ink is irradiated with ultraviolet rays. InFIG.2, for the sake of explanation, five liquid ejecting units are denoted by ink ejecting units10,10b,10c,10d, and10e. The ink supply unit19includes the sub tank70that stores the ink in the ink flow path51. The sub tank70is coupled to the ink flow path51so that the ink is supplied from the ink cartridge50. The ink flow path51couples the sub tank70and a supply port85A of the ink ejecting section15so that the ink stored in the sub tank70can be supplied to the ink ejecting section15. The internal space of the sub tank70is open to the atmosphere at the time of printing. The liquid surface of the ink stored in the sub tank70is located below a nozzle face25where the nozzle24of the ink ejecting section15is opened in the direction of gravity shown inFIG.2, and is the atmospheric pressure applied to the liquid surface is adjusted so as to be a pressure at which the meniscus, as a gas-liquid interface, formed in the nozzle24is not broken, for example, a gauge pressure of −1000 Pa to −3500 Pa. Then, when the ink in the sub tank70is consumed by the printing operation, the position of the liquid surface of the ink to be stored is adjusted by driving the supply pump54to replenish the ink from the ink cartridge50. Further, the sub tank70is coupled to the pressurizing pump56so as to be able to pressurize the internal space, and the pressure applied to the stored ink may be adjusted to the pressure at which the meniscus of the nozzle24is broken to perform pressure cleaning in which the ink is forcibly discharged from the nozzle24of the ink ejecting section15. The sub tank70is provided with a liquid amount sensor71that detects the amount of ink stored in the sub tank70. The ink supply unit19includes the ink return path57capable of returning the ink supplied to the ink ejecting section15to the ink flow path51. The ink return path57together with the ink ejecting section15, the sub tank70, and the ink flow path51forms the ink circulation path80. In the present embodiment, the ink return path57couples a common liquid chamber side discharge port96bof the ink ejecting section15and the sub tank70so that the ink discharged from the common liquid chamber side discharge port96bof the ink ejecting section15flows to the ink flow path51. The ink supply unit19includes the feed pump82capable of flowing the ink in the ink circulation path80. The feed pump82is interchangeably provided at a position between the sub tank70and the ink ejecting section15in the ink flow path51. As shown inFIG.2, the feed pump82includes a pump chamber821, a suction-side flow path including a suction-side one-way valve823that is located on the sub tank70side of the pump chamber821and that allows the ink to flow toward the pump chamber821and prevents the ink from flowing toward the sub tank70, and an ejection-side flow path including an ejection-side one-way valve824that is located on the ink ejecting section15side of the pump chamber821and that allows the ink to flow toward the ink ejecting section15and prevents the ink from flowing toward the pump chamber821. The feed pump82of the present embodiment is a diaphragm pump that is classified into a positive displacement pump that feeds a liquid by repeating a suction operation in which a diaphragm822formed of a flexible member as a flexible wall is deformed in a direction in which the volume of the pump chamber821increases, and an ejection operation in which the diaphragm822is deformed in a direction in which the volume of the pump chamber821decreases. The feed pump82is a two-phase system which includes two suction-side flow paths, two pump chambers821, and two ejection-side flow paths, and that reduces pressure fluctuations in the feed liquid by shifting the phase of the repetitive operation including the suction operation and the ejection operation by 180 degrees. The flow rate of the ink fed by the feed pump82is preferably 10 g/min or more from the viewpoint of ensuring the printing speed by supplying the ink amount required for printing to the ink ejecting section15. In this case, the lower limit flow rate at the time of printing is 10 g/min. The upper limit flow rate of the ink is preferably 400 g/min or less from the viewpoint of stabilizing the meniscus formed in the nozzle24of the ink ejecting section15. The feed pump82may be a tube pump classified into a positive displacement pump that feeds a liquid by deforming a tube as a flexible pump chamber forming part of the ink flow path51with a roller. The ink supply unit19includes the warming device900capable of heating the ink in the ink circulation path80. While the warming mechanism is not particularly limited as long as it can heat the ink, the warming device900of the present embodiment includes a temperature control module904provided in the ink circulation path80as shown inFIG.2. The temperature control module904is provided between the feed pump82in the ink flow path51and the ink ejecting section15. The warming device900can heat the ink in the temperature control module904by circulating the hot water in a hot water tank901between the temperature control module904and the hot water tank901by a hot water circulation pump902. As shown inFIG.2, the warming device900of the present embodiment includes a hot water circulation path905that couples the five temperature control modules904,904b,904c,904d, and904eprovided in the ink circulation paths80,80b,80c,80d, and80eof the five ink ejecting units10,10b,10c,10d,10e, respectively, and a hot water tank901. The hot water circulation path905is provided with a hot water temperature sensor906as the detector group112, and the controller111controls a heater903of the hot water tank901based on the temperature, of the hot water, detected by the hot water temperature sensor906to adjust collectively the temperature of the ink in the five temperature control modules904to a set temperature. The controller111of the printer1controls the feed pump82provided in the ink circulation path80of each of the five ink ejecting units10to adjust, for each ink ejecting unit10, the flow rate of the ink, in the ink circulation path80in each of the temperature control modules904, heated to substantially the same temperature by the warming device900, and adjust, to a predetermined viscosity, the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by each state detection unit113. The predetermined viscosity of the ink in the ink ejecting section15in the present embodiment is 5 to 15 mPa·s. From the temperature characteristics of the ink and the predetermined viscosity of the ink in the ink ejecting section15in the present embodiment, the predetermined temperature of the ink in the ink ejecting section15is more preferably 28 to 45° C. In this case, the lower limit temperature of the ink in the ink ejecting section15is 28° C. The ink supply unit19includes the degassing device100capable of degassing the ink in the ink circulation path80. While the degassing mechanism is not particularly limited as long as it can degas the ink, but the degassing device100of the present embodiment includes a degassing module102provided in the ink circulation path80. The degassing module102of the present embodiment is provided between the temperature control module904in the ink flow path51and the ink ejecting section15. As shown inFIG.2, the degassing module102is located downstream of the temperature control module904in the ink flow direction in the ink flow path51. As a result, the degassing device100can degas the ink in a high temperature state, and the degassing efficiency can be further increased. The degassing module102includes a degassing chamber1103into which the ink flows, and a decompression chamber1104that contacts the degassing chamber1103via a separation membrane that does not allow a liquid such as the ink to pass through. A decompression pump101as a vacuum degree adjustment mechanism decompresses the decompression chamber1104. When the decompression chamber1104is decompressed, the degree of vacuum in the decompression chamber1104increases, so that the ink in the degassing chamber1103is degassed and the amount of dissolved gas decreases. Then, the degassed ink in the degassing chamber1103circulates in the ink circulation path80, so that the growth of air bubbles and the generation of air bubbles in the ink in the ink circulation path80including the inside of the ink ejecting section15are suppressed. That is, the degassing device100can degas the ink in the ink circulation path80by decompressing the degassing module102and increasing the degree of vacuum of the degassing module102. As shown inFIG.2, the degassing device100of the present embodiment includes a decompression path1102coupling the decompression chamber1104of each of the degassing modules102,102b,102c,102d, and102eof the five ink ejecting units10,10b,10c,10d, and10e, respectively, and the decompression pump101. Further, a pressure sensor1101as the detector group112is provided between the degassing modules102,102b,102c,102d, and102e, and the decompression pump101in the decompression path1102, and based on the pressure value detected by the pressure sensor1101, the controller111causes the decompression pump101to adjust collectively the degree of vacuum of the degassing modules102,102b,102c,102d, and102e. The amount of dissolved oxygen in the ink, which is an example of the dissolved gas amount of the ink in the ink circulation path80, is determined by the amount of dissolved oxygen in the ink contained in the ink cartridge50and the degassing ability to be degassed by the degassing device100, specifically, the ability of the decompression pump101that adjusts the degree of vacuum in the degassing module102. As the ink is consumed, the undegassed ink is sequentially replenished from the sub tank70to the ink circulation path80, and when oxygen supplied from the outside is dissolved in the ink during a process in which the ink is fed from the ink cartridge50to the ink circulation path80and during circulation, the amount of dissolved oxygen in the ink increases slightly. Further, the degassing ability to be degassed by the degassing device100changes depending on the flow rate of the ink flowing in the degassing module102. For example, even when the degree of vacuum of the degassing module102is constant, when the flow rate of the ink in the ink circulation path80is decreased, the amount of dissolved oxygen in the ink in the ink circulation path80decreases, and when the flow rate of the ink in the ink circulation path80is increased, the amount of dissolved oxygen in the ink in the ink circulation path80increases. In this case, the degassing device100is provided at a position between the feed pump82in the ink flow path51forming part of the ink circulation path80and the ink ejecting section15, and the controller111causes the decompression pump101to adjust the degree of vacuum of the degassing module102so that the amount of dissolved oxygen in the ink flowing into the degassing module102in the ink circulation path80is within a predetermined range. As a result, the ink whose amount of dissolved oxygen is adjusted to a predetermined range can be supplied to the ink ejecting section15. Therefore, it is possible to reduce the accumulation of air bubbles in the ink ejecting section15, and improve ejection stability of the ink from the ink ejecting section15. In a case where the flow rate of the ink in the ink circulation path80is the same, when the degree of vacuum of the degassing module102is increased, the amount of dissolved oxygen in the ink in the ink circulation path80is decreased, and when the degree of vacuum of the degassing module102is decreased, the amount of dissolved oxygen in the ink in the ink circulation path80increases. Therefore, the degree of vacuum of the degassing module102required to supply the ink whose amount of dissolved oxygen is the upper limit value in a predetermined range to the ink ejecting section15at the flow rate is the lower limit degree of vacuum. The ink supply unit19includes the filter unit81that filters foreign matter in the ink. As shown inFIG.2, the filter unit81of the present embodiment is provided interchangeably between the degassing module102in the ink flow path51and the ink ejecting section15. The filter unit81includes a filter813, an upstream filter chamber811, located toward the sub tank70, and a downstream filter chamber812located toward the ink ejecting section15, which are partitioned by the filter813. The filter unit81is provided above the nozzle face25of the ink ejecting section15with a posture in which the upstream filter chamber811is above the downstream filter chamber812in the direction of gravity and. As shown inFIG.2, when a head filter84is provided in the ink ejecting section15, it is preferable that the filtration particle size of the filter813be set to 5 μm, which is smaller than the filtration particle size of the head filter84, which is, for example, 10 μm to 20 μm, and the filter area of the filter813is set to larger than that of the head filter84. The ink supply unit19includes the damper unit83that reduces pressure fluctuations of the ink in the ink flow path51. As shown inFIG.2, the damper unit83of the present embodiment is provided interchangeably between the filter unit81in the ink flow path51and the ink ejecting section15. The damper unit83is provided at a position below the filter unit81and above the nozzle face25of the ink ejecting section15in the direction of gravity. Next, the ink ejecting section15in the embodiment will be described. As shown inFIG.2, the ink ejecting section15has the supply port85A through which the ink can flow into the ink ejecting section15. The supply port85A is coupled to the ink flow path51so that the ink can be supplied to the ink ejecting section15. The ink ejecting section15has a common liquid chamber85that communicates with the supply port85A. The ink ejecting section15includes the head filter84that filters the supplied ink. The head filter84captures air bubbles, foreign matter, and the like in the supplied ink. The head filter84is provided in the common liquid chamber85with which the ink flow path51communicates. The ink ejecting section15includes a plurality of individual liquid chambers86that communicate with the common liquid chamber85. One nozzle24is correspondingly provided in one individual liquid chamber86. Part of the wall face of the individual liquid chamber86is formed by a vibration plate87. The common liquid chamber85and the plurality of individual liquid chambers86communicate with each other via a supply side communication passage88. The plurality of nozzles24communicates with the common liquid chamber85via the corresponding individual liquid chambers86, and are open to the nozzle face25. The ink ejecting section15includes a plurality of ejection elements89and a plurality of accommodation chambers90each of which accommodates the ejection element89. The accommodation chambers90are disposed at a position different from that of the common liquid chamber85. One accommodation chamber90accommodates one ejection element89. The ejection element89is provided on a face, of the vibration plate87, opposite to a face, of the vibration plate87, facing the individual liquid chamber86. The ink ejecting section15is provided in the printer1so that the ink in the individual liquid chambers86can be ejected as ink droplets from the plurality of nozzles24by driving the ejection element89. The ejection element89of the present embodiment is composed of a piezoelectric element that contracts when a drive voltage is applied. When the application of the drive voltage to the ejection element89is released after the vibration plate87is deformed by the contraction of the ejection element89due to the application of the drive voltage, the ink in the individual liquid chamber86whose volume has changed is ejected from the nozzle24as the ink droplets. As shown inFIG.2, the ink ejecting section15has the common liquid chamber side discharge port96B as a discharge port capable of discharging the supplied ink to the outside without the ink passing through the nozzle24. The ink ejecting section15has a common liquid chamber side discharge flow path92that communicates with the common liquid chamber side discharge port96B. As a result, the common liquid chamber85and the common liquid chamber side discharge flow path92of the ink ejecting section15constitute part of the ink circulation path80. Next, a method of estimating the state in the individual liquid chamber86as the state of the ink in the ink ejecting section15will be described based on the detection result by the state detection unit113. When a voltage is applied to the ejection element89by a signal from the drive circuit119, the vibration plate87bends and deforms. As a result, pressure fluctuations occur in the individual liquid chamber86. Due to the fluctuations, the vibration plate87vibrates for a while. This vibration is referred to as a residual vibration. From the state of this residual vibration, it is possible to estimate the state of the range including the individual liquid chamber86and the nozzle24communicating with the individual liquid chamber86. FIG.3is a diagram showing a calculation model of a simple vibration assuming a residual vibration of the vibration plate87. When the drive circuit119applies a drive signal to the ejection element89, the ejection element89expands and contracts according to the voltage of the drive signal. The vibration plate87bends according to the expansion and contraction of the ejection element89. As a result, the volume of the individual liquid chamber86expands and then contracts. At this time, due to the pressure generated in the individual liquid chamber86, part of the ink with which the individual liquid chamber86is filled is ejected as the ink droplets from the nozzle24. During the series of operations of the vibration plate87described above, the vibration plate87freely vibrates at a natural vibration frequency that is determined by the shape of the flow path through which the ink flows, a flow path resistance r due to the viscosity of the ink and the like, an inertance m due to the weight of the ink in the flow path, and a compliance C of the vibration plate87. The free vibration of the vibration plate87is the residual vibration. The calculation model of the residual vibration of the vibration plate87shown inFIG.3can be represented by the pressure P, the inertance m, the compliance C, and the flow path resistance r. When the step response when the pressure P is applied to the circuit ofFIG.3is calculated for a volume velocity u, the following equation is obtained. u=Pω·me-ωt·sinωt(1)ω=1m·C-α2(2)α=r2m(3) FIG.4is an explanatory diagram of the relationship between the viscosity of the ink and the residual vibration waveform. The horizontal axis ofFIG.4represents time t and the vertical axis represents the magnitude of the residual vibration. Em inFIG.4is a peak value of the first half wave in the residual vibration waveform. For example, when the ink near the nozzle24is dried or the temperature of the ink in the ink ejecting section15is lowered, the viscosity of the ink is increased, that is, the ink is thickened. As the viscosity of the ink increases, the flow path resistance r increases, so that the damping of the vibration cycle and the residual vibration increase. FIG.5is an explanatory diagram of the relationship between the air bubble and the residual vibration waveform. The horizontal axis ofFIG.5represents time t and the vertical axis represents the magnitude of the residual vibration. For example, when air bubbles are present in any of the inks in the individual liquid chamber86and the nozzle24, the inertance m, which is the ink weight, decreases by the volume of the air bubbles, compared with that when the state of the individual liquid chamber86and the nozzle24is normal. When m decreases, the angular velocity ω increases by the equation (2), so that the vibration cycle is shorter. That is, the vibration frequency is high. The frequency of the vibration waveform detected in the state in which air bubbles are present in the individual liquid chamber86and the nozzle24filled with the ink is higher than the frequency of the vibration waveform detected in the state in which no air bubbles are present in the ink-filled individual liquid chamber86and the nozzle24. The frequency of the vibration waveform detected in the state in which the individual liquid chamber86and the nozzle24are filled with air is higher than the frequency of the vibration waveform detected in the state in which air bubbles are present in the individual liquid chamber86and the nozzle24filled with the ink. Further, the larger the volume of air bubbles existing in either the individual liquid chamber86filled with the ink or the ink in the nozzle24, the higher the frequency of the vibration waveform. On the other hand, for example, when the ink adheres to the nozzle face25, and the ink adhering to the nozzle face25is coupled to the ink in the nozzle24, the ink adhering to the nozzle face25is coupled to the ink with which the individual liquid chamber86is filled via the nozzle24, so that it is conceivable that the ink weight, that is, the inertance m, increases as the amount of ink adhering to the nozzle face25when viewed from the vibration plate87increases, compared with that when the state of the nozzle24is normal. Therefore, when the ink adhering to the nozzle face25is coupled to the ink in the individual liquid chamber86, the frequency is lower than the frequency at the normal time. In addition, when foreign matter such as paper dust adheres near the opening of the nozzle24, the amounts of ink in the individual liquid chamber86and the seeping ink as viewed from the vibration plate87increases, compared with that when the state of the nozzle24is normal, so that it is conceivable that the inertance m increases. It is conceivable that the flow path resistance r is increased by the fibers of the paper dust attached to the vicinity of the outlet of the nozzle24. Therefore, when paper dust attaches to the vicinity of the opening of the nozzle24, the frequency is lower than that at the time of normal ejection. When the ink is thickened, air bubbles are mixed in, or foreign matter is stuck, the state in the nozzle24and the individual liquid chamber86is not normal, so that the ink is typically not ejected from the nozzle24. Therefore, a missing dot occurs in an image printed on the printing paper. Even when the ink droplets are ejected from the nozzle24, the amount of the ink droplets may be small, or the flight direction of the ink droplets may be deviated and the ink droplets may not land at the target position. The nozzle24in which such ejection failure occurs is referred to as an abnormal nozzle. As described above, the residual vibration of the individual liquid chamber86communicating with the abnormal nozzle is different from the residual vibration of the individual liquid chamber86communicating with the normal nozzle24. Therefore, the state detection unit113detects the vibration waveform of the individual liquid chamber86. Based on the detection result by the state detection unit113, the controller111estimates the state of the range including the individual liquid chamber86and the nozzle24leading to the individual liquid chamber86. The controller111estimates whether the state of the ink ejecting section15is normal or abnormal based on the vibration waveform, of the individual liquid chamber86, which is the detection result by the state detection unit113. When the state in the individual liquid chamber86is abnormal, the nozzle24communicating with the individual liquid chamber86is estimated to be an abnormal nozzle. Based on the vibration waveform of the individual liquid chamber86, the controller111estimate whether the state in the individual liquid chamber86is abnormal due to the presence of air bubbles, or the state in the individual liquid chamber86is abnormal due to thickening of the ink. Based on the vibration waveform of the individual liquid chamber86, the controller111estimates the total volume of air bubbles existing in the individual liquid chamber86and the nozzle24communicating with the individual liquid chamber86, and the degree of thickening of the ink in the individual liquid chamber86and the nozzle24communicating with the individual liquid chamber86. The controller111may estimate whether the head filter84is normal from the detection result detected by the state detection unit113. When the head filter84is clogged, the flow of the ink passing through the head filter84tends to be stagnant. When the ink flow is stagnant, air tends to come in from the nozzle24, and air bubbles tend to accumulate in the individual liquid chamber86. Therefore, the controller111estimates that the head filter84has an abnormality based on the detected abnormality due to the air bubbles in the individual liquid chamber86. Specifically, for example, the controller111estimates that the head filter84has an abnormality when an abnormality occurs due to the air bubbles in a predetermined number or more of the individual liquid chambers86of the plurality of individual liquid chambers86. The predetermined number is, for example, a number which is not enough to perform complementary printing in which the ink to be ejected from the abnormal nozzle is supplemented with the ink ejected from the surrounding nozzles24. The controller111estimates the viscosity of the ink in the individual liquid chamber86as the state of the ink in the ink ejecting section15based on the vibration waveform, of the individual liquid chamber86, which is the detection result detected by the state detection unit113. For example, the controller111compares the vibration waveform, of the individual liquid chamber86, detected by the state detection unit113when the viscosity of the ink in the individual liquid chamber86is within a predetermined viscosity range with the vibration waveform, of the individual liquid chamber86, which is the detection result detected by the state detection unit113to estimate the viscosity of the ink in the individual liquid chamber86to determine whether the viscosity of the ink in the individual liquid chamber86is in the predetermined viscosity range, lower than the predetermined viscosity range, or higher than the predetermined viscosity range. Information about the vibration waveform, of the individual liquid chamber86, detected by the state detection unit113when the viscosity of the ink in the individual liquid chamber86is within the predetermined viscosity range is stored in the memory117of the controller111. Further, the information about the vibration waveform, of the individual liquid chamber86, which is the detection result detected by the state detection unit113, and the viscosity of the ink in the individual liquid chamber86estimated from the detection result together with the detection time are stored as a detection history in the memory117of the controller111. The controller111estimates the degree of degassing of the ink in the ink ejecting section15based on the vibration waveform, of the individual liquid chamber86, which is the detection result detected by the state detection unit113. When the air bubbles in the ink that has been degassed to a predetermined degree of degassing or higher and whose amount of dissolved gas is small are present, the volume of the air bubbles decreases with the passage of time. In addition, the air bubbles are unlikely to generate in the ink degassed at a predetermined degree of degassing or higher. Therefore, the controller111estimates that the degree of degassing of the ink in the ink ejecting section15is a predetermined degree of degassing when the total volume of air bubbles, existing in the individual liquid chamber86, estimated from the vibration waveform, of the individual liquid chamber86, which is the detection result detected by the state detection unit113, is less than the total volume of air bubbles, existing in the individual liquid chamber86, estimated from the vibration waveform of the individual liquid chamber86detected before a predetermined time, and estimates that the degree of degassing of the ink in the ink ejecting section15is lower than the predetermined degree of degassing when the total volume of air bubbles, existing in the individual liquid chamber86, estimated from the vibration waveform, of the individual liquid chamber86, which is the detection result detected by the state detection unit113, is equal to or larger than the total volume of air bubbles, existing in the individual liquid chamber86, estimated from the vibration waveform of the individual liquid chamber86detected before the predetermined time. Alternatively, the controller111estimates that the degree of degassing of the ink in the ink ejecting section15is equal to or higher than the predetermined degree of degassing when the total volume of air bubbles, existing in the individual liquid chamber86, estimated from the vibration waveform, of the individual liquid chamber86, which is the detection result detected by the state detection unit113, is equal to or smaller than the predetermined value, and estimates that the degree of degassing of the ink in the ink ejecting section15is lower than the predetermined degree of degassing when the total volume of air bubbles, existing in the individual liquid chamber86, estimated from the vibration waveform, of the individual liquid chamber86, which is the detection result detected by the state detection unit113, is larger than the predetermined value. The predetermined value is stored in the memory117of the controller111. Further, the total volume of air bubbles existing in the individual liquid chamber86estimated from the detection result detected by the state detection unit113and the degree of degassing of the ink in the ink ejecting section15together with the detection time are stored as a detection history in the memory117of the controller111. In the printer1, when the temperature of the ink in the ink ejecting section15is lower than the predetermined temperature, the viscosity of the ink in the ink ejecting section15may be higher than the predetermined viscosity, and the ink may not be ejected normally from the nozzle24. Therefore, the printer1is configured to perform a maintenance operation for adjusting the viscosity of the ink. The controller111of the present embodiment controls, as a maintenance operation for the printer1, the feed pump82based on the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113to adjust the flow rate of the ink, in the ink circulation path80, heated by the warming device900to adjust the viscosity of the ink in the ink ejecting section15to a predetermined viscosity. Further, the controller111of the present embodiment, as the maintenance operation of the printer1, controls the corresponding feed pump82based on the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113of each of the five ink ejecting units10. For example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113with the flow rate sets to the set flow rate is lower than the predetermined viscosity, the controller111controls the feed pump82of the ink ejecting unit10so that the flow rate is smaller than the set flow rate. Further, for example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is the predetermined viscosity, the controller111controls the feed pump82of the ink ejecting unit10so that the flow rate is maintained. Further, for example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113with the flow rate of the ink in the ink circulation path80set to the set flow rate is higher than the predetermined viscosity, the controller111controls the feed pump82of the ink ejecting unit10so that the flow rate is larger than the set flow rate. Further, the controller111of the present embodiment controls, as a maintenance operation for the printer1, the warming device900based on the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113of each of the five ink ejecting units10, the set flow rate when the detection result is detected, and the detection history related to the detection result stored in the memory117of the controller111. For example, when the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113is lower than the predetermined viscosity, and the flow rate of the ink in the ink circulation path80is the lower limit flow rate, the controller111controls the warming device900so that the temperature of the ink in the temperature control module904is lower than the temperature of the ink, in the temperature control module904, when the detection result is detected. The lower limit flow rate is stored in the memory117of the controller111. In addition, when the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113is higher than the predetermined viscosity, and the flow rate of the ink in the ink circulation path80is the upper limit flow rate, the controller111controls the warming device900so that the temperature of the ink in the temperature control module904is higher than the temperature of the ink, in the temperature control module904, when the detection result is detected. The upper limit flow rate is stored in the memory117of the controller111. Further, for example, when it is estimated that the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113is higher than the predetermined viscosity, and the viscosity of the ink is lower than the predetermined viscosity when the temperature of the ink in the temperature control module904is increased, the controller111may set the flow rate of the feed pump82to smaller than the set flow rate when the detection result is detected, and may control the warming device900so that the temperature of the ink in the temperature control module904is higher than the temperature of the ink, in the temperature control module904, when the detection result is detected. In the printer1, when the degree of degassing of the ink in the ink ejecting section15is lower than the predetermined degree of degassing, air bubbles are likely to generate from the ink in the ink ejecting section15and the air bubbles are likely to stay in the ink, so that the ink may not be normally ejected from the nozzle24. Therefore, the printer1is configured to perform a maintenance operation for adjusting the degree of degassing of the ink. The controller111of the present embodiment controls, as a maintenance operation of the printer1, the degassing device100so that the degree of degassing of the ink, in the ink ejecting section15, estimated from the detection result by the state detection unit113is the predetermined degree of degassing. For example, when the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113is lower than the predetermined degree of degassing, the controller111controls the degassing device100so that the degree of vacuum of the degassing module102is higher than the degree of vacuum of the degassing module102when the detection result is detected. Further, for example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is higher than the predetermined viscosity, and the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result is lower than the predetermined degree of degassing, the controller111controls the feed pump82of the ink ejecting unit10so that the flow rate is larger than the set flow rate, and controls the degassing device100so that the degree of vacuum of the degassing module102is higher than the degree of vacuum of the degassing module102when the detection result is detected. Further, considering that even when the degree of vacuum of the degassing module102is constant, the amount of dissolved oxygen in the ink in the ink circulation path80decreases when the flow rate of the ink in the ink circulation path80is decreased, and the amount of dissolved oxygen in the ink in the ink circulation path80increases when the flow rate of the ink in the ink circulation path80is increased, the degassing device100may be controlled so that the degree of degassing of the ink, in the ink ejecting section15, estimated from the detection result by the state detection unit113is the predetermined degree of degassing. For example, when the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is lower than the predetermined degree of degassing, and the controller111controls the feed pump82so that the set flow rate is maintained from the detection result, the controller111controls the degassing device100so that the degree of vacuum of the degassing module102is higher than the degree of vacuum of the degassing module102when the detection result is detected. In addition, when the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is lower than the predetermined degree of degassing, and the controller111controls the feed pump82so that the flow rate is higher than the set flow rate from the detection result, the controller111controls the degassing device100so that the degree of vacuum of the degassing module102is higher than the degree of vacuum of the degassing module102when the detection result is detected. In addition, when the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is smaller than the predetermined degree of degassing, and the controller111controls the feed pump82so that the flow rate is lower than the set flow rate from the detection result, the controller111controls the degassing device100so that the degree of vacuum of the degassing module102when the detection result is detected is maintained. Also, considering the detection history related to the detection result, when the degree of degassing of the ink, in the ink ejecting section15, estimated from the detection result this time is lower than the predetermined degree of degassing, and there is a previous detection history in which the degree of degassing of the ink in the ink ejecting section15is lower than the predetermined degree of degassing, the degassing device100is driven and controlled so that the degree of vacuum of the degassing module102is higher than the degree of vacuum of the degassing module102when the detection result is detected, and when the degree of degassing of the ink, in the ink ejecting section15, estimated from the current detection result is lower than the predetermined degree of degassing, and there is a detection history in which the degree of degassing of the ink in the ink ejecting section15is equal to or higher than the predetermined degree of degassing, the flow rate of the feed pump82may be set to smaller than the set flow rate when the detection result is detected. For example, when the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is higher than the predetermined viscosity, and an ink ejecting unit10in which the degree of degassing of the ink, in the ink ejecting section15, estimated from the current detection result is lower than the predetermined degree of degassing, and that has a detection history in which the degree of degassing of the ink, in the ink ejecting section15, estimated from the previous detection result is equal to or higher than the predetermined degree of degassing is present, the controller111controls the warming device900so that the flow rate of the feed pump82of the ink ejecting unit10is smaller than the set flow rate when the detection result is detected, and the temperature of the ink in the temperature control module904is higher than the temperature of the ink, in the temperature control module904, when the detection result is detected. For example, among the plurality of nozzles24in the ink ejecting section15during the printing process, a non-ejection nozzle that does not eject the ink because it is not used for printing and an ejection nozzle that ejects the ink because it is used for printing ejects may appear. In this case, in the ejection nozzle and the individual liquid chamber86communicating with the ejection nozzle, the ink is ejected from the nozzle24, so that the air bubbles are not likely to generate and the air bubbles are not likely to grow in the ink, and the ink is not likely to thicken. In the non-ejection nozzle and the individual liquid chamber86communicating with the non-ejection nozzle, the ink is not ejected from the nozzle24, so that the ink is stagnant. Therefore, in the individual liquid chamber86communicating with the non-ejection nozzle, the air bubbles are likely to generate and the air bubbles are likely to grow in the ink as compared with the individual liquid chamber86communicating with the ejection nozzle, and the ink is likely to thicken. When among the plurality of nozzles24, there are a non-ejection nozzle that does not eject the ink and an ejection nozzle that ejects the ink, the controller111may cause the state detection unit113to detect a state of the individual liquid chamber86that communicates with the non-ejection nozzle. Next, the maintenance method of the printer1will be described. The maintenance process routine in the printer1maintenance method shown inFIG.6may be executed when the printer1is started, or may be repeated at predetermined intervals while the printer1is performing the print process. At the initial execution of the maintenance process routine, the controller111sets the set flow rate when controlling the feed pump82to a reference flow rate. The reference flow rate is stored in the memory117of the controller111. In the present embodiment, the reference flow rate when controlling the feed pump82is the lower limit flow rate at the time of printing. Further, the controller111sets the set temperature of the ink in the temperature control module904when controlling the warming device900to a reference temperature. The reference temperature is stored in the memory117of the controller111. In the present embodiment, the reference temperature of the ink in the temperature control module904is the lower limit temperature of the ink in the ink ejecting section15at the time of printing. Further, the controller111sets the set degree of vacuum of the degassing module102when controlling the degassing device100to a reference degree of vacuum. The reference degree of vacuum is stored in the memory117of the controller111. In the present embodiment, the reference degree of vacuum of the degassing module102when controlling the degassing device100is the lower limit degree of vacuum. Further, when necessary, the controller111sets the individual liquid chamber86to be detected by the state detection unit113to the individual liquid chamber86that communicates with the non-ejection nozzle when there is a non-ejection nozzle, and to the individual liquid chamber86that communicates with the ejection nozzle when there is no non-ejection nozzle. The above-mentioned settings of the set flow rate, the set temperature, and the set degree of vacuum together with the set time as a setting history are stored in the memory117of the controller111. The controller111drives each mechanism based on a set value which is set. That is, the controller111controls the feed pump82to adjust the flow rate of the ink in the ink circulation path80to the set flow rate. Further, the controller111controls the warming device900to adjust the temperature of the ink in the temperature control module904to the set temperature. Further, the controller111controls the degassing device100to adjust the degree of vacuum of the degassing module102to the set degree of vacuum. As shown inFIG.6, in step S101, the controller111controls respective mechanisms to adjust them to respective set values, and then determines whether a predetermined time has elapsed. In step S101, when respective mechanisms are driven and controlled to adjust them to respective set values, and then the predetermined time elapses, step S101is YES. The controller111advances the process to step S102. When respective mechanisms are driven and controlled to adjust them to respective set values, and then the predetermined time does not elapse, step S101is NO, and the controller111executes step S101again. The controller111repeatedly executes step S101until step S101is YES. In step S102, the controller111estimates the viscosity and degree of degassing of the ink in the individual liquid chamber86as the state of the ink in the ink ejecting section15from the detection result detected by the state detection unit113of each of the five ink ejecting units10. In step S103, with respect to each ink ejecting unit10, based on the difference between the viscosity of the ink, in each individual liquid chamber86, estimated from the detection result and the predetermined viscosity, the difference between the degree of degassing of the ink and the predetermined degree of degassing, the set flow rate of the feed pump82when the detection result is detected, the temperature of the ink in the temperature control module904, the degree of vacuum of the degassing module102, and the amount of adjustment of each setting obtained from the detection history regarding the detection result stored in the memory117of the controller111, the controller111sets the flow rate of the feed pump82, sets the temperature of the ink, in the temperature control module904, when controlling the warming device900, and sets the degree of vacuum of the degassing module102when controlling the degassing device100. The amount of adjustment of each setting is obtained in advance from the experimental result and is stored in the memory117of the controller111. For example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result is lower than a predetermined viscosity, the controller111sets the flow rate of the feed pump82in the ink ejecting unit10to smaller than the set flow rate when the detection result is detected within the range where the flow rate is not smaller than the lower limit flow rate. Further, for example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result is a predetermined viscosity, the controller111maintains the setting of the flow rate of the feed pump82in the ink ejecting unit10at the set flow rate when the detection result is detected. Further, for example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result is higher than a predetermined viscosity and the set flow rate when the detection result is detected is smaller than the upper limit flow rate, the controller111sets the flow rate of the feed pump82in the ink ejecting unit10to larger than the set flow rate when the detection result is detected within a range not exceeding the upper limit flow rate. Further, for example, when the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result is lower than the predetermined viscosity, and the set flow rate of the feed pump82when the detection result is detected is the lower limit flow rate, the controller111sets the temperature of the ink, in the temperature control module904, when controlling the warming device900to lower than the set temperature of the ink, in the temperature control module904, when the detection result is detected. Further, for example, when the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result is higher than the predetermined viscosity, and the set flow rate of the feed pump82when the detection result is detected is the upper limit flow rate, the controller111sets the temperature of the ink, in the temperature control module904, when controlling the warming device900to higher than the set temperature of the ink, in the temperature control module904, when the detection result is detected. Further, for example, when it is estimated that the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113is higher than the predetermined viscosity, and the viscosity of the ink is lower than the predetermined viscosity when the temperature of the ink in the temperature control module904is increased, the controller111may set the flow rate of the feed pump82to smaller than the set flow rate when the detection result is detected, and may set the temperature of the ink in the temperature control module904to higher than the temperature of the ink, in the temperature control module904, when the detection result is detected. Also, for example, when the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is higher than the predetermined viscosity, and an ink ejecting unit10in which the degree of degassing of the ink, in the ink ejecting section15, estimated from the current detection result is lower than the predetermined degree of degassing, and that has a detection history in which the degree of degassing of the ink, in the ink ejecting section15, estimated from the previous detection result is equal to or higher than the predetermined degree of degassing is present, the controller111sets the flow rate of the feed pump82of the ink ejecting unit10to smaller than the set flow rate when the current detection result is detected, and sets the temperature of the ink in the temperature control module904to higher than the set temperature of the ink, in the temperature control module904, when the current detection result is detected. Further, for example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is higher than a predetermined viscosity, and the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result is lower than the predetermined degree of degassing, the controller111sets the flow rate of the feed pump82in the ink ejecting unit10to larger than the set flow rate when the detection result is detected, and sets the degree of vacuum of the degassing module102when controlling the degassing device100to higher than the set degree of vacuum of the degassing module102when the detection result is detected. Further, for example, when the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is lower than the predetermined degree of degassing, and the setting of the flow rate is maintained at the set flow rate from the detection result, the controller111sets the degree of vacuum of the degassing module102when controlling the degassing device100to higher than the set degree of vacuum of the degassing module102when the detection result is detected. Further, when the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is lower than the predetermined degree of degassing, and the flow rate is set to larger than the set flow rate from the detection result, the controller111sets the degree of vacuum of the degassing module102when controlling the degassing device100to higher than the set degree of vacuum of the degassing module102when the detection result is detected. Further, when the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is lower than the predetermined degree of degassing, and the flow rate is set to smaller than the set flow rate from the detection result, the controller111maintains the setting of the degree of vacuum of the degassing module102when controlling the degassing device100at the set degree of vacuum of the degassing module102when the detection result is detected. The controller111controls each mechanism so as to have the set value set. When the controller111executes the process of step S103, the maintenance process routine is terminated. The controller111adjusts the viscosity of the ink in the ink ejecting section15to a predetermined viscosity by executing the maintenance process routine shown inFIG.6. Further, the controller111adjusts the degree of degassing of the ink in the ink ejecting section15to a predetermined degree of degassing by executing the maintenance process routine shown inFIG.6. For example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result is lower than a predetermined viscosity, the controller111sets the flow rate of the feed pump82in the ink ejecting unit10to smaller than the set flow rate when the detection result is detected within the range where the flow rate is not smaller than the lower limit flow rate. Further, for example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result is a predetermined viscosity, the controller111maintains the setting of the flow rate of the feed pump82in the ink ejecting unit10at the set flow rate when the detection result is detected. Further, for example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result is higher than a predetermined viscosity and the set flow rate when the detection result is detected is smaller than the upper limit flow rate, the controller111sets the flow rate of the feed pump82in the ink ejecting unit10to larger than the set flow rate when the detection result is detected. Further, for example, when the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result is lower than the predetermined viscosity, and the set flow rate of the feed pump82when the detection result is detected is the lower limit flow rate, the controller111sets the temperature of the ink in the temperature control module904to lower than the temperature of the ink in the temperature control module904when the detection result is detected. Further, for example, when the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result is higher than the predetermined viscosity, and the set flow rate of the feed pump82when the detection result is detected is the upper limit flow rate, the controller111sets the temperature of the ink in the temperature control module904to higher than the temperature of the ink in the temperature control module904when the detection result is detected. Further, for example, when it is estimated that the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113is higher than the predetermined viscosity, and the viscosity of the ink is lower than the predetermined viscosity when the temperature of the ink in the temperature control module904is increased, the controller111may set the flow rate of the feed pump82to smaller than the set flow rate when the detection result is detected, and may control the warming device900so that the temperature of the ink in the temperature control module904is higher than the temperature of the ink, in the temperature control module904, when the detection result is detected. Further, for example, when an ink ejecting unit10is present in which the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is higher than a predetermined viscosity, and the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result is lower than the predetermined degree of degassing, the controller111sets the flow rate of the feed pump82in the ink ejecting unit10to larger than the set flow rate when the detection result is detected, and sets the degree of vacuum of the degassing module102to higher than the degree of vacuum of the degassing module102when the detection result is detected. Also, for example, when the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is lower than the predetermined degree of degassing, and the setting of the flow rate is maintained at the set flow rate from the detection result, the controller111sets the degree of vacuum of the degassing module102to higher than the degree of vacuum of the degassing module102when the detection result is detected. Also, for example, when the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is lower than the predetermined degree of degassing, and the flow rate is set to larger than the set flow rate from the detection result, the controller111sets the degree of vacuum of the degassing module102to higher than the degree of vacuum of the degassing module102when the detection result is detected. Further, when the degree of degassing of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is lower than the predetermined degree of degassing, and the flow rate is set to smaller than the set flow rate from the detection result, the controller111maintains the setting of the degree of vacuum of the degassing module102when controlling the degassing device100at the degree of vacuum of the degassing module102when the detection result is detected. Also, for example, when the viscosity of the ink, in the ink ejecting sections15of all the ink ejecting units10, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is higher than the predetermined viscosity, and an ink ejecting unit10in which the degree of degassing of the ink, in the ink ejecting section15, estimated from the current detection result is lower than the predetermined degree of degassing, and that has a detection history in which the degree of degassing of the ink, in the ink ejecting section15, estimated from the previous detection result is equal to or higher than the predetermined degree of degassing is present, the controller111sets the flow rate of the feed pump82of the ink ejecting unit10to smaller than the set flow rate when the current detection result is detected, and sets the temperature of the ink in the temperature control module904to higher than the temperature of the ink in the temperature control module904when the current detection result is detected. Further, the controller111adjusts the viscosity of the ink in the ink ejecting section15of each of the five ink ejecting units10by collectively heating and adjusting the ink in the ink circulation path80of each of the five ink ejecting units10, and by adjusting the flow rate of the ink in the ink circulation path80of each of the five ink ejecting units10. As described above, according to the first embodiment, the following effects can be obtained. The printer1includes the ink ejecting section15that ejects the ink from the nozzle24, the ink flow path51capable of supplying the ink to the ink ejecting section15, the ink return path57together with the ink flow path51forming the ink circulation path80so that the ink supplied to the ink ejecting section15can be returned, the warming device900that includes the temperature control module904provided in the ink circulation path80, and that can heat the ink in the temperature control module904, the feed pump82capable of flowing the ink in the ink circulation path80, the state detection unit113capable of detecting the state of the ink in the ink ejecting section15, and the controller111, wherein the controller111controls the feed pump82based on the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113to adjust the flow rate of the ink, in the ink circulation path80, heated by the warming device900to adjust the viscosity of the ink in the ink ejecting section15to a predetermined viscosity. According to this, the viscosity of the ink is adjusted by causing the feed pump82to adjust the flow rate of the ink in the ink circulation path80, so that the frequency of control of the warming device900can be reduced. When the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is higher than the predetermined viscosity, the controller111of the printer1controls the feed pump82so that the flow rate is larger than the set flow rate when the detection result is detected. According to this, the flow rate of the ink in the ink circulation path80is adjusted based on the viscosity of the ink in the detected ink ejecting section15so that the frequency of control of the warming device900can be reduced. When the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113is higher than the predetermined viscosity and the flow rate is the upper limit flow rate, the controller111of the printer1controls the warming device900so that the temperature of the ink in the temperature control module904is higher than the temperature of the ink when the detection result is detected. According to this, the viscosity of the ink can be adjusted by adjusting the flow rate by the feed pump82and adjusting the temperature of the ink by the warming device900. The printer1includes the degassing device100that includes the degassing module102provided in the ink circulation path80, and that is capable of degassing the ink by increasing the degree of vacuum of the degassing module102, and when the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is higher than the predetermined viscosity, and the degree of degassing of the, ink in the ink ejecting section15, estimated from the detection result is lower than the predetermined degree of degassing, the controller111of the printer1sets the flow rate to smaller than the set flow rate when the current detection result is detected, and controls the warming device900so that the temperature of the ink in the temperature control module904is higher than the temperature of the ink when the current detection result is detected. According to this, the degree of degassing of the ink and the viscosity of the ink can be adjusted by adjusting the flow rate by the feed pump82and adjusting the temperature of the ink by the warming device900. The printer1includes the degassing device100that includes the degassing module102provided in the ink circulation path80, and that is capable of degassing the ink by increasing the degree of vacuum of the degassing module102, and when the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113with the flow rate set to the set flow rate is higher than the predetermined viscosity, and the degree of degassing of the, ink in the ink ejecting section15, estimated from the detection result is lower than the predetermined degree of degassing, the controller111of the printer1controls the feed pump82so that the flow rate is larger than the set flow rate when the detection result is detected, and controls the degassing device100so that the degree of vacuum of the degassing module102is higher than the degree of vacuum when the detection result is detected. According to this, the degree of degassing of the ink and the viscosity of the ink can be adjusted by adjusting the flow rate by the feed pump82and adjusting the degree of degassing of the ink by the degassing device100. The printer1includes a plurality of ink ejecting units10each of which includes the ink ejecting section15, the ink circulation path80, the feed pump82, and the state detection unit113, the warming device900can collectively heat and adjust the ink in the temperature control module904provided in the ink circulation path80of each of the plurality of ink ejecting units10, and the controller111controls the corresponding feed pump82based on the viscosity of the ink, in the ink ejecting section15, estimated from the detection result detected by the state detection unit113of each of the plurality of ink ejecting units10. According to this, even when the plurality of ink circulation paths80each of which is coupled to the ink ejecting section15and the ink ejecting section15is provided, the viscosity of each ink can be adjusted without controlling the warming device900in a complicated manner. The ink ejecting section15of the printer1includes the individual liquid chamber86communicating with the nozzle24and the ejection element89, and can drive the ejection element89to eject the ink in the individual liquid chamber86from the nozzle24. The state detection unit113detects the vibration, of the individual liquid chamber86, driven by the ejection element89, thereby detecting the state of the ink in the ink ejecting section15. According to this, the state in the individual liquid chamber86as the state of the ink in the ink ejecting section15can be detected by using the ejection element89that ejects the ink from the nozzle24without separately providing a detection element or the like. The method of maintaining the printer1is a method of maintaining the liquid ejecting apparatus including the ink ejecting section15that ejects the ink from the nozzle24, the ink flow path51coupled to the ink ejecting section15so that the ink can be supplied to the ink ejecting section15, the ink return path57together with the ink flow path51forming the ink circulation path80so that the ink supplied to the ink ejecting section15can be returned, the warming device900that includes the temperature control module904provided in the ink circulation path80and that can heat the ink in the temperature control module904, and the feed pump82capable of flowing the ink in the ink circulation path80. The method includes adjusting the viscosity of the ink in the ink ejecting section15to a predetermined viscosity by adjusting the flow rate of the ink, in the ink circulation path80, heated by the warming device900. According to this, the viscosity of the ink is adjusted by adjusting the flow rate of the ink in the ink circulation path80, so that the frequency of control of the warming device900can be reduced. The maintenance method of the printer1includes, when the viscosity of the ink in the ink ejecting section15when the flow rate is set to the set flow rate is higher than the predetermined viscosity, setting the flow rate to larger than the set flow rate. According to this, the frequency of control of the warming device900can be reduced by adjusting the flow rate of the ink based on the detected viscosity of the ink in the ink ejecting section15. The maintenance method of the printer1includes, when the viscosity of the ink in the ink ejecting section15when the flow rate is set to the set flow rate is higher than the predetermined viscosity, and the set flow rate is the upper limit flow rate, setting the temperature of the ink in the temperature control module904to higher than the temperature of the ink in the temperature control module904when the flow rate is set to the set flow rate. According to this, the viscosity of the ink can be adjusted by adjusting the flow rate in the ink circulation path80and adjusting the temperature of the ink by the warming device900. The printer1includes the degassing device100that includes the degassing module102provided in the ink circulation path80, and that is capable of degassing the ink by increasing the degree of vacuum of the degassing module102. The maintenance method of the printer1includes, when the viscosity of the ink in the ink ejecting section15when the flow rate is set to the set flow rate is higher than the predetermined viscosity, and the degree of degassing of the ink in the ink ejecting section15is lower than the predetermined degree of degassing, setting the flow rate to smaller than the set flow rate, and setting the temperature of the ink in the temperature control module904to higher than the temperature of the ink in the temperature control module904when the flow rate is set to the set flow rate. According to this, the degree of degassing of the ink and the viscosity of the ink can be adjusted by adjusting the flow rate in the ink circulation path80and adjusting the temperature of the ink by the warming device900. The printer1includes the degassing device100that includes the degassing module102provided in the ink circulation path80, and that is capable of degassing the ink by increasing the degree of vacuum of the degassing module102. The maintenance method of printer1includes, when the viscosity of the ink in the ink ejecting section15when the flow rate is set to the set flow rate is higher than the predetermined viscosity, and the degree of degassing of the ink in the ink ejecting section15is lower than the predetermined degree of degassing, setting the flow rate to larger than the set flow rate, and setting the degree of vacuum of the degassing module102to higher than the degree of vacuum of the degassing module102when the flow rate is set to the set flow rate. According to this, the viscosity of the ink can be adjusted while ensuring the degree of degassing of the ink by adjusting the flow rate in the ink circulation path80and adjusting the degree of degassing of the ink by the degassing device100. The printer1includes a plurality of ink ejecting units10each of which includes the ink ejecting section15, the ink circulation path80, and the feed pump82, and adjusts the viscosity of the ink in the ink ejecting sections15of each of the plurality of ink ejecting units10to the predetermined viscosity by collectively heating and adjusting the ink in the temperature control module904provided in the ink circulation path80of each of the plurality of ink ejecting units10, and adjusting the flow rate of the ink in the ink circulation path80of each of the plurality of ink ejecting units10. According to this, even when the plurality of ink circulation paths80each of which is coupled to the ink ejecting section15and the ink ejecting section15is provided, the viscosity of each ink can be adjusted without controlling the warming device900in a complicated manner. 2. Second Embodiment FIG.7is an explanatory diagram schematically showing a liquid ejecting unit in a liquid ejecting apparatus according to the second embodiment. An ink ejecting unit510of a printer501of the present embodiment includes an ink ejecting section515and an ink supply unit519, which correspond to the ink ejecting section15and the ink supply unit19constituting the ink ejecting unit10of the first embodiment are shown inFIG.7. For the same constituent parts as those in the first embodiment, the same numbers will be used, and duplicate description thereof will be omitted. As shown inFIGS.7and8, the ink ejecting section515has a discharge liquid chamber side discharge port96A and the common liquid chamber side discharge port96B as discharge ports capable of discharging the supplied ink to the outside without the ink passing through the nozzle24. The ink ejecting section515includes a discharge liquid chamber side discharge flow path91communicating with the discharge liquid chamber side discharge port96A, the common liquid chamber side discharge flow path92communicating with the common liquid chamber side discharge port96B, and a discharge liquid chamber93that couples the discharge liquid chamber side discharge flow path91and the individual liquid chambers86. As a result, the discharge liquid chamber93communicates with the discharge liquid chamber side discharge port96A via the discharge liquid chamber side discharge flow path91, and communicates with the supply port85A via the individual liquid chamber86and the common liquid chamber85. Further, the common liquid chamber85communicates with the discharge liquid chamber side discharge port96A via the individual liquid chamber86, the discharge liquid chamber93, and the discharge liquid chamber side discharge flow path91, and communicates with the common liquid chamber side discharge port96B via the common liquid chamber side discharge flow path92. The discharge liquid chamber93communicates with the plurality of individual liquid chambers86via a discharge side communication passage94provided for each individual liquid chamber86. As shown inFIG.7, the ink ejecting section515includes an ink temperature sensor599as a state detection unit capable of detecting the temperature of the ink in the ink ejecting section515. The ink temperature sensor599of the present embodiment detects the temperature, of the ink in the common liquid chamber85, as the state of the ink in the ink ejecting section515. The controller111estimates the viscosity of the ink in the ink ejecting section515from the relationship between the ink temperature, in the ink ejecting section515, as a detection result detected by the ink temperature sensor599, and the ink temperature and the ink viscosity stored in the memory117. As shown inFIG.7, the ink supply unit519of the present embodiment includes an ink return path557as a return flow path where an ink flow path551as a supply flow path and the ink return path557form an ink circulation path580as a circulation flow path, a feed pump582as a flow mechanism, and a warming device950as a warming mechanism. The ink supply unit519of the present embodiment includes the ink flow path551, the ink circulation path580the ink return path557, the feed pump582, and the warming device950, which correspond to the ink flow path51, the ink circulation path80, the ink return path57, the feed pump82, and the warming device900of the first embodiment, but does not include a unit corresponding to the degassing device100. The ink flow path551couples the sub tank70and the supply port85A of the ink ejecting section515so that the ink stored in the sub tank70can be supplied to the ink ejecting section515. The ink flow path551of the present embodiment does not include a unit corresponding to the feed pump82as a flow mechanism in the first embodiment. The ink return path557together with the ink flow path551forms the ink circulation path580so that the ink supplied to the ink ejecting section515can be returned. The ink return path557includes the feed pump582capable of flowing the ink in the ink circulation path580in the direction of the arrow shown inFIG.7. The feed pump582is provided at a position between the sub tank70in the ink return path557and the ink ejecting section515. The controller111adjusts the flow rate of the ink in the ink circulation path580by keeping the inside of the sub tank70in a sealed state and controlling the feed pump582. As shown inFIGS.7and8, the ink return path557includes a discharge liquid chamber side return path557A coupled to the discharge liquid chamber side discharge port96A and a common liquid chamber side return path557B coupled to the common liquid chamber side discharge port96B so that the ink supplied to the ink ejecting section515can be returned to the ink flow path551. The ink return path557of the present embodiment is configured so that the discharge liquid chamber side return path557A and the common liquid chamber side return path557B merge. A discharge liquid chamber side return valve97A is provided in the discharge liquid chamber side return path557A. A common liquid chamber side return valve97B is provided in the common liquid chamber side return path557B. By opening either the discharge liquid chamber side return valve97A or the common liquid chamber side return valve97B, the controller111can switch between a mode in which the common liquid chamber85, the individual liquid chamber86, the discharge liquid chamber93, and the discharge liquid chamber side discharge flow path91of the ink ejecting section515, and the discharge liquid chamber side return path557A constitute part of the ink circulation path580, and a mode in which the common liquid chamber85and the common liquid chamber side discharge flow path92of the ink ejecting section515, and the common liquid chamber side return path557B constitute part of the ink circulation path580. With part of the ink in the nozzle24moved into the individual liquid chamber86by opening the discharge liquid chamber side return valve97A, and controlling the feed pump582so that the flow rate of the ink in the ink circulation path580is increased, the controller111may circulate the ink in the ink circulation path580to suppress the thickening of the ink in the nozzle24. As shown inFIG.7, the warming device950includes a heater953capable of collectively heating the sub tanks70,70b,70c,70d, and70eprovided in the respective ink circulation paths580,580b,580c,580d, and580eof the five ink ejecting units510, respectively, and a heater temperature sensor956as the detector group112capable of detecting the temperature of the heater953. The sub tanks70,70b,70c,70d, and70eof the present embodiment function as the temperature control modules904,904b,904c,904d, and904ein the first embodiment. The controller111controls the heater953based on the temperature, of the heater953, detected by the heater temperature sensor956, and collectively adjusts the temperature of the ink in the five sub tanks70to the set temperature. In the printer501, when the temperature of the ink in the ink ejecting section515is lower than the predetermined temperature, the viscosity of the ink in the ink ejecting section515may be higher than the predetermined viscosity, and the ink may not be ejected normally from the nozzle24. Therefore, the printer501is configured to perform a maintenance operation for adjusting the viscosity of the ink. The controller111of the embodiment controls, as a maintenance operation for the printer501, the feed pump582to adjust the flow rate of the ink, in the ink circulation path580, heated in the warming device950to adjust the viscosity of the ink, in the ink ejecting section515, estimated from the detection result detected by the ink temperature sensor599to a predetermined viscosity. Further, the controller111of the present embodiment controls, as a maintenance operation of the printer501, the corresponding feed pump582based on the viscosity of the ink, in the ink ejecting section515, estimated from the detection result detected by the ink temperature sensor599of each of the plurality of ink ejecting units510. For example, when the viscosity of the ink, in the ink ejecting section515, estimated from the detection result detected by the ink temperature sensor599with the flow rate set to the set flow rate is lower than the predetermined viscosity, the controller111controls the feed pump582so that the flow rate is smaller than the set flow rate. Further, for example, when the viscosity of the ink, in the ink ejecting section515, estimated from the detection result detected by the ink temperature sensor599with the flow rate set to the set flow rate is the predetermined viscosity, the controller111controls the feed pump582so that the flow rate is maintained. Further, for example, when the viscosity of the ink, in the ink ejecting section515, estimated from the detection result detected by the ink temperature sensor599with the flow rate of the ink in the ink circulation path580set to the set flow rate is higher than the predetermined viscosity, the controller111controls the feed pump582so that the flow rate is larger than the set flow rate. Further, for example, when the viscosity of the ink, in the ink ejecting section515, estimated from the detection result detected by the ink temperature sensor599is higher than the predetermined viscosity, and the flow rate of the ink in the ink circulation path580is the upper limit flow rate, the controller111controls the warming device950so that the temperature of the ink in the sub tank70as the temperature control module is higher than the temperature of the ink, in the sub tank70, when the detection result is detected. As described above, according to the second embodiment, the following effects can be obtained. The printer501includes the ink ejecting section515that ejects the ink from the nozzle24, the ink flow path551capable of supplying the ink to the ink ejecting section515, the ink return path557together with the ink flow path551forming the ink circulation path580so that the ink supplied to the ink ejecting section515can be returned, the warming device950that includes the sub tank70provided in the ink circulation path580, and that can heat the ink in the sub tank70, the feed pump582capable of flowing the ink in the ink circulation path580, the ink temperature sensor599capable of detecting the state of the ink in the ink ejecting section515, and the controller111, wherein the controller111controls the feed pump582based on the viscosity of the ink, in the ink ejecting section515, estimated from the detection result detected by the ink temperature sensor599to adjust the flow rate of the ink, in the ink circulation path580, heated by the warming device950to adjust the viscosity of the ink in the ink ejecting section515to a predetermined viscosity. According to this, the viscosity of the ink is adjusted by causing the feed pump582to adjust the flow rate of the ink in the ink circulation path580, so that the frequency of control of the warming device950can be reduced. When the viscosity of the ink, in the ink ejecting section515, estimated from the detection result detected by the ink temperature sensor599with the flow rate set to the set flow rate is higher than the predetermined viscosity, the controller111of the printer501controls the feed pump582so that the flow rate is larger than the set flow rate when the detection result is detected. According to this, the flow rate of the ink in the ink circulation path580is adjusted based on the viscosity of the ink in the detected ink ejecting section515so that the frequency of control of the warming device950can be reduced. When the viscosity of the ink, in the ink ejecting section515, estimated from the detection result detected by the ink temperature sensor599is higher than the predetermined viscosity and the flow rate is the upper limit flow rate, the controller111of the printer501controls the warming device950so that the temperature of the ink in the sub tank70is higher than the temperature of the ink when the detection result is detected. According to this, the viscosity of the ink can be adjusted by adjusting the flow rate by the feed pump582and adjusting the temperature of the ink by the warming device950. The printer501includes the plurality of ink ejecting units510each of which includes the ink ejecting section515, the ink circulation path580, the feed pump582, and the ink temperature sensor599, the warming device950can collectively heat and adjust the ink in the sub tank70provided in the ink circulation path580of each of the plurality of ink ejecting units510, and the controller111controls the corresponding feed pump582based on the viscosity of the ink, in the ink ejecting section515, estimated from the detection result detected by the ink temperature sensor599of each of the plurality of ink ejecting units510. According to this, even when the plurality of ink circulation paths580each of which is coupled to the ink ejecting section515and the plurality of ink ejecting sections515are provided, the viscosity of each ink can be adjusted without controlling the warming device950in a complicated manner. The above embodiment and other embodiments described below can be implemented in combination with each other to the extent that they are technically consistent. Hereinafter, other embodiments will be described. In the first embodiment, the printer1may include one ink ejecting unit10so as to correspond to one kind of ink. The reference flow rate set by the controller111as the set flow rate when controlling the feed pump82at the initial execution of the maintenance process routine in the maintenance method of the printer1is an any flow rate between the upper limit flow rate and the lower limit flow rate. Further, the reference temperature set by the controller111as the set temperature of the ink in the temperature control module904may be an any temperature higher than the lower limit temperature of the ink in the ink ejecting section15at the time of printing. Further, the reference degree of vacuum set by the controller111as the set degree of vacuum of the degassing module102when controlling the degassing device100may be an any degree of vacuum lower than the lower limit degree of vacuum. In step S103of the maintenance process routine in the maintenance method of the printer1, the adjustment amount when the controller111changes the setting of the flow rate of the feed pump82, the setting of the temperature of the ink in the temperature control module904when controlling the warming device900, and the setting of the degree of vacuum of the degassing module102when controlling the degassing device100may be a fixed value set in advance. In this case, the controller111adjusts the viscosity of the ink and the degree of degassing of the ink as a liquid state in the ink ejecting section15to a predetermined viscosity of the ink and a predetermined degree of degassing of the ink in the ink ejecting section15by repeating the adjustment to the set value set by the control of each mechanism, and the estimation of the state of the liquid in the ink ejecting section15. In the maintenance method of printer1, when an ink ejecting unit10is present in which even when the temperature of the ink in the temperature control module904is set to higher than the set temperature, and the maintenance process of circulating the ink in the ink circulation path80is repeated, the viscosity of the ink in the ink ejecting section15does not decrease, or the temperature of the ink in the ink ejecting section15does not rise, the controller111may determine that the filter813of the filter unit81of the ink ejecting unit is clogged to finish the maintenance process, and may urge the operator of the printer1to replace the filter unit81. In the first embodiment, when it is estimated that the viscosity of the ink, in the ink ejecting section15included in the ink ejecting unit10, estimated from the detection result detected by the state detection unit113is higher than a predetermined viscosity, and the nozzle24of the ink ejecting section15has a concave meniscus, the controller111of the printer1may set the flow rate of the feed pump82included in the ink ejecting unit10to larger than the set flow rate when the detection result is detected, exceeding the upper limit flow rate. In this case, when it is estimated that the meniscus of the nozzle24, of the ink ejecting section15of the ink ejecting unit10, estimated from the detection result detected next by the state detection unit113is broken, the controller111may set the flow rate of the feed pump82of the ink ejecting unit10to the upper limit flow rate, and may control the warming device900so that the temperature of the ink in the temperature control module904is higher than the temperature of the ink, in the temperature control module904, when the previous detection result is detected. In the first embodiment, the controller111of the printer1may not estimate the degree of degassing of the ink in the ink ejecting section15based on the vibration waveform, of the individual liquid chamber86, which is the detection result detected by the state detection unit113. In this case, for example, the controller111sets, at the initial execution of the maintenance process routine in the maintenance method of the printer1, the reference degree of vacuum set as the set degree of vacuum of the degassing module102to the upper limit degree of vacuum when the degassing module102is decompressed with the maximum capacity of the decompression pump101. Further, in this case, the controller111may not estimate the degree of degassing of the ink and may not set the set degree of vacuum of the degassing mechanism in the ink ejecting section15in the maintenance process routine in the maintenance method of the printer1. In the first embodiment, the ink ejecting section15of the printer1may be provided with an ink temperature sensor as a state detection unit capable of detecting the temperature of the ink in the ink ejecting section15. The controller111may estimate the viscosity of the ink in the ink ejecting section15based on the temperature of the ink, in the ink ejecting section15, which is the detection result detected by the ink temperature sensor as the state detection unit. In the first embodiment, the ink ejecting section15of the printer1may be provided with a degree of degassing sensor as a state detection unit capable of measuring the amount of dissolved oxygen in the ink in the ink ejecting section15. The controller111may estimate the degree of degassing of the ink in the ink ejecting section15based on the amount of dissolved oxygen in the ink, in the ink ejecting section15, which is the detection result detected by the degree of degassing sensor as the state detection unit. In the first embodiment, the controller111of the printer1may store the history of the amount of ink ejected by the nozzle24in the memory117. In this case, when among the nozzles24, there is a nozzle24in which the amount of ink ejected is an amount corresponding less than a predetermined number of times and a nozzle24in which the amount of ink ejected is an amount corresponding more than the predetermined number of times, the state detection unit113may perform detection on the individual liquid chamber86communicating with the nozzle24in which the amount of ink ejected is an amount corresponding to less than the predetermined number of times. In the first embodiment, when the ink is flowed in the ink circulation path80, the controller111of the printer1may cause the state detection unit113to perform detection on the individual liquid chambers86communicating with a region where the ink is difficult to flow in the common liquid chamber85of the ink ejecting section15, for example, the individual liquid chamber86at the right end inFIG.2. In the first embodiment, the controller111of the printer1may cause the state detection unit113to perform on the plurality of individual liquid chambers86without distinguishing an individual liquid chamber86communicating with the non-ejection nozzle from an individual liquid chamber86communicating with the ejection nozzle. In the first embodiment, the ink ejecting section15of the printer1may not include the common liquid chamber side discharge port96B. In this case, for example, the ink return path57may couple a portion between the ink ejecting section15and the damper unit83in the ink flow path51and the sub tank70so that the ink supplied to the ink ejecting section15can be returned. In the first embodiment, the degassing module102included in the degassing device100of the printer1may be provided in the ink return path57. In the second embodiment, the degassed ink is stored in the ink cartridge50, and the controller111may control the supply pump54and the feed pump582to supply the degassed ink to the sub tank70, and may adjust the amount of dissolved oxygen in the ink circulating in the ink circulation path580to be within a predetermined range to supply the ink whose amount of dissolved oxygen is adjusted to a predetermined range to the ink ejecting section515. The liquid ejecting apparatus may include a carriage on which the liquid ejecting section is mounted, and may eject the liquid from the liquid ejecting section mounted on the carriage that moves along the printing paper as a medium to print an image on the printing paper. In this case, for example, in the second embodiment, the sub tank70, the filter unit81, the damper unit83, the ink ejecting section515, the feed pump582, and the warming device950that constitute the ink circulation path580of the ink ejecting unit510may be mounted on the carriage. In the second embodiment, the damper unit83of the printer501may be a pressure reducing valve having a damper function capable of absorbing pressure fluctuations of the supplied ink. The liquid ejecting apparatus may include an electric heat conversion element such as a heater capable of heating the liquid in the individual liquid chamber as the ejection element included in the liquid ejecting section. For example, in the first embodiment, the controller111of the printer1may drive the heater as the ejection element89of the ink ejecting section15to heat the ink in the individual liquid chamber86to cause the film boiling, and may cause the nozzle24to eject the ink. In this case, the state detection unit may compare the maximum temperature, at the time of ink ejection, detected by the temperature detection element as the detector group112directly provided under the heater with a predetermined threshold value, or calculate the difference in temperature change to estimate the state inside the individual liquid chamber86. Further, a flying object detector, using an optical element, as the detector group112may be further provided, and the state detection unit may detect the ejection state by using the flying object detector. The controller111may estimate the ink state of the ink ejecting section15by combining the state detection in the individual liquid chamber86and the detection result by the flying object detector using the optical element. | 100,506 |
11858267 | DETAILED DESCRIPTION First, the operating principle of a CIJ printer will be explained schematically based onFIGS.1ato1d. The characters to be printed are each defined as a group of dots on a matrix, with the dots then created by ink droplets. This can be represented as bitmap90for machine processing. InFIG.1a, the letter “E” on a 7×5 matrix1is shown as a simple example of such a bitmap90. In reality, however, today a CIJ printer can usually illustrate more dots in one row, e.g. 32 dots, which allows the user to compile complex contents, as shown by way of example inFIG.1d, as a desired printed image, which is then converted into the corresponding bitmap and processed. When such a bitmap90is printed, one dimension of the matrix on which it is based, in the orientation ofFIG.1athe direction z of the rows, is realized by a different deflection of the ink droplets, while the other dimension, in the orientation ofFIG.1a, the direction s columns, is realized by a movement of the material to be printed. In particular, in the case of a different orientation, the role of the rows and columns can of course be reversed. FIG.1cshows schematically how the production and deflection of the ink droplets is realized by the CU printer. The ink is provided with defined properties, in particular defined pressure and defined viscosity, by a hydraulic module5shown only schematically inFIG.1cand is supplied to the ink channel of the nozzle10, which cannot be seen inFIG.1c. The ink column in the ink channel of the nozzle10is modulated by means of an oscillator20, which can be designed, for example, as a piezo actuator. With suitably selected jet conditions, which theoretically were derived from C. Weber in the journal of applied mathematics and mechanics, volume 11, 1931, constrictions are formed after exiting the nozzle10, until there is a splatter-free separation of ink droplets12at tear-off point11, which form an ink droplet jet. Typically, the ink droplets12of a jet that meets these conditions propagate at a speed of 20 m/s to 30 m/s, and high five-digit and even six-digit numbers of ink droplets12can be produced per second today. After the separation of an ink droplet12, it is provided with a target charge on the charge electrode25, wherein the success of the charging process can be checked with a detector electrode, which is not recognizable inFIG.1c, and is deflected at an energized deflection plate or deflection electrode30to different degrees depending on the charge, so that, as is shown by way of example inFIG.1c, the charged ink droplets12, when they hit the substrate100to be printed, land at a more or less well-defined position, at the present orientation row position, of the matrix defining the character, while unused ink droplets12a, that are not charged, continue to fly into the catcher tube35and are returned to the ink mixing tank (not shown) in the hydraulic module5. The charge electrode25is controlled by a control unit, which converts a printed image which is produced directly or indirectly in a memory60by a user into a bitmap90in a grid image processor65, and forwards the information about the rows or columns to be printed to a charging voltage computer70on the one hand, which is preferably designed as a separate processor. The charging voltage computer70generates a corresponding charging signal according to the calculated charge to be applied and passes it on as a control signal to the charge electrode25. The fact that the substrate100to be printed is moved makes it necessary, in particular if the printing speed is to be maximized, to print the rows (or columns) produced by different deflections of the droplets12as quickly as possible, since otherwise these are no longer on one row. Therefore, these are each processed by the CIJ printer as a common “stroke”40,41, as illustrated inFIG.1b. Specifically, the processing, as shown inFIG.3in the form of a schematic flow diagram, is accomplished in the CIJ printer in that a printed image predefined by the user in step110, which, if it contains a counter information, for example, can change between printing processes to be carried out directly one after the other and is stored or cached in the memory60, the bitmap90to be printed is obtained on a processor or processor core, the Raster Image Processor (RIP)65, in a process referred to as ripping120and in particular the respective dot sequence, the current stroke40,41, to be imaged next by the CIJ printer, is determined, which indicates, at which locations of the substrate100ink droplets12are to be applied in order to generate dots. It is important for the invention that at this point there is already at least implicit information about the expected printed image, which is configured according to the invention as a target specification for success monitoring. This information is then, on the one hand, in step125forwarded as input to the data processing system75, which is here implemented with a separate processor, which carries out the comparison between the signal to be printed and an image of the printing carried out, which images is forwarded from the optical monitoring means80, which here is executed as a CCD camera, to the data processing system75. On the other hand, the information is further processed by the charging voltage computer70. The charging voltage computer70calculates from said information—preferably taking into account the information which stroke or which strokes were printed shortly before and, if applicable, also already which stroke or which strokes are printed immediately afterwards—in step130, the charging voltage which has to be applied to the droplets associated with the stroke so that they land at the desired location of the substrate so that said charging voltage can be applied to the charge electrode25during flyby. These calculations are particularly complex because, on the one hand, space charges and, on the other hand, aerodynamic effects such as the slipstream of other droplets can significantly influence the trajectory of the ink droplets and their point of impact on the substrate. Therefore, the process step130is also preferably carried out on a separate processor or processor core. The charging voltage obtained in this way is then used to control the charge electrode25in step140during the execution of the actual printing process and charges droplets12of the continuous ink droplet stream so that said ink droplets are deflected by the deflection voltage applied to the deflection plate30from the stream of the uncharged ink droplets12atraveling to the catcher tube35and are applied to the substrate100. In order to define the start time of the printing process for a printed image to be applied and to enable its timing, a “print GO” signal is generated, e.g. when an object to be printed, which passes through the CIJ printer and is to be printed while passing through, reaches a defined position relative to the CIJ printer. This then triggers the printing—possibly after an adjusted waiting time—starting with the first stroke40,41; it may be useful to wait for a prespecifiable waiting time between successive strokes40,41. For checking and monitoring the printing process, a camera image is captured at step150, preferably with an optical monitoring means80here designed as a CCD camera. This can be triggered, for example using the print go signal as a time frame of reference. The image data of the camera image are then forwarded to a data processing system75and evaluated in step160. While this evaluation in the state of the art is usually carried out as an evaluation of the entire print on the object in comparison with the bitmap90to be printed according to the invention, this is done by an evaluation of the individual rows or columns of the printed image, each formed by a stroke40,41. It should be pointed out explicitly that this is not already the case automatically if the individual cells of the CCD chip of the optical monitoring means80, which is here designed as a CCD camera, are read out row by row or column by column during an image evaluation and the corresponding data are then processed further, which is not an evaluation of rows or columns of the printed image but an evaluation of rows or columns of the camera image. However, this cannot provide the same results for the reason alone that it would be unsatisfactory for the attainable accuracy of the resolution if an ink droplet on the substrate would correspond only to a set pixel in the camera image. If the evaluation in step160shows indications of a malfunction or a printing error, an error warning or a printing stop can be triggered in step170. Otherwise, the processing can be continued by returning to step120, especially if the next stroke40,41has not yet been calculated. However, in the return to step120, it is also possible to read out an already calculated further stroke from a local memory, which is preferably managed according to the FIFO principle. In order to understand even more precisely the advantages of the procedure resulting from such a row- or column-based evaluation, an example of a bitmap190to be printed and the corresponding printed image195shown inFIG.2b, as it is captured by the optical monitoring means80, executed here as a CCD camera, is discussed here with reference toFIG.2a. The imaging of an ink droplet12in the printed image195captured by the optical monitoring means80, executed here as a CCD camera, typically comprises between 10 and 20 pixels; the exact value of course dependents on the resolution of the respective optical monitoring means80used and its geometric arrangement relative to the substrate100to be printed. The bitmap190shown inFIG.2a, which in particular can also be used for a teach-in process according to the invention, is formed by a sequence of all dots or ink droplet combinations that can be written with a five-dot stroke40,41, i.e., all possible strokes40,41that are executed by a printer that writes five droplets wide. When comparing the twoFIGS.2aand2bwith one another, a number of systematic deviations of the real printed image195according toFIG.2bfrom bitmap190according toFIG.2acan be clearly seen. For example, one can immediately see a slight tilting of the individual strokes40,41to the left, so that the uppermost droplet of a stroke40,41in each case is the droplet of the stroke40,41arranged furthest left on the substrate. This effect is related to the speed at which the substrate100is moved. In addition, however, it can also be seen that the position of the individual rows changes, in particular depending on whether an adjacent droplet is present or not. This effect can be particularly clearly seen in the top row when comparing the group of droplets belonging to this group of droplets of the last eight strokes40,41with the group belonging to this group of droplets of the ninth to sixteenth last stroke40,41, which are offset upwards as compared to the first group, but said effect clearly also results from the height offset of the droplets that belong to the last row. A further deviation from the ideal image, which is specified by the bitmap190ofFIG.2a, in the generated printed image195as captured by the optical monitoring means80according toFIG.2b, consists in that adjacent ink droplets can converge. For example, this can be seen in some of the droplet pairs that can be seen in the second-lowest row ofFIG.2b, for example, in the fifth and eighth droplet pairs of this row. These respective deviations are not an indication of an interference effect, but also occur with printing that occurs without interference. In the previously customary comparison of the entire printed image195with the bitmap190to be printed, deviations are accordingly taken into account that are actually not caused by any newly occurring printing errors. Instead, when using the teaching according to the invention, the printed images of the individual strokes40,41captured by the optical monitoring means80can be used as the desired image which should be produced in response to the printing command for this stroke40,41, which leads to a very rapid evaluation. Firstly, it is not necessary to wait until the entire bitmap190is printed in order to then compare it with the printed result, but the comparison is possible immediately after the execution of a stroke40,41. With the image evaluation, it is not only advantageous that the corresponding objects to be compared with one another are much smaller, but also that one knows in advance where to look for dots of the currently printed stroke40,41on the CCD chip of the optical monitoring means80, because, on the one hand, from a camera image such as that shown inFIG.2bthe ink droplet positions in the y-direction characteristic of a stroke40,41can be derived and, on the other hand, the offset in the x-direction between adjacent strokes40,41. This allows a very targeted comparison algorithm, in which the search for the printed ink droplet can begin immediately in the correct area of the CCD chip and an expected position of the ink droplet image can be specified with a relatively high degree of certainty. If deviations between such expected positions and the positions at which the corresponding ink droplets of the respective stroke40,41are then found in the camera image are systematically logged, then changes that are gradually emerging and in the long-term require corrections to print parameters such as changes in ink viscosity or in the proportions of concentrated ink and solvent, can potentially be derived at an early stage from the corresponding changes in the printed image and then corrected by initiating appropriate countermeasures before any malfunctions or misprints occur. In addition, the stroke-based approach enables an extremely simple teach-in process which may ultimately even make it possible to operate an optical monitoring means80on a CU printer as a true plug-and-play module and which teach-in process is shown schematically inFIG.4. In order to teach-in an optical monitoring means80after installation, it is, in step210, only necessary to generate at least one defined sequence of all strokes40,41, i.e. all possible combinations of written ink droplet positions in a stroke40,41, as a bitmap and to print this sequence on the substrate100in step220under the operation conditions to be used later. This printed image is then captured in step230with the optical monitoring means80, which is designed as a camera, and at least one corresponding camera image is evaluated in step240, preferably in order to obtain expected values for ink droplet positions of the individual strokes40,41. Specifically, for example, each stroke40,41or a control signal corresponding to this stroke40,41is assigned or logically connected to the position of the ink droplets12on the CCD chip of the optical monitoring means (80), which is executed as a camera, in a y-direction, which corresponds to the deflection direction of the ink droplets12, as expected ink droplet positions. On the other hand, by analyzing the distance between the images of the individual strokes40,41on the CCD chip of the optical monitoring means80, which is designed as a camera, information is obtained, at which x-positions on the CCD chip of the optical monitoring is to be expected by means of 80 ink droplets of an n-th stroke40,41of a predetermined sequence of strokes40,41. If a bitmap90,190is then printed after the teach-in process in real operation, the output of the ripper65representing a specific stroke40,41may be directly forwarded, if applicable, together with information about which stroke40,41for writing this bitmap90,190it is, as input for the data processing device75that analyzes the camera image. This input can then be converted directly into a set of expected pixel positions for the ink droplets12associated with this stroke40,41and it can be checked whether the corresponding pixels are set in the camera image. Even if the droplet position has moved slightly, quickly locating the newly added droplets12is ensured in this way, and by analyzing deviations it is possible to determine, on the one hand, whether the imprint is still acceptable or not by a comparison with the acceptance ranges to be determined, while, on the other hand, indications of the problems at hand that cause a deviation from the target position may already be obtained. LIST OF REFERENCE NUMBERS 5Hydraulic module10Nozzle11Tear-off point12Ink droplet12aUncharged ink droplet20Oscillator25Charge electrode30Deflection plate35Catcher tube40,41Stroke65Raster Image Processor (Ripper)70Charging voltage computer75Data processing system80Optical monitoring means90Bitmap100Substrate110Specifying a printed image120Ripping125Forwarding input to data processing system130Calculating the charging voltage140Controlling the charge electrode150Capturing a camera image160Evaluating the camera image170Error warning190Bitmap195Printed image210Generating a sequence of all possible strokes as a bitmap220Printing the bitmap230Capturing a camera image240Evaluating the camera images Direction of the columnsz Direction of the rows | 17,218 |
11858268 | DETAILED DESCRIPTION OF EMBODIMENTS With reference toFIGS.4-5there is illustrated an end-user fillable fluid cartridge30having a cartridge body32and one or more empty chambers34a,34btherein. The chambers34a,34bare isolated from one another by a dividing wall36. Each of the chambers34aand34bis devoid of a backpressure device. Fluid slots38aand38bare provided in each of the chambers34aand34bto provide flow of fluid from the chambers34aand34bto the ejector arrays20aand20battached adjacent to the fluid slots38aand38b. The ejector arrays20aand20bare contained in a fluid ejection head chip40attached to the cartridge body32by means of an adhesive and a flexible circuit tape42. FIGS.7and8provide details of the fluid ejector array20. A nozzle plate44containing nozzle holes24and fluid ejection chambers46is attached to a semiconductor substrate50having fluid ejectors52thereon. For simplicity, a portion of an ejector array illustrating a single fluid ejector52and corresponding ejection nozzle hole24is shown. However, a single fluid ejection head chip40may include one or more ejector arrays20. Likewise, one or more fluid ejection head chips40may be attached to the cartridge body32. Ejector arrays20typically contain one or more fluid ejectors52and corresponding ejection nozzles24. Fluid is provided to each ejector array20aand20bfrom the fluid slots38aand38bin the chambers34aand34bof the fluid cartridge30through a fluid supply via54etched through the semiconductor substrate50. As shown inFIG.8, the fluid supply via54may provide fluid to one or more fluid ejector arrays56aand56b. For the purposes of the disclosure, the term “open-top” refers primarily to a lack of a backpressure device found in standard fluid cartridges and does not necessitate the lack of a cover or lid on the fluid cartridge. However, the fluid cartridge30has one or more chambers34therein for filling by a user to provide fluid to the fluid ejection head chip40. In order to prime the fluid ejection head chip40with fluid, a mechanical shock, heat, and/or rapid acceleration of the fluid cartridge30is provided to disturb the fluid, thereby promoting capillary action of the fluid from the fluid chambers46to the nozzles24of the nozzle plate44thereby establishing a fluidic connection throughout the ejection head chip40and the fluid in the cartridge body32. The term “impact” as used herein refers to a high force or shock applied to the cartridge body32over a short period of time. The ejection head chip40is a micro electromechanical system that contains one or more fluid paths from the backside58of the chip40to the front side of the chip40and one or more arrays20of fluid ejectors52that are activated to eject fluid from the external face28of the chip and onto a substrate. The backside58of the ejector head chip40is sealed against a bottom wall of the cartridge body32and is in fluidic connection fluid in the chamber(s)34of the cartridge body32. As described above with reference toFIG.3, the backpressure device in a standard fluid cartridge causes a slight concavity of the meniscus26of the fluid at the fluid/air interface. Due to the concavity of the meniscus26, an impact applied to the fluid cartridge may cause the meniscus26to collapse and ingest air into the ejector array20. Such air bubbles pose a significant issue for reliable jetting of fluid from the ejector array20. However, in open-top fluid cartridges30, that do not contain a backpressure device, the meniscus56of the fluid22at fluid/air interface is convex as shown inFIG.9. The convexity of the meniscus56helps prevent ingestion of air as the impact to the fluid cartridge body30takes place when priming any arrays in the fluid ejection head chip40. Although spontaneous priming of the ejection head chip40is ideal, the surface tension of many fluids may be too great to allow for the initiation of capillary motion from the backside58of the ejector array20to the front side of the external face28of the ejector array20. Accordingly, an impact to the cartridge body32as shown by arrow60(FIG.10) or a rapid acceleration of the fluid cartridge in a direction perpendicular to a plane defined by the external face28of the ejector array20may provide a disturbance necessary to cause the fluid22to transition to the next part of the fluid path without the need for increasing the pressure head of the fluid, thereby allowing for reliable priming of smaller volumes of fluids. Other fluid properties that may impact the capillary action of the fluid through the ejector array20include, but are not limited to, viscosity, polarity, and density. The magnitude and frequency of the impact may need to be adjusted for different fluids. FIG.11illustrates a manual priming device70that may be used to provide an impact to an open-top fluid cartridge72containing a single chamber74. The device70includes a cartridge mounting area76, a spring biased plunger78and a plunger knob80. Once the fluid cartridge is positioned in the cartridge mounting area76, a user may pull and release the plunger knob80to provide a sharp impact to the cartridge body82. One or more impacts to the cartridge body82by the plunger78may be required to adequately prime the fluid ejection head chip attached to the cartridge body82. While a mechanical plunger78is illustrated inFIG.11, it will be appreciated that a pneumatic, hydraulic or electro-mechanical actuator may also be used. Likewise, the plunger knob80may be rotated to provide a spring-loaded rotational impact to the cartridge body82. In some embodiments, the mechanical or otherwise actuated plunger78may be incorporated in the fluid ejection device10.FIGS.12-14illustrate the use of a linear solenoid activated plunger84that is mounted to a frame86of a fluid ejection device. The fluid cartridge is mounted into a carriage88for moving the fluid cartridge and ejection head chip40in an x direction back and forth over a substrate as fluid is dispensed from the fluid cartridge. After filling the fluid cartridge, the carriage88is positioned adjacent to the linear activated solenoid for activating the plunger90so that the plunger90impacts a side of the carriage88to prime the fluid cartridge.FIG.12is a front, elevational view, of the frame86, carriage88, and linear solenoid plunger84.FIG.13is a top perspective view of the linear solenoid plunger84, frame86, and carriage88ofFIG.12. Another embodiment of the disclosure is illustrated inFIGS.14-15. In this embodiment, rather than using a dedicated impactor84, the frame92of the fluid ejection device contains one or more fixed impact devices94A and94B for impacting the side of the cartridge30as the carriage88moves from one side of the frame92(FIG.14) to the other side of the frame92(FIG.15). According to the embodiment, the carriage88of the device10is driven by a motor which may be programmed to move the carriage88to a specified position to impact the cartridge30on impact device94A or94B at a specified speed. Accordingly, the impact position for the cartridge30may be slightly outside of a typical operating range which causes the carriage88to impact the fixed impact devices94A and94B on the frame92. The collision of the carriage88with the impact devices94A and94B provides energy sufficient to initiate priming of the ejection head chip40. Since the motion of the carriage88is programmable, any sequence of speed and position may be used to ensure priming of the ejection head chip40. While the foregoing embodiments illustrate fixed impact points for the carriage88relative to the frame86and92of the device10, an adjustable impact device may be used to adjust the location where the carriage88is impacted. While the impact device may be adjustable in the y direction parallel to a plane defined by a side of the carriage88, the impact device may also be adjustable in the direction of motion of the carriage88along the x direction which is perpendicular to the plane defined by the side of the carriage88. In other embodiments, instead of the impact device being rigidly mounted, the impact device may be hung from an axle to act as a pendulum that repeatedly swings and taps a side of the carriage88until all energy of the pendulum is dissipated. Counterweights or damping materials may be used to modify the energy of the impact on the carriage88. In yet another embodiment, the empty chamber(s)34may be filled and the cartridge30rapidly accelerated in a direction perpendicular to a plane defined by the external face28of the ejector array20(FIG.6). Without desiring to be bound by theoretical considerations, it is believed that an inertia of the fluid may resist the change in motion and provides enough pressure against a backside58of the ejector array20(FIG.7) to initiate capillary wicking action of fluid through the fluid supply via54and into the fluid supply channel48and fluid ejection chambers46. In a similar manner, a cartridge30containing fluid could be placed in a centrifugal-type device with the ejector array20facing radially outward. Thus, the inertial resistance of the fluid now coupled with the centrifugal force from the centrifugal-type device may be sufficient to prime the ejector array20. In still another embodiment, ultrasonic vibrations may be used to induce priming of the ejector array20and promote fluid flow to fluid ejection chambers46. In some embodiments, priming may be achieved by shaking the cartridge30. Often when an open-topped cartridge30(FIGS.4-5) is filled with a pipette, some fluid adheres to the walls of the empty chambers34aand34band are not recoverable for ejection by the ejector array20. Rapidly moving the cartridge30back and forth in the x direction, with a high frequency and small amplitude, can help dislodge fluid from the side walls of the chambers34aand34band cause fluid to flow into the fluid slots38aand38bwhere it can then flow to the ejector array20. A series of shaking and then impact, as described above, may produce the optimal conditions for ensuring priming of the ejector array20when filling the chambers34aand34bof the cartridge30with small volumes of fluid. Additionally, since the ejector array20is typically not centered with respect to the chambers34aand34b, the direction of impact may affect the priming process. For example, if the fluid slot38afeeding the ejector array20is offset to the right side of the chamber34a, tapping the right sidewall98of the cartridge body32(FIG.10) may improve the priming process. The following non-limiting examples illustrate an impact process for priming an ejector array20. Example 1 Using an open-top four-chamber cartridge required a fluid pressure head of about 28.5 millimeters to induce spontaneous priming of all nozzles24of an ejector array20. Using the same fluid, a fluid pressure head of only 0.5 millimeters consistently primed all nozzles24with the use of the impact apparatus ofFIG.11. Using a desktop printer, a sequence of carriage movement overdrive commands was able to reliably prime an ejector array20with a 50-microliter sample of ink in the fluid cartridge, equivalent to a fluid pressure head of 2.5 millimeters. Example 2 Phosphate buffered saline (PBS) is a common reagent used in biochemical assays. Two solutions, with or without a sorbitan monolaurate non-ionic surfactant, underwent testing. Spontaneous priming of an ejection head chip with either solution was undeterminable, both requiring a fluid pressure head greater than the maximum testing fluid height of 43 millimeters. Using the impact apparatus ofFIG.11, the PBS without the surfactant was able to reliably prime the ejection head chip with 2.3 millimeters of fluid pressure head while PBS with added 0.04% surfactant was able to reliably prime the ejection head chip with 2.0 millimeters of fluid pressure head. A carriage impact sequence was determined which could reliably prime the ejection head chip with the PBS and surfactant solution at a fluid pressure head of 3.4 millimeters. In other embodiments, pre-heating the fluid using a heater positioned on the ejection head chip40may be sufficient to induce flow of fluid from the cartridge30into the ejector array20. Example 3 Priming sequences have been determined which can reliably prime 30 microliters of phosphate buffered saline (PBS)—in the open-top fluid cartridge30. In this test, 30 microliters of fluid provided approximately 2.6 millimeters of fluid pressure head. The fluid was heated to 45° C. for 20 seconds using the ejection head chip heater on the ejector array20, and then the carriage88was tapped against the frame92of the device10two times at a speed of about 51 cm per second. The temperature, duration, and impact parameters are fluid dependent. It was found that either heating the fluid or tapping the frame was enough to prime most nozzles of the ejection head chip. Even greater success was found with both heating the fluid and tapping the frame which consistently primed all nozzles of the ejection head chip. Using a lower preheat temperature required a longer heating period for a given fluid. In accordance with the disclosed embodiments, a priming sequence is defined as a series of steps that are used to ensure that a cartridge containing a specific fluid is ready to be dispensed through all nozzles of ejector array20. Once the cartridge is placed in the carriage of a device, the priming sequence may include one or more of the following steps:1) Tapping the carriage against the frame of the device to impart an impulse to the ejection head chip.2) Repeating step (1) multiple times, with or without pauses in between.3) Impacting the carriage against the frame of the fluid ejection device at various speeds.4) Warming the fluid by using the ejection head chip heater on the ejection head chip. Modifying the temperature and duration of heating for a specific fluid or application.6) Ejecting fluid from the ejection head chip. Accordingly, a priming sequence for a particular fluid may include of one or more of the foregoing steps in any sequence. In some cases, it may be determined that some of the steps are not required. For more difficult to prime fluids, it may be determined that some of these steps need to be repeated more than once. For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or can be presently unforeseen can arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they can be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents. | 15,469 |
11858269 | DETAILED DESCRIPTION For simplicity and illustrative purposes, the present disclosure is described by referring mainly to examples. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be readily apparent however, that the present disclosure may be practiced without limitation to these specific details. In other instances, some methods and structures have not been described in detail so as not to unnecessarily obscure the present disclosure. Throughout the present disclosure, the terms “a” and “an” are intended to denote at least one of a particular element. As used herein, the term “includes” means includes but not limited to, the term “including” means including but not limited to. The term “based on” means based at least in part on. Disclosed herein are apparatuses, e.g., fluidic dies, print heads, or other types of apparatuses that may include segmented cavitation plates for fluidic chambers in the apparatuses. Each of the segmented, e.g., individual, cavitation plates may function as a fluidic sensor for a respective fluidic chamber (e.g., nozzle chamber). For instance, the individual cavitation plates may function as sensors that may be implemented to sense the presence of drive bubbles used to propel droplets of fluid, e.g., printing medium, ink, or the like, held in the fluidic chambers. By way of example, the individual cavitation plates may function as impedance sensors in the fluidic chamber to detect characteristics of the fluid during drive bubble formation. In addition to functioning as sensors, the individual cavitation plates may protect underlying thin film layers (e.g., conductive traces, metal layers, insulative layers, oxide layers, and/or the like) susceptible to over-etch during manufacturing processes. Also disclosed herein are fluidic dies, which may be print heads, and methods for fabricating an apparatus that may include the individual cavitation plates. Through implementation of the apparatuses, fluidic dies, and methods disclosed herein, individual cavitation plates may be provided to both protect underlying thin film layers and to detect conditions, e.g., impedance levels during bubble formation. The individual cavitation plates disclosed herein may afford both the protection and the condition detection and thus, the apparatuses disclosed herein may be fabricated with a fewer number of components, which may reduce complexity and costs associated with the fabrication of the fluidic dies. Reference is made toFIGS.1A-3.FIGS.1A and1B, respectively, depict diagrams of an example apparatus100that may include a segmented cavitation plate130.FIG.2depicts a diagram of an example apparatus200that may include a heating component120and a dielectric layer240.FIG.3depicts a diagram of an example device300that may include a plurality of the apparatuses200depicted inFIG.2. It should be understood that the apparatus100depicted inFIGS.1A and1B, the apparatus200depicted inFIG.2, and/or the device300depicted inFIG.3may include additional features and that some of the features described herein may be removed and/or modified without departing from scopes of the present disclosure. In the examples illustrated inFIGS.1A-3, the apparatus100is described with respect to a single fluidic chamber110and other components (as shown inFIGS.1A and1B) and the apparatuses200,300are described with respect to multiple fluidic chambers110-1to110-nand other components (as shown inFIGS.2and3). The descriptions of the apparatuses100-300and the methods of the present disclosure make reference to particular types of printers, such as inkjet printers. However, it should be appreciated that other examples are envisioned in the present disclosure, for example, implementation of multiple controllers102to control different arrays of fluidic dies, e.g., print heads, or other types of devices, implementation on two-dimensional (2D) or three-dimensional (3D) print applications, micro-fluidic die applications, bio applications, lab-on-a-chip (LOC), and/or other types of applications. According to examples, and a shown inFIGS.1A-2, the apparatus100may include a fluidic chamber110, a heating component120, and a cavitation plate130. A fluid111, which may be ink, a chemical, or other type of fluid, may be temporarily held in the fluidic chamber110. For instance, the fluid111may be delivered into the fluidic chamber110from a reservoir (not shown) as denoted by the arrow104and may be expelled from the fluidic chamber110through a nozzle106as denoted by the arrow108. Thus, the fluid111may temporarily be held in the fluidic chamber110prior to the fluid111being expelled through the nozzle106. In operation, the heating component120may generate heat to form a drive bubble112in the fluid111held in the fluidic chamber110. As also discussed herein, the heating component120may be a thin film layer formed of a resistive element206coupled to a conductive layer202,204. An electric current may be applied through the resistive element206from the conductive layer202,204, which may cause the resistive element206to become heated. The generated heat may flow through the cavitation plate130and into the fluidic chamber110as denoted by the arrows114. In instances in which fluid111is held in the fluidic chamber110, the heat may vaporize some of the fluid111, which may cause the drive bubble112to be formed. The drive bubble112may be formed rapidly, causing the pressure within the fluidic chamber110to rapidly increase. The rapid increase in pressure may cause some of the fluid111to move out of the fluidic chamber110, e.g., expelled through the nozzle106as a droplet of the fluid111. According to examples, electric current may be applied to the resistive element206in the heating component120for a relatively short duration of time, e.g., for a fraction of a second. Following the cessation of the electric current application, the drive bubble112may dissipate. As the drive bubble112dissipates, the pressure level inside the fluidic chamber110may become lower, which may cause fluid111to be drawn into the fluidic chamber110from the reservoir as denoted by the arrow104. As shown inFIG.1A, the cavitation plate130may be provided between the fluidic chamber110and the heating component120to protect the heating component120from, for instance, the forces caused by the formation and collapse of the drive bubble112. The cavitation plate130may also protect the heating component120during a fabrication process of the apparatus100. The cavitation plate130may be in communication with the fluidic chamber110and may physically separate the heating component120from the fluidic chamber110such that no section of the heating component120is exposed to the fluidic chamber110. In some examples, a portion of the cavitation plate130may be positioned in the fluidic chamber110, in physical contact with the fluid111, and may function as a “floor” for the fluidic chamber110. In addition, the cavitation plate130may be electrically isolated from the heating component120. For instance, the cavitation plate130may be physically separated from the heating component120and/or an electrically insulative material may be provided between the cavitation plate130and the heating component120such that electric current may not be conducted from the conductive layer202,204and/or the resistive element206to the cavitation plate130and vice versa. The cavitation plate130may also be implemented as a sensor, e.g., an impedance sensor, to detect a condition in the fluidic chamber110during or after generation of the drive bubble112. According to examples, a controller102may be electrically connected to the cavitation plate130and the controller102may detect an electrical signal from the cavitation plate. That is, for instance, the controller102may cause an electric current to be applied across the cavitation plate130and through the fluid111, which may have a resistive component220, as shown inFIG.2. The controller102may detect an electrical signal level through the cavitation plate130and may determine the condition, e.g., impedance, in the fluidic chamber110according to a value, e.g., strength, resistance, or the like, of the detected electrical signal. According to examples, a plurality of fluidic chambers110may be provided, and the cavitation plate130may be segmented into a plurality of electrically isolated plates that function as sensors for respective fluidic chambers110. According to examples, the apparatus100may be a fluidic die, such as a print head. In these examples, the heating component120may cause fluid111to be ejected through the nozzle106as droplets. The apparatus100may be part of a two-dimensional printer that may deposit droplets of the fluid111onto a print media, such as paper. Alternatively, the apparatus100may be part of a three-dimensional (3D) printer that may deposit droplets of the fluid111onto build material particles during a 3D printing operation. In other examples, and as shown inFIG.1B, the apparatus100may function as a fluidic pump that may move fluid111from one location to another, e.g., without causing the fluid111to be ejected from the apparatus100through a nozzle106. For instance, the apparatus100may have a u-fluidic pump architecture. In examples in which the apparatus100is to function as a fluidic pump as shown inFIG.1B, the apparatus100may not include a nozzle106. Instead, the expansion of the drive bubble112may not cause some of the fluid111to be ejected from the fluidic chamber110, but may cause fluid111within the fluidic chamber110to be displaced within the fluidic chamber110and/or a channel in fluidic communication with the fluidic chamber110. Referring toFIG.2, an apparatus200may include similar components as the apparatus100depicted inFIG.1A. The apparatus200is depicted as, however, including additional components. The common components depicted inFIG.2are not described in detail and instead, the descriptions of these components with respect toFIG.1Ais relied upon to describe the common components ofFIG.2. Alternatively, it should be understood that the apparatus200may instead include the features shown inFIG.1B. As shown inFIG.2, the heating component120may be a thin film layer and may include the conductive layers202,204and the resistive element206. The resistive element206may include a resistor or multiple resistors and may receive electric current that may flow through the conductive layers202,204. In this regard, the resistive element206may be electrically coupled to a conductive layer202and/or204. In some examples, the conductive layers202,204may be made of metal, such as copper, silver, gold, and/or the like, and may be formed as conductive traces. Electric current may be applied into one of the conductive layers202and may flow through the resistive element206as the electric current flows out of the other conductive layer204. As discussed above, as current is applied through the resistive element206via the conductive layers202,204, the resistive element206may become heated, which may cause some of the fluid111in the fluidic chamber110to vaporize, which in turn may cause formation of the drive bubble112. Although not shown, an insulation layer may electrically isolate the conductive layers202and204, and the conductive layers202and204may be electrically connected by a connection208(e.g., a via) to form a return path for the current. A dielectric layer240(e.g., thin film layer formed of TetraEthyl OrthoSilicate (TEOS), or the like) may be provided over portions of the cavitation plate130and the heating component120, or other underlying thin film layers as illustrated inFIG.2. The dielectric layer240may protect the portions of the cavitation plate130and the heating component over which the dielectric layer240is provided. For proper operation of the heating components120and cavitation plate130, the dielectric layer240may not be provided in regions corresponding to the fluidic chamber110. For example, as depicted inFIG.2, a boundary between a protected region252and an unprotected region251is represented by a dotted line250, and the dielectric layer240may be provided in the protected region252without extending into the unprotected region251. The heating component120may include a first portion located in the unprotected region251and a second portion located in the protected region252. As such, the dielectric layer240may not cover the underlying thin film layers (e.g., conductive layer202and/or resistive element206) located in the unprotected region251. In some examples as described herein, the cavitation plate130, which is disposed over the portions of the heating component120that may not be protected by the dielectric layer240, may cover the underlying conductive layers202,204(e.g., conductive layer202and/or resistive element206) in the unprotected region251. FIG.3depicts a diagram of an example device300that may include a plurality of the apparatuses200-1to200-ndepicted inFIG.2, in which the variable “n” may represent a value greater than one.FIG.3shows a top view of the apparatuses200-1to200-n. As shown, each of the apparatuses200-1to200-nmay be physically separate from each other, and may include respective cavitation plates130-1to130-n. In this regard, the cavitation plates130-1to130-nmay be segmented with respect to each other. In addition, each of the apparatuses200-1to200-nmay have the same components. For example, a cavitation plate130-1of one of the apparatuses200-1and a cavitation plate130-nof another one of the apparatuses200-nmay have the same structure, and may be coplanar to each other, e.g., formed from the same tantalum layer. Furthermore, each of the plurality of cavitation plates130-1to130-nmay overlap a corresponding one of the plurality of heating components120-1to120-nas shown. There may be an interest in a structural arrangement of cavitation plates130-1to130-noverlapping heating components120-1to120-n. Indeed, a unitary cavitation plate extending across and covering multiple underlying heating components may be undesirable, such as due to potential parasitic capacitance. Referring again toFIG.3, the plurality of cavitation plates130-1to130-nmay be disposed to protect the underlying heating components120-1to120-n. Particularly, the cavitation plates130-1to130-nmay be formed to overlap the heating components120-1to120-nin the unprotected region251. For example, in the unprotected region251where the dielectric layer240is not provided, the cavitation plates130-1to130-nmay be patterned to fully overlap portions of the underlying heating components120-1to120-n. The shapes of the cavitation plates130-1to130-nmay be formed to have shapes similar to those of the underlying conductive layers202,204. In some examples, a first portion of the heating components120-1to120-nwhich are disposed in the unprotected region251may have a prescribed width and the cavitation plates130-1to130-nwhich are disposed in the unprotected region251may have a width greater than the width of the first portion of the heating components120-1to120-n. In some examples, the cavitation plates130-1to130-nmay also cover sides of the heating components120-1to120-n. For example, to ensure acceptable performance of the cavitation plates130-1to130-nas sensors, parasitic capacitance of the sensor nodes may be minimized (e.g., by minimizing area). As such, overlapping of the heating components120-1to120-nby the cavitation plates130-1to130-nmay be designed to be a minimum amount to sufficiently protect the heating components120-1to120-nfrom over-etch, while maintaining sensor performance of the cavitation plates130-1to130-n. The shapes and widths of the heating components120-1to120-nand the cavitation plates130-1to130-nmay enable minimum overlapping and/or enclosure of the heating components120-1to120-nwhile maintaining a desired level of sensor performance of the cavitation plates130-1to130-n. Various manners in which the apparatuses100,200,300may be formed are discussed in greater detail with respect to the method400depicted inFIG.4. Particularly,FIG.4shows a flow diagram of an example method400for forming an apparatus100,200,300having a singulated cavitation plate130. It should be understood that the method400depicted inFIG.4may include additional operations and that some of the operations described therein may be removed and/or modified without departing from the scope of the method400. The descriptions of the method400are made with reference to the features depicted inFIGS.1A-3for purposes of illustration. At block402, a heating component120for a fluidic chamber110of a fluidic die, such as a print head, may be formed. The heating component120may have a first portion adjacent to the fluidic chamber110and a second portion that is offset from the fluidic chamber110. The first portion may be disposed in the unprotected region251and the second portion may be disposed in the protected region252. At block404, a cavitation plate130may be formed. The cavitation plate130may be positioned between the fluidic chamber110and the first portion of the heating component120in the unprotected region251. At block406, a dielectric layer240may be formed. The dielectric layer240may be in contact with the heating component120and/or the cavitation plate130in the protected region252without causing the dielectric layer240to be in contact with the portion of the heating component120and/or the cavitation plate130in the unprotected region251. At block408, the cavitation plate130may be connected to an electrical connection. The cavitation plate130may be coupled to a controller102, in which the controller102may determine a condition in the fluidic chamber110based on an electrical signal received from the cavitation plate130as discussed herein. The determined condition may be an electrical property of fluid111in a fluidic chamber110, and more particularly, the electrical property, e.g., impedance, of the fluid111during formation of a drive bubble112in the fluidic chamber110. In some examples, forming the heating component120may include forming a plurality of heating components120-1to120-nfor a plurality of fluidic chambers110-1to110-nof a fluidic die. In addition, forming the cavitation plate may include forming a plurality of cavitation plates130-1to130-nto be positioned between respective fluidic chambers110-1to110-nand heating components120-1to120-n. Furthermore, each of the plurality of cavitation plates130-1to130-nmay be formed to overlap a respective heating component120-1to120-nof the plurality of heating components120-1to120-nin order to provide protection for underlying thin film layers while also functioning as a sensor in the fluidic chamber110-1to110-n. Although described specifically throughout the entirety of the instant disclosure, representative examples of the present disclosure have utility over a wide range of applications, and the above discussion is not intended and should not be construed to be limiting, but is offered as an illustrative discussion of aspects of the disclosure. What has been described and illustrated herein is an example of the disclosure along with some of its variations. The terms, descriptions and figures used herein are set forth by way of illustration and are not meant as limitations. Many variations are possible within the spirit and scope of the disclosure, which is intended to be defined by the following claims—and their equivalents—in which all terms are meant in their broadest reasonable sense unless otherwise indicated. | 19,644 |
11858270 | DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, with reference to the attached drawings, preferable embodiments according to the present disclosure will be described. In addition, the dimensions and the scales of portions shown in the drawings are appropriately changed from the actual values, and to facilitate understanding of the present disclosure, some portions are schematically shown in some cases. In addition, the scope of the present disclosure is not limited to those described below unless otherwise particularly noted. In addition, the following description will be performed appropriately using an X axis, a Y axis, and a Z axis which intersect with each other. In addition, one direction along the X axis is called an X1 direction, and a direction opposite to the X1 direction is called an X2 direction. As is the case described above, directions along the Y axis opposite to each are called a Y1 direction and a Y2 direction. In addition, directions along the Z axis opposite to each other are called a Z1 direction and a Z2 direction. To view in the direction along the Z axis is called “in plan view”. In addition, in general, the Z axis is a vertical axis, and the Z2 direction corresponds to a downward direction along the vertical direction. However, the Z axis is not always required to be the vertical direction. In general, although being orthogonal to each other, the X axis, the Y axis, and the Z axis are not limited thereto, and for example, those axes may intersect with each other within an angle of 80° to 100°. 1. First Embodiment 1-1. Total Structure of Liquid Ejection Apparatus FIG.1is a schematic structural view of a liquid ejection apparatus100according to a first embodiment. The liquid ejection apparatus100is an ink jet type printing apparatus which ejects ink droplets, that is, one example of a liquid, to a medium12. The medium12is typically printing paper. In addition, the medium12is not limited to printing paper and for example, may be a printing object, such as a resin film or a cloth, formed from an arbitrary material. As shown inFIG.1, to the liquid ejection apparatus100, a liquid container14which stores an ink is fitted. As a particular mode of the liquid container14, for example, a cartridge detachable to the liquid ejection apparatus100, a bag-shaped ink pack formed from a flexible film, or an ink tank into which the ink can be replenished may be mentioned. In addition, the type of ink to be stored in the liquid container14may be arbitrarily selected. The liquid ejection apparatus100includes a control unit20, a transport mechanism22, a transfer mechanism24, and a liquid ejection head26. The control unit20includes a processing circuit, such as a central processing unit (CPU) or a field programmable gate array (FPGA), and a memory circuit such as a semiconductor memory and controls operations of elements of the liquid ejection apparatus100. In this liquid ejection apparatus100, the control unit20is one example of a “control portion” and controls a drive of a piezoelectric body443which will be described below. The transport mechanism22transports the medium12in the Y2 direction under the control by the control unit20. The transfer mechanism24reciprocally transfers the liquid ejection head26in the X1 direction and the X2 direction under the control by the control unit20. In the example shown inFIG.1, the transfer mechanism24includes an approximately box-shaped transport body242, which is a so-called carriage, to receive the liquid ejection head26and a transport belt244to which the transport body242is fixed. In addition, the number of the liquid ejection heads26mounted in the transport body242is not limited to one and may be at least two. In addition, in the transport body242, besides the liquid ejection head26, the liquid container14described above may also be mounted. Under the control by the control unit20, the liquid ejection head26ejects the ink to be supplied from the liquid container14from nozzles to the medium12in the Z2 direction. Since this ejection is performed in parallel with the transport of the medium12by the transport mechanism22and the reciprocation of the liquid ejection head26by the transfer mechanism24, on a surface of the medium12, an image of the ink is formed. In this case, the liquid ejection head26is one example of a “piezoelectric device”. In addition, the structure of the liquid ejection head26and the manufacturing method thereof will be described below in detail. 1-2. Total Structure of Liquid Ejection Head FIG.2is an exploded perspective view of the liquid ejection head26according to the first embodiment.FIG.3is a cross-sectional view taken along the line III-III shown inFIG.2. As shown inFIG.2, the liquid ejection head26has a plurality of nozzles N aligned in the direction along the Y axis. In the example shown inFIG.2, the nozzles N are separated into a first line L1and a second line L2which are arranged in the direction along the X axis with a predetermined interval therebetween. The first line L1and the second line L2are each a group of nozzles N aligned in the direction along the Y axis. In this case, elements relating to the respective nozzles N of the first line L1and elements relating to the respective nozzles N of the second line L2in the liquid ejection head26have structures approximately symmetric to each other in the direction along the X axis. However, the positions of the nozzles N in the first line L1and the positions of the nozzles N in the second line L2in the direction along the Y axis may or may not coincide with each other. Hereinafter, the structure in which the positions of the nozzles N in the first line L1and the positions of the nozzles N in the second line L2in the direction along the Y axis coincide with each other will be described by way of example. As shown inFIGS.2and3, the liquid ejection head26includes a flow path structural body30, a nozzle plate62, vibration absorbing bodies64, an vibration plate36, a wiring substrate46, a housing portion48, and a drive circuit50. The flow path structural body30is a structural body in which flow paths to supply the ink to the nozzles N are formed. The flow path structural body30of this embodiment includes a flow path substrate32and a pressure chamber substrate34, and those substrates are laminated in this order in the Z1 direction. The flow path substrate32and the pressure chamber substrate34are each a long plate-shaped member extending in the direction along the Y axis. The flow path substrate32and the pressure chamber substrate34are bonded to each other with an adhesive or the like. In a region located in the Z1 direction than the flow path structural body30, the vibration plate36, the wiring substrate46, the housing portion48, and the drive circuit50are disposed. On the other hand, in a region located in the Z2 direction than the flow path structural body30, the nozzle plate62and the vibration absorbing bodies64are disposed. The elements of the liquid ejection head26are each a long plate-shaped member extending in the Y axis approximately similar to the flow path substrate32and the pressure chamber substrate34and are bonded to each other with an adhesive or the like. The nozzle plate62is a plate-shaped member in which the nozzles N are formed. The nozzles N are each a circular through-hole through which the ink is allowed to pass. The nozzle plate62may be manufactured by processing a silicon single crystal substrate by a semiconductor manufacturing technology which uses processing techniques, such as dry etching or wet etching. However, in the manufacturing of the nozzle plate62, other known methods and materials may also be appropriately used. In the flow path substrate32, a space Ra, supply flow paths322, communication flow paths324, and a supply liquid chamber326are formed for each of the first line L1and the second line L2. The space Ra is a long opening extending in the direction along the Y axis in a plan view viewed in the direction along the Z axis. The supply flow path322and the communication flow path324are through-holes formed for each nozzle N. The supply liquid chamber326is a long space extending in the direction along the Y axis so as to be along the nozzles N and communicates the space Ra with the supply flow paths322. The communication flow paths324are overlapped with nozzles N which correspond thereto in plan view. The pressure chamber substrate34is a plate-shaped member in which pressure chambers C, each of which is called a cavity, are formed for each of the first line L1and the second line L2. The pressure chambers C are aligned in the direction along the Y axis. The pressure chamber C is formed for each nozzle N and is a long space extending in the direction along the X axis in plan view. As is the case of the nozzle plate62described above, the flow path substrate32and the pressure chamber substrate34are each manufactured, for example, by processing a silicon single crystal substrate using a semiconductor manufacturing technology. However, for the manufacturing of each of the flow path substrate32and the pressure chamber substrate34, other known methods and materials may also be appropriately used. The pressure chamber C is a space located between the flow path substrate32and the vibration plate36. For each of the first line L1and the second line L2, the pressure chambers C are aligned in the direction along the Y axis. In addition, the pressure chamber C communicates with the communication flow path324and the supply flow path322. Hence, the pressure chamber C communicates with the nozzle N through the communication flow path324and also communicates with the space Ra through the supply flow path322and the supply liquid chamber326. On a surface of the pressure chamber substrate34facing in the Z1 direction, the vibration plate36is disposed. The vibration plate36is a plate-shaped member which can be elastically vibrated. The vibration plate36will be described later in detail. On a surface of the vibration plate36facing in the Z1 direction, piezoelectric elements44corresponding to the nozzles N are disposed for each of the first line L1and the second line L2. The piezoelectric elements44are each a passive element which is deformed by a drive signal supply. The piezoelectric elements44each have a long shape extending in the direction along the X axis in plan view. The piezoelectric elements44are aligned in the direction along the Y axis so as to correspond to the pressure chambers C. In association with the deformation of the piezoelectric element44, when the vibration plate36is vibrated, the pressure in the pressure chamber C is changed, so that the ink is ejected from the nozzle N. The piezoelectric element44will be described later in detail. The housing portion48is a case which stores the ink to be supplied into the pressure chambers C. As shown inFIG.3, in the housing portion48of this embodiment, for each of the first line L1and the second line L2, a space Rb is formed. The space Rb of the housing portion48and the space Ra of the flow path substrate32communicate with each other. A space formed by the space Ra and the space Rb functions as a liquid storage chamber (reservoir) R which stores the ink to be supplied into the pressure chambers C. The ink is supplied to the liquid storage chamber R through an inlet port482formed in the housing portion48. The ink in the liquid storage chamber R is supplied into the pressure chambers C through the supply liquid chamber326and the supply flow paths322. The vibration absorbing body64is a flexible film (compliance substrate) forming a wall surface of the liquid storage chamber R and absorbs the change in pressure of the ink therein. The wiring substrate46is a plate-shaped member in which wires which electrically couple the drive circuit50to the piezoelectric elements44are formed. A surface of the wiring substrate46facing in the Z2 direction is bonded to the vibration plate36with electrically conductive bumps B interposed therebetween. On the other hand, on a surface of the wiring substrate46facing in the Z1 direction, the drive circuit50is mounted. The drive circuit50is an integrated circuit (IC) chip which outputs a drive signal to drive each piezoelectric element44and a reference voltage. To a surface of the wiring substrate46facing in the Z1 direction, an end portion of an external wire52is bonded. The external wire52is formed, for example, of a coupling component, such as a flexible printed circuit (FPC) or a flexible flat cable (FFC). In this case, in the wiring substrate46, as shown inFIG.2, there are formed wires461which electrically couple the external wire52and the drive circuit50and wires462to which the drive signal and the reference voltage to be output from the drive circuit50are supplied. 1-3. Details of Vibration Plate and Piezoelectric Element FIG.4is a plan view showing the vibration plate36of the liquid ejection head26according to the first embodiment.FIG.5is a cross-sectional view taken along the line V-V shown inFIG.4. In the liquid ejection head26, as shown inFIGS.4and5, the pressure chamber substrate34, the vibration plate36, and the piezoelectric elements44are laminated in this order in the Z1 direction. As shown inFIG.5, in the pressure chamber substrate34, a hole341forming the pressure chamber C is provided. Accordingly, in the pressure chamber substrate34, between two holes341adjacent to each other, a wall-shaped partition342extending in the direction along the X axis is provided. InFIG.4, a plan view shape of the hole341formed by anisotropic etching of a silicon single crystal substrate having a plane orientation of (110) is shown by a dotted line. In addition, the plan view shape of the hole341is not limited to the example shown inFIG.4and may be arbitrarily formed. As shown inFIG.4, the piezoelectric element44is overlapped with the pressure chamber C in plan view. As shown inFIG.5, the piezoelectric element44includes a first electrode441, the piezoelectric body443, and a second electrode442, and those mentioned above are laminated in this order in the Z1 direction. In addition, the piezoelectric element44may also be configured such that at least one electrode and at least one piezoelectric layer are alternately laminated to form a multilayer structure so as to be expanded and contracted toward the vibration plate36. In addition, between the layers of the piezoelectric element44or between the vibration plate36and the piezoelectric element44, another layer, such as a layer which enhances the adhesion, may also be appropriately provided. The first electrodes441are individual electrodes disposed separately from each other for the respective piezoelectric elements44. In particular, the first electrodes441extending in the direction along the X axis are aligned in the direction along the Y axis with predetermined intervals therebetween. To the first electrode441of the piezoelectric element44, a drive signal to eject the ink from the nozzle N corresponding to the piezoelectric element44described above is applied through the drive circuit50. The first electrode441includes, for example, a layer formed from iridium (Ir) and a layer formed from titanium (Ti), and those layers described above are laminated in this order in the Z1 direction. In this case, iridium is an excellent electrically conductive electrode material. Hence, when iridium is used as a constituent material of the first electrode441, a decrease in resistance of the first electrode441can be achieved. In addition, according to the layer formed from titanium, when the piezoelectric body443is formed, an island-shaped Ti functions as a crystal nuclei and controls the orientation of the piezoelectric body443, so that the crystallinity or the orientation of the piezoelectric body443is improved. In addition, instead of or in addition to the layer formed from iridium, a layer formed from another metal material may also be provided. As the another metal material, for example, a metal material, such as platinum (Pt), aluminum (Al), nickel (Ni), gold (Au), or copper (Cu), may be mentioned, and one metal material thereof may be used alone, or at least two types thereof may be used in combination. Alternatively, an oxide of at least one of the metal elements mentioned above may also be used. The piezoelectric body443has a belt shape continuously extending in the direction along the Y axis so as to form the piezoelectric elements44. Although not shown in the drawings, in the piezoelectric body443, in regions each corresponding to a space between pressure chambers C adjacent to each other in plan view, through-holes penetrating the piezoelectric body443are provided so as to extend in the direction along the X axis. The piezoelectric body443is formed from a piezoelectric material having a perovskite crystal structure represented by a general formula ABO3. As the piezoelectric material described above, for example, there may be mentioned lead titanate (PbTiO3), lead titanate zirconate (Pb(Zr,Ti)O3), lead zirconate (PbZrO3), lead lanthanum titanate ((Pb,La),TiO3), lead lanthanum zirconate titanate ((Pb,La)(Zr,Ti)O3), lead niobate zirconium titanate (Pb(Zr,Ti,Nb)O3), or lead magnesium niobate zirconium titanate (Pb(Zr,Ti) (Mg,Nb)O3). Among those mentioned above, as the constituent material of the piezoelectric body443, lead titanate zirconate may be preferably used. The second electrode442is a belt-shaped common electrode continuously extending in the direction along the Y axis so as to form the piezoelectric elements44. To the second electrode442, a predetermined reference voltage is applied. The second electrode442is formed, for example, from iridium (Ir). In addition, the constituent material of the second electrode442is not limited to iridium, and for example, a metal material, such as platinum (Pt), aluminum (Al), nickel (Ni), gold (Au), or copper (Cu), may also be used. In addition, as the second electrode442, one metal material of those mentioned above may be used alone, or at least two types thereof may be used in combination in the form of a laminate or the like. Alternatively, an oxide of at least one of the metal elements mentioned above may also be used. In the example shown inFIG.4, on the surface of the second electrode442, a first electrically conductive body55and a second electrically conductive body56are provided. The first electrically conductive body55is a belt-shaped electrically conductive film extending in the direction along the Y axis so as to be along one edge side of the second electrode442in the X1 direction. The second electrically conductive body56is a belt-shaped electrically conductive film extending in the direction along the Y axis so as to be along the other edge side of the second electrode442in the X2 direction. The first electrically conductive body55and the second electrically conductive body56are each formed, for example, from an electrically conductive material, such as gold, having a low electrical resistance and are simultaneously formed as the layers equivalent to each other. By the first electrically conductive body55and the second electrically conductive body56described above, a voltage drop of the reference voltage in the second electrode442can be suppressed. In addition, the first electrically conductive body55and the second electrically conductive body56each function as a weight which defines an vibration region of the vibration plate36. In addition, the first electrically conductive body55and the second electrically conductive body56may be provided if needed and may be omitted in some cases. As described above, the liquid ejection head26includes the piezoelectric body443, the vibration plate36which is vibrated by the drive of the piezoelectric body443, and the pressure chamber substrate34in which the pressure chambers C are provided to apply a pressure to the ink which is one example of the liquid by an vibration of the vibration plate36. In addition, the pressure chamber substrate34, the vibration plate36, and the piezoelectric body443are laminated in this order. As shown inFIG.5, the vibration plate36includes a first layer361, a second layer362, and a third layer363, and those layers are laminated in this order in the Z1 direction. That is, the vibration plate36includes the first layer361, the second layer362disposed between the first layer361and the piezoelectric body443, and the third layer363disposed between the second layer362and the piezoelectric body443. In this case, the first layer361is bonded to the pressure chamber substrate34. The third layer363is bonded to the piezoelectric elements44. The second layer362is provided between the first layer361and the third layer363. In addition, inFIG.5, for the convenience of illustration, although the interfaces between the layers forming the vibration plate36are each clearly shown, the interfaces may be not clear, and for example, in the vicinity of the interface between two layers adjacent to each other, constituent materials of the two layers may be mixed with each other. The first layer361is a layer containing silicon (Si) as a constituent element. In more particular, the first layer361is an elastic film formed, for example, from silicon oxide (SiO2). In addition, in the first layer361, besides silicon oxide and its constituent elements, an element, such as zirconium (Zr), titanium (Ti), iron (Fe), chromium (Cr), or hafnium (Hf), may also be contained in a small amount as an impurity. The impurity as mentioned above has a function to soften silicon oxide (SiO2). As described above, the first layer361contains, for example, silicon oxide. The first layer361as described above may be productively formed by thermal oxidation of a silicon single crystal substrate as compared to the case in which the formation is performed by a sputtering method. In addition, the silicon in the first layer361is present in the form of an oxide and may also be present in the form of a single element, a nitride, an oxynitride, or the like. In addition, the impurity in the first layer361may be an element inevitably mixed therein when the first layer361is formed or may also be an element which is intentionally mixed therein. Although a thickness T1of the first layer361is determined in accordance with a thickness T, a width W, and the like of the vibration plate36and is not particularly limited, the thickness T1is preferably in a range of 100 to 2,000 nm and more preferably in a range of 500 to 1,500 nm. The third layer363is a layer containing zirconium (Zr) as a constituent element. In more particular, the third layer363is an insulating layer formed, for example, from zirconium oxide (ZrO2). In this case, in the third layer363, besides zirconium oxide and its constituent elements, an element, such as titanium (Ti), iron (Fe), chromium (Cr), or hafnium (Hf), may also be contained in a small amount as an impurity. The impurity as described above has a function to soften zirconium oxide (ZrO2). As described above, the third layer363contains, for example, zirconium oxide. The third layer363as described above may be formed such that after a layer of a zirconium element is formed by a sputtering method or the like, the layer described above is thermal-oxidized. Hence, when the third layer363is formed, a third layer363having a desired thickness can be obtained. In addition, since zirconium oxide has excellent electrically insulating property, mechanical strength, and toughness, when the third layer363contains zirconium oxide, the performance of the vibration plate36can be improved. In addition, for example, when the piezoelectric body443is formed from lead titanate zirconate, since the third layer363contains zirconium oxide, upon the formation of the piezoelectric body443, a highly oriented (100) piezoelectric body443is also advantageously easily obtained. In addition, the zirconium in the third layer363is present in the form of an oxide and may also be present in the form of a single element, a nitride, an oxynitride, or the like. In addition, the impurity in the third layer363may be an element inevitably mixed therein upon the formation of the third layer363or may also be an element intentionally mixed therein. For example, the impurity described above is an impurity contained in a zirconium target which is used when the third layer363is formed by a sputtering method. Although a thickness T3of the third layer363is determined in accordance with the thickness T, the width W, and the like of the vibration plate36and may not be particularly limited, for example, the thickness T3is in a range of 100 to 2,000 nm. Between the first layer361and the third layer363, the second layer362is provided. Hence, the first layer361is prevented from being in contact with the third layer363. Hence, compared to the structure in which the first layer361is in contact with the third layer363, the silicon oxide in the first layer361is suppressed from being reduced by the zirconium in the third layer363. The second layer362is a layer containing as a constituent element, a metal element unlikely to be oxidized as compared to zirconium. In more particular, the second layer362is formed, for example, from an oxide of the above metal element. As the metal element, as described below, although aluminum, titanium, or chromium may be mentioned, for example, as another example, manganese, vanadium, tungsten, iron, copper, or the like may also be mentioned. As described above, the second layer362contains a metal element unlikely to be oxidized as compared to zirconium. In other words, the second layer362contains a metal element having free energy of oxide formation higher than that of zirconium. The second layer362preferably contains as a constituent element, one metal element selected from chromium, titanium, and aluminum. In addition, the magnitude relationship in terms of free energy of oxide formation may be determined, for example, based on a known Ellingham diagram. The metal element contained in the second layer362is unlikely to be oxidized as compared to zirconium. In other words, the free energy of oxide formation of the metal element contained in the second layer362is higher than the free energy of oxide formation of zirconium. Accordingly, compared to the structure in which the metal element contained in the second layer362is likely to be oxidized as compared to zirconium, that is, compared to the structure in which the free energy of oxide formation of the metal element contained in the second layer362is lower than the free energy of oxide formation of zirconium, the silicon oxide contained in the first layer361can be suppressed being reduced. Accordingly, since a silicon element generated by the reduction described above is suppressed from being diffused from the first layer361to the second layer362, the generation of air gaps between the first layer361and the third layer363caused by the diffusion described above can suppressed. As a result, compared to the structure in which the second layer362is not used, the adhesion between the first layer361and the third layer363can be enhanced. Chromium is unlikely to be oxidized as compared to silicon. In other words, the free energy of oxide formation of chromium is higher than the free energy of oxide formation of silicon. Hence, when chromium is contained as a metal element in the second layer362, compared to the structure in which a metal element unlikely to be oxidized as compared to silicon is not contained in the second layer362, the reduction of the silicon oxide contained in the first layer361can be suppressed. In addition, an oxide of titanium or aluminum is likely to be transferred by heat. Hence, when titanium or aluminum is contained in the second layer362as a metal element, by an anchor effect or a chemical bond by an oxide of the metal element described above, the adhesion of the second layer362to each of the first layer361and the third layer363can be enhanced. In addition, titanium is likely to form an oxide with silicon or zirconium. Hence, when titanium is contained in the second layer362as a metal element, since titanium forms an oxide together with silicon, the adhesion between the first layer361and the second layer362is enhanced, and/or since titanium forms an oxide together with zirconium, the adhesion between the first layer361and the third layer363is enhanced. In addition, when the second layer362contains chromium, for example, chromium forms an oxide, and chromium oxide is contained. The second layer362as described above can be obtained such that after a layer of a chromium element is formed by a sputtering method or the like, the layer described above is thermal-oxidized. Hence, when the second layer362is formed, a second layer362having a desired thickness can be easily obtained. In this case, the chromium oxide contained in the second layer362may be any one of a polycrystal, an amorphous substance, and a single crystal. However, when the chromium oxide contained in the second layer362has an amorphous structure which is in an amorphous state, compared to the structure in which the chromium oxide contained in the second layer362is in a polycrystal state or a single crystal state, a compression stress generated in the second layer362can be reduced. As a result, a strain generated in the interface between the second layer362and the first layer361or the third layer363can be reduced. In addition, when the second layer362contains titanium, for example, titanium forms an oxide, and titanium oxide is contained. The second layer362as described above can be obtained such that after a layer of a titanium element is formed by a sputtering method or the like, the layer described above is thermal-oxidized. Hence, when the second layer362is formed, a second layer362having a desired thickness can be easily obtained. In this case, the titanium oxide contained in the second layer362may be any one of a polycrystal, an amorphous substance, and a single crystal. However, the titanium oxide contained in the second layer362is preferably in a polycrystal state or a single crystal state, and as the crystal structure, a rutile structure is particularly preferable. Among the crystal structures which titanium oxide is able to have, the rutile structure is most stable and is not likely to be changed into a polymorph, such as an anatase or a brookite structure, even if being transferred by heat. Hence, since the titanium oxide contained in the second layer362has a rutile structure, compared to the case in which the titanium oxide contained in the second layer362has another crystal structure, thermal stability of the second layer362can be enhanced. In addition, when the second layer362contains aluminum, for example, aluminum forms an oxide, and aluminum oxide is contained. The second layer362as described above can be obtained such that after a layer of an aluminum element is formed by a sputtering method or the like, the layer described above is thermal-oxidized. Hence, when the second layer362is formed, a second layer362having a desired thickness can be easily obtained. In this case, the aluminum oxide contained in the second layer362may be any one of a polycrystal, an amorphous substance, and a single crystal, and when being in a polycrystal state or a single crystal state, the aluminum oxide described above has as a crystal structure, a trigonal structure. In addition, besides the metal elements described above, the second layer362may also contain a small amount of an element, such as titanium (Ti), silicon (Si), iron (Fe), chromium (Cr), or hafnium (Hf), as an impurity. For example, the impurity described above is an element contained in the first layer361or the third layer363. The impurity is present in the form of an oxide together with the metal element in the second layer362. The impurity as described above suppresses the diffusion of silicon from the first layer361to the second layer362, or even when silicon is diffused from the first layer361to the second layer362, the impurity has an effect to suppress the diffusion of the silicon to the third layer363. From the points described above, the second layer362and the third layer363each preferably contain the impurity. In the case described above, compared to the case in which no impurity is contained, since the second layer362and the third layer363are each softened, risks, such as cracks in the vibration plate36, can be favorably reduced. The content of the impurity in the second layer362is preferably higher than the content of the impurity in the third layer363. In other words, a concentration peak of the impurity in a thickness direction of a laminate formed of the second layer362and the third layer363is preferably located in the second layer362. In this case, a space is prevented or suppressed from being formed in the interface between the second layer362and the third layer363or in the third layer363. On the other hand, when the concentration peak described above is located in the third layer363, the crystal structure in the third layer363is distorted by the impurity. Hence, the space is formed in the interface between the second layer362and the third layer363or in the third layer363, and as a result, risks, such as cracks in the vibration plate36, may be unfavorably increased in some cases. The metal element in the second layer362described above is present in the form of an oxide and may also be present in the form of a single element, a nitride, an oxynitride, or the like. In addition, the impurity in the second layer362may be an element inevitably mixed therein when the second layer362is formed or may also be an element intentionally mixed therein. In addition, although a thickness T2of the second layer362is determined in accordance with the thickness T and the width W of the vibration plate36and is not particularly limited, the thickness T2is preferably smaller than each of the thickness T1of the first layer361and the thickness T3of the third layer363. In the case described above, the performance of the vibration plate36can be advantageously optimized. When the metal element contained in the second layer362is titanium, the concrete thickness T2of the second layer362is preferably in a range of 20 to 50 nm and more preferably in a range of 25 to 40 nm. In addition, when the metal element contained in the second layer362is aluminum, the concrete thickness T2of the second layer362is preferably in a range of 20 to 50 nm and more preferably in a range of 20 to 35 nm. In addition, when the metal element contained in the second layer362is chromium, the concrete thickness T2of the second layer362is preferably in a range of 1 to 50 nm and more preferably in a range of 2 to 30 nm. From those described above, it is found that even when the metal element contained in the second layer362is any one of titanium, aluminum, and chromium, if the thickness T2of the second layer362is set in a range of 20 to 50 nm, preferable conditions are satisfied. Since the thickness T2is set in the range described above, an effect to increase the adhesion between the first layer361and the third layer363by the second layer362can be preferably obtained. On the other hand, when the thickness T2is excessively small, depending on the type of metal element contained in the second layer362, an effect to suppress the diffusion of a silicon element from the first layer361by the second layer362tends to be degraded. For example, when the second layer362is formed from titanium oxide, and the thickness T2is excessively small, for example, depending on the condition of a thermal treatment in manufacturing, a silicon element diffused from the first layer361to the second layer362may reach the third layer363in some cases. On the other hand, when the thickness T2is excessively large, the thermal treatment performed in manufacturing of the second layer362may not be sufficiently carried out in some cases, or since the thermal oxidation takes a long time, the other layers may be adversely influenced thereby in some cases. 1-4. Method for Manufacturing Piezoelectric Device FIG.6is a flowchart illustrating a method for manufacturing a piezoelectric device. Hereinafter, with reference toFIG.6, a method for manufacturing a piezoelectric device will be described using the case in which the liquid ejection head26described above is manufactured as an example. As shown inFIG.6, a method for manufacturing the liquid ejection head26includes a substrate preparing step S10, an vibration plate forming step S20, a piezoelectric element forming step S30, and a pressure chamber forming step S40. In this case, the vibration plate forming step S20includes a first layer forming step S21, a second layer forming step S22, and a third layer forming step S23. Hereinafter, the individual steps will be sequentially described. The substrate preparing step S10is a step of preparing a substrate to be formed into the pressure chamber substrate34. The substrate is, for example, a silicon single crystal substrate. The vibration plate forming step S20is a step of forming the vibration plate36and is performed after the substrate preparing step S10. In the vibration plate forming step S20, the first layer forming step S21, the second layer forming step S22, and the third layer forming step S23are performed in this order. The first layer forming step S21is a step of forming the first layer361described above. In the first layer forming step S21, for example, by thermal oxidation of one surface of the silicon single crystal substrate prepared in the substrate preparing step S10, the first layer361is formed from silicon oxide (SiO2). The second layer forming step S22is a step of forming the second layer362described above. In the second layer forming step S22, after a layer of chromium, titanium, or aluminum is formed on the first layer361by a sputtering method, the layer described above is thermal-oxidized, so that the second layer362is formed from chromium oxide, titanium oxide, or aluminum oxide. In addition, the formation of the second layer362is not limited to a method using thermal oxidation, and for example, a chemical vapor deposition (CVD) method or an atomic layer deposition (ALD) method may also be used. In addition, the thermal oxidation in the second layer forming step S22may be simultaneously performed together with the thermal oxidation in the third layer forming step S23which will be described below. The third layer forming step S23is a step of forming the third layer363described above. In the third layer forming step S23, for example, after a layer of zirconium is formed on the second layer362by a sputtering method, the layer described above is thermal-oxidized, so that the third layer363is formed from zirconium oxide. The piezoelectric element forming step S30is a step of forming the piezoelectric elements44described above and is performed after the third layer forming step S23. In the piezoelectric element forming step S30, the first electrodes441, the piezoelectric body443, and the second electrode442are formed on the third layer363in this order. The first electrode441and the second electrode442are each formed, for example, by a known film forming technique, such as a sputtering method, and known processing techniques, such as photolithography and etching. The piezoelectric body443is formed such that after a precursor layer of the piezoelectric body is formed by a sol-gel method, the precursor layer is crystallized by firing. After the piezoelectric elements44are formed, if needed, one of the two surfaces of the substrate opposite to that on which the piezoelectric elements44are formed is polished by chemical mechanical polishing (CMP), so that the surface described above is planarized, or the thickness of the substrate is adjusted. The pressure chamber forming step S40is a step of forming the pressure chambers C described above and is performed after the piezoelectric element forming step S30. In the pressure chamber forming step S40, for example, after the piezoelectric elements44are formed, one of the two surfaces of the silicon single crystal substrate opposite to the surface on which the piezoelectric elements44are formed is anisotropically etched, so that the holes341forming the pressure chambers C are formed. Since the holes341are formed, the pressure chamber substrate34is obtained. In this case, as an etching solution for the anisotropic etching, for example, an aqueous potassium hydroxide (KOH) solution may be used. In addition, in this case, the first layer361functions as a stop layer to stop the anisotropic etching. After the pressure chamber forming step S40, for example, a step of bonding the flow path substrate32and the like to the pressure chamber substrate34with an adhesive is appropriately performed, so that the liquid ejection head26is obtained. 2. Second Embodiment Hereinafter, a second embodiment of the present disclosure will be described. In the embodiment which will be described by way of example, elements having actions or functions similar to those described in the first embodiment will be designated by the same reference numerals used in the first embodiment, and detailed descriptions thereof will be appropriately omitted. FIG.7is a cross-sectional view of a liquid ejection head26A according to the second embodiment. Except for that an vibration plate36A is provided instead of the vibration plate36, the liquid ejection head26A is similar to the liquid ejection head26of the first embodiment. The vibration plate36A is similar to the vibration plate36except for that a second layer362A is used instead of the second layer362. In addition, inFIG.7, for the convenience for illustration, although the interfaces between layers forming the vibration plate36A are clearly shown, the interfaces may be not clear, and for example, in the vicinity of the interface between two layers adjacent to each other, constituent materials of the two layers may be mixed with each other. The second layer362A includes a layer362aand a layer362b, and those layers are laminated in this order in the Z1 direction. The layers362aand362bare each a layer containing a metal element unlikely to be oxidized as compared to zirconium and are each formed, for example, from an oxide containing the metal element mentioned above. However, compositions of the materials forming the layers362aand362bare different from each other. In particular, the type of impurity or the content thereof of the layer362ais different from that of the layer362b. The impurity is, as is the case of the first embodiment described above, an element, such as titanium (Ti), silicon (Si), iron (Fe), chromium (Cr), or hafnium (Hf). The layers362aand362bare each formed such that, for example, after a layer of the above single metal element is formed by a sputtering method or the like, the time, the temperature, or the like of a heat treatment is adjusted so that the distribution of the impurity in the layer is changed in its thickness direction. In addition, the formation of those layers is not particularly limited, and for example, by a CVD method or the like, the individual layers may be separately formed. When silicon is contained in the layer362aas the impurity, the layer362bcan be regarded as a “second layer”, and in this case, the layer362acan be regarded as a “fourth layer”. That is, the layer362ais disposed between the first layer361and the layer362band contains the metal element contained in the layer362band silicon. As described above, since silicon is contained in the layer362a, the diffusion of silicon from the first layer361to the second layer362A is suppressed, or even when silicon is diffused from the first layer361to the second layer362A, the silicon can be suppressed from being diffused to the third layer363. In addition, an effect in which a space is not likely to be formed in the interface between the first layer361and the second layer362A is also obtained. In this case, although the layer362bmay contain silicon, the content of silicon in the layer362ais preferably higher than the content of silicon in the layer362b. In other words, the content of silicon in the layer362bis preferably lower than the content of silicon in the layer362a. Since the relationship of the content of silicon between the layer362aand362bis set as described above, for example, when the second layer362A contains titanium oxide, a crystal strain of titanium oxide in the second layer362A caused by silicon can be reduced. In addition, since the content of silicon in the layer362bis decreased, the adhesion between the layer362band the third layer363can be enhanced. In addition, when zirconium is contained in the layer362bas the impurity, the layer362acan be regarded as a “second layer”, and in this case, the layer362bcan be regarded as a “fifth layer”. That is, the layer362bis disposed between the layer362aand the third layer363and contains the metal element contained in the layer362aand zirconium. As described above, since zirconium is contained in the layer362b, diffusion of zirconium from the third layer363to the second layer362A is suppressed, or even when zirconium is diffused from the third layer363to the second layer362A, the zirconium can be suppressed from being diffused to the first layer361. In addition, an effect in which a space is not likely to be generated in the interface between the third layer363and the second layer362A is also obtained. In the second embodiment described above, as is the case of the first embodiment, the generation of damages, such as delamination and/or cracks, on the vibration plate can be suppressed. 3. Third Embodiment Hereinafter, a third embodiment of the present disclosure will be described. In the embodiment which will be described by way of example, elements having actions and functions similar to those of the first embodiment will be designated by the same reference numerals used in the first embodiment, and detailed descriptions thereof will be appropriately omitted. FIG.8is a cross-sectional view of a liquid ejection head26B according to the third embodiment. Except for that an vibration plate36B is used instead of the vibration plate36, the liquid ejection head26B is similar to the liquid ejection head26of the first embodiment described above. Except for that a second layer362B is used instead of the second layer362, the vibration plate36B is similar to the vibration plate36. In addition, inFIG.8, although the interfaces between layers forming the vibration plate36B are clearly shown, the interfaces may be not clear, and for example, in the vicinity of the interface between two layers adjacent to each other, constituent materials of the two layers described above may be mixed with each other. The second layer362B includes a layer362a, a layer362b, and a layer362c, and those layers are laminated in this order in the Z1 direction. The layer362a, the layer362b, and the layer362care each a layer containing a metal element unlikely to be oxidized as compared to zirconium and are each formed, for example, from an oxide of the metal element described above. However, compositions of materials forming the layers362a,362b, and362care different from each other. In particular, the types of impurities or the contents thereof of the layers362a,362b, and362care different from each other. As is the case of the first embodiment described above, the impurity is an element, such as titanium (Ti), silicon (Si), iron (Fe), chromium (Cr), or hafnium (Hf). The formation of the layers362a,362b, and362cis performed such that after a layer is formed from the above single metal element by a sputtering method or the like, the time, the temperature, or the like of a heat treatment is adjusted so that the distribution of the impurity in the layer is changed in its thickness direction. In addition, the formation of those layers is not particularly limited, and for example, by a CVD method or the like, the individual layers may be separately formed. As is the case of the second embodiment described above, when silicon is contained in the layer362aas the impurity, the layer362bcan be regarded as a “second layer”, and in this case, the layer362acan be regarded as a “fourth layer”. In addition, when zirconium is contained in the layer362cas the impurity, the layer362bcan be regarded as a “second layer”, and in this case, the layer362ccan be regarded as a “fifth layer”. That is, the layer362cis disposed between the layer362band the third layer363and contains the metal element contained in the layer362band zirconium. As described above, since zirconium is contained in the layer362c, diffusion of zirconium from the third layer363to the second layer362B is suppressed, or even when zirconium is diffused from the third layer363to the second layer362B, the zirconium can be suppressed from being diffused to the first layer361. In addition, an effect in which a space is not likely to be generated in the interface between the third layer363and the second layer362B is also be obtained. As is the case of the first embodiment described above, in the third embodiment described above, the generation of damages, such as delamination and/or cracks, on the vibration plate can also be suppressed. 4. Modified Examples The embodiments described above by way of example may be variously changed and/or modified. Concrete modified modes to be applied to the above embodiments will be described by way of example. In addition, at least two modes arbitrarily selected from the following examples may be appropriately used in combination with each other as long as no contradiction occurs therebetween. 4-1. Modified Example 1 As long as having a structure including a piezoelectric body and an vibration plate, the liquid ejection head is not limited to the structure described in the above embodiments. In addition, in the embodiments described above, as one example of the piezoelectric device, although the liquid ejection head has been described, the piezoelectric device is not limited thereto. Besides the liquid ejection head, for example, the piezoelectric device may be a drive device, such as a piezoelectric actuator which includes a piezoelectric body and an vibration plate or a detection device, such as a pressure sensor which includes a piezoelectric body and an vibration plate. 4-2. Modified Example 2 In the embodiments described above, the liquid ejection head26,26A, or26B includes the piezoelectric elements44which contain the piezoelectric body443. In this case, the piezoelectric elements44include the first electrodes441provided for the respective piezoelectric elements44and the second electrode442commonly provided for the piezoelectric elements44. The first electrodes441are disposed between the piezoelectric body443and the vibration plate36. As described above, in the embodiments described above, although the structure in which the first electrodes441are individual electrodes and in which the second electrode442is a common electrode has been describe by way of example, the first electrode441may be a continuous common electrode to form the piezoelectric elements44, and the second electrodes442may be individual electrodes provided for the respective piezoelectric elements44. Alternatively, both of the first electrodes441and the second electrodes442may be individual electrodes. 4-3. Modified Example 3 In the embodiments described above, although the serial type liquid ejection apparatus100in which the transport body242mounting the liquid ejection head26is reciprocally transferred has been described by way of example, the present disclosure may also be applied to a line type liquid ejection apparatus in which the nozzles N are provided over the entire width of the medium12. 4-4. Modified Example 4 The liquid ejection apparatus100described in each of the above embodiments may be applied to, besides an apparatus exclusively used for printing, various types of apparatuses, such as a facsimile apparatus and a copying machine. In addition, the application of the liquid ejection apparatus of the present disclosure is not limited to printing. For example, a liquid ejection apparatus which ejects solutions of colorants may be used as a manufacturing apparatus which forms a color filter of a liquid crystal display apparatus. In addition, a liquid ejection apparatus which ejects a solution of an electrically conductive material may be used as a manufacturing apparatus which forms wires and/or electrodes of a wiring substrate. EXAMPLES Hereinafter, concrete examples of the present disclosure will be described. In addition, the present disclosure is not limited to the following examples. A. Manufacturing of Vibration Plate Using Titanium Oxide for Second Layer A-1. Example A1 First, one surface of a silicon single crystal substrate having a plane orientation of (110) was thermal-oxidized, so that a first layer having a thickness of 1,460 nm was formed from silicon oxide. Next, on the first layer, after a film was formed from titanium by a sputtering method, the film thus formed was thermal-oxidized at 650° C., so that a second layer having a thickness of 10 nm was formed primarily from titanium oxide. Subsequently, on the second layer, after a film was formed from zirconium by a sputtering method, the film thus formed was thermal-oxidized at 900° C., so that a third layer having a thickness of 400 nm was formed from zirconium oxide. Next, for example, by using an aqueous potassium hydroxide solution (KOH) as an etching solution, the other surface of the silicon single crystal substrate was anisotropically etched, so that a concave portion using the first layer as a bottom surface was formed. Accordingly, an vibration plate including the first layer, the second layer, and the third layer was formed. A-2. Example A2 Except for that the thickness of the second layer was changed to 15 nm by changing the thickness of the film formed from titanium, an vibration plate was manufactured in a manner similar to that of Example A1 described above. A-3. Example A3 Except for that the thickness of the second layer was changed to 20 nm by changing the thickness of the film formed from titanium, an vibration plate was manufactured in a manner similar to that of Example A1 described above. A-4. Example A4 Except for that the thickness of the second layer was changed to 25 nm by changing the thickness of the film formed from titanium, an vibration plate was manufactured in a manner similar to that of Example A1 described above. A-5. Example A5 Except for that the thickness of the second layer was changed to 30 nm by changing the thickness of the film formed from titanium, an vibration plate was manufactured in a manner similar to that of Example A1 described above. A-6. Example A6 Except for that the thickness of the second layer was changed to 35 nm by changing the thickness of the film formed from titanium, an vibration plate was manufactured in a manner similar to that of Example A1 described above. A-7. Example A7 Except for that the thickness of the second layer was changed to 40 nm by changing the thickness of the film formed from titanium, an vibration plate was manufactured in a manner similar to that of Example A1 described above. A-8. Example A8 Except for that the thickness of the second layer was changed to 50 nm by changing the thickness of the film formed from titanium, an vibration plate was manufactured in a manner similar to that of Example A1 described above. A-9. Example A9 Except for that the thickness of the second layer was changed to 60 nm by changing the thickness of the film formed from titanium, an vibration plate was manufactured in a manner similar to that of Example A1 described above. B. Manufacturing of Vibration Plate Using Aluminum Oxide for Second Layer B-1. Example B1 Except for that a second layer having a thickness of 20 nm was formed primarily from aluminum oxide, an vibration plate was manufactured in a manner similar to that of Example A1 described above. In this case, the second layer was formed by an atomic layer deposition method. B-2. Example B2 Except for that the thickness of the second layer was changed to 30 nm, an vibration plate was manufactured in a manner similar to that of Example B1 described above. B-3. Example B3 Except for that the thickness of the second layer was changed to 35 nm, an vibration plate was manufactured in a manner similar to that of Example B1 described above. B-4. Example B4 Except for that the thickness of the second layer was changed to 40 nm, an vibration plate was manufactured in a manner similar to that of Example B1 described above. B-5. Example B5 Except for that the thickness of the second layer was changed to 45 nm, an vibration plate was manufactured in a manner similar to that of Example B1 described above. B-6. Example B6 Except for that the thickness of the second layer was changed to 50 nm, an vibration plate was manufactured in a manner similar to that of Example B1 described above. C. Manufacturing of Vibration Plate Using Chromium Oxide for Second Layer C-1. Example C1 Except for that a second layer having a thickness of 1 nm was formed primarily from chromium oxide, and the thickness of the third layer was set to 600 nm, an vibration plate was manufactured in a manner similar to that of Example A1 described above. In this example, the second layer was formed such that after a film was formed from chromium on the first layer by a sputtering method, the film described above was thermal-oxidized at 650° C. C-2. Example C2 Except for that the thickness of the second layer was changed to 2 nm, an vibration plate was manufactured in a manner similar to that of Example C1 described above. C-3. Example C3 Except for that the thickness of the second layer was changed to 5 nm, an vibration plate was manufactured in a manner similar to that of Example C1 described above. C-4. Example C4 Except for that the thickness of the second layer was changed to 15 nm, an vibration plate was manufactured in a manner similar to that of Example C1 described above. C-5. Example C5 Except for that the thickness of the second layer was changed to 30 nm, an vibration plate was manufactured in a manner similar to that of Example C1 described above. C-6. Example C6 Except for that the thickness of the second layer was changed to 50 nm, an vibration plate was manufactured in a manner similar to that of Example C1 described above. D. Manufacturing of Vibration Plate Using No Second Layer D-1. Comparative Example Except for that the formation of the second layer was omitted, an vibration plate was manufactured in a manner similar to that of Example A1 described above. E. Evaluation E-1. Position of Impurity Peak, Structure of Second Layer, and Si Diffusion Analysis was performed on the vibration plates of Examples and Comparative Example by a secondary ion mass spectroscopy (SIMS). Some analysis results are representatively shown inFIGS.9to12.FIG.9shows a SIMS analysis result of the vibration plate of Example A7.FIG.10shows a SIMS analysis result of the vibration plate of Example B1.FIG.11shows a SIMS analysis result of the vibration plate of Comparative Example.FIG.12shows SIMS analysis results of the vibration plates of Examples C3 and C4 and Comparative Example. In addition, inFIG.12, the distribution of silicon is shown. From the results of the analysis, in Examples A1 to A7 and B1 to B6, it is found that the peak of the impurity concentration of iron (Fe), chromium (Cr), or the like in the thickness direction of the vibration plate is located in the second layer. In Examples A8, A9, and C1 to C6, it is found that the peak of the impurity concentration is located in the third layer. In Comparative Example, it is found that the peak of the impurity concentration is located in the interface between the first layer and the third layer. Those results are shown in Table 1. TABLE 1LAYER STRUCTURE OF VIBRATION PLATEFIRST LAYERSECOND LAYERTHIRD LAYERTHICKNESSTHICKNESSTHICKNESSMATERIAL[nm]MATERIAL[nm]MATERIAL[nm]EXAMPLE A1SiO21460TiO210ZrO2400EXAMPLE A2SiO21460TiO215ZrO2400EXAMPLE A3SiO21460TiO220ZrO2400EXAMPLE A4SiO21460TiO225ZrO2400EXAMPLE A5SiO21460TiO230ZrO2400EXAMPLE A6SiO21460TiO235ZrO2400EXAMPLE A7SiO21460TiO240ZrO2400EXAMPLE A8SiO21460TiO250ZrO2400EXAMPLE A9SiO21460TiO260ZrO2400EXAMPLE B1SiO21460AlOx20ZrO2400EXAMPLE B2SiO21460AlOx30ZrO2400EXAMPLE B3SiO21460AlOx35ZrO2400EXAMPLE B4SiO21460AlOx40ZrO2400EXAMPLE B5SiO21460AlOx45ZrO2400EXAMPLE B6SiO21460AlOx50ZrO2400EXAMPLE C1SiO21460CrOx1ZrO2600EXAMPLE C2SiO21460CrOx2ZrO2600EXAMPLE C3SiO21460CrOx5ZrO2600EXAMPLE C4SiO21460CrOx15ZrO2600EXAMPLE C5SiO21460CrOx30ZrO2600EXAMPLE C6SiO21460CrOx50ZrO2600COMPARATIVESiO21460——ZrO2400EXAMPLEEVALUATIONPOSITION OFSECONDSiIMPURITYLAYERDIFFU-MOISTURECOMPREHENSIVEPEAKSTRUCTURESIONINTRUSIONADHESIONEVALUATIONEXAMPLE A1SECONDFIRSTBB—CLAYERLAYEREXAMPLE A2SECONDFIRSTBB—CLAYERLAYEREXAMPLE A3SECONDFIRSTBB—BLAYERLAYEREXAMPLE A4SECONDTHIRDAA—ALAYERLAYEREXAMPLE A5SECONDTHIRDAA—ALAYERLAYEREXAMPLE A6SECONDTHIRDAA—ALAYERLAYEREXAMPLE A7SECONDTHIRDAA—ALAYERLAYEREXAMPLE A8THIRDTHIRDAA—BLAYERLAYEREXAMPLE A9THIRDTHIRDAA—CLAYERLAYEREXAMPLE B1SECONDSECONDAA—ALAYERLAYEREXAMPLE B2SECONDSECONDAA—ALAYERLAYEREXAMPLE B3SECONDSECONDAA—ALAYERLAYEREXAMPLE B4SECONDSECONDAA—BLAYERLAYEREXAMPLE B5SECONDSECONDAA—BLAYERLAYEREXAMPLE B6SECONDSECONDAA—BLAYERLAYEREXAMPLE C1THIRDFIRSTAABBLAYERLAYEREXAMPLE C2THIRDFIRSTAABALAYERLAYEREXAMPLE C3THIRDFIRSTAABALAYERLAYEREXAMPLE C4THIRDFIRSTAAAALAYERLAYEREXAMPLE C5THIRDSECONDAAAALAYERLAYEREXAMPLE C6THIRDSECONDAAABLAYERLAYERCOMPARATIVEINTERFACE—CCCDEXAMPLEBETWEENFIRSTLAYER ANDTHIRDLAYER In addition, in Examples A1 to A3 and C1 to C4, it is found that over the entire region of the second layer in the thickness direction, the impurity is diffused, and the second layer is formed from one layer. In Examples B1 to B6, C5, and C6, it is found that the impurity is diffused only to a part of the second layer at a third layer side, and the second layer is formed from two layers, that is, from one layer in which the impurity is diffused and the other layer in which no impurity is diffused. In Examples A4 to A9, it is found that since the impurity is diffused only to a part of the second layer at a third layer side, and silicon is diffused to a part of the second layer at a first layer side in which no impurity is diffused, the second layer is formed from three layers. Those results are also shown in Table 1. In addition, the presence or absence of the diffusion of silicon to the third layer was evaluated by the following criteria. The results thereof are shown in Table 1.A: no diffusion of silicon to third layerB: slight diffusion of silicon to third layerC: apparent diffusion of silicon to third layer E-2. Moisture Intrusion In Examples and Comparative Example, after the vibration plate was cut into small pieces, the small pieces were exposed in a heavy water environment at a temperature of 45° C. and a humidity of 95% for 24 hours and were then analyzed by a SIMS. This analysis result was evaluated in accordance with the following criteria. The evaluation results are shown in Table 1.A: no moisture intrusion between first layer and third layerB: slight moisture intrusion between first layer and third layerC: apparent moisture intrusion between first layer and third layer E-3. Adhesion In Examples C1 to C6 and Comparative Example, as described below, the adhesion between the first layer and the third layer was evaluated. First, after the vibration plate was cut into small pieces, by using a diluted hydrofluoric acid (water:hydrogen fluoride=50:1) as an etching solution, the small pieces were dipped in the etching solution for 60 minuets. Subsequently, the width of a portion discolored by the etching from the end surface of the small piece was measured at 10 points, and an average value of etching amounts was obtained. As a result, in Example C1, the etching amount was 310 μm. In Example C2, the etching amount was 288 μm. In Example C3, the etching amount was 170 μm. In Example C4, the etching amount was 11 μm. In Examples C5 and C6, the etching amounts were each 10 μm. In Comparative Example, the etching amount was 346 μm. From the results described above, the adhesion was evaluated in accordance with the following criteria. The results are shown in Table 1.A: Etching amount is significantly small, and preferable adhesion is obtained.B: Although etching amount is slightly large, adhesion is improved.C: Etching amount is seriously large, and adhesion is inferior. E-4. Others In Examples and Comparative Example, a cross-section of the vibration plate was observed by a scanning transmission electron microscope (STEM). As a result, in each Example, no space is generated between the first layer and the third layer. On the other hand, in Comparative Example, a space is generated between the first layer and the third layer. However, in Example A9, a space is generated in the third layer. The reason for this is the generation of strain in a crystal structure of zirconium oxide of the third layer caused by Fe and Cr. E-5. Comprehensive Evaluation In consideration of those evaluation results, the comprehensive evaluation was performed. The results are shown in Table 1. Among A, B, C, and D shown as the results of the comprehensive evaluation in Table 1, A is best, and B, C, and D are inferior in this order. As described above, it is found that compared to Comparative Example, in each Example, the diffusion of silicon to the third layer is suppressed, and excellent durability is obtained. | 65,970 |
11858271 | The accompanying drawings are intended to depict embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. In addition, identical or similar reference numerals designate identical or similar components throughout the several views. DETAILED DESCRIPTION In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that have the same function, operate in a similar manner, and achieve a similar result. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It is to be noted that the suffixes Y, M, C, and Bk attached to each reference numeral indicate only that components indicated thereby are used for forming yellow, magenta, cyan, and black images, respectively, and hereinafter may be omitted when color discrimination is not necessary. With reference to drawings, descriptions are given below of embodiments of the present disclosure. In the drawings for illustrating embodiments of the present disclosure elements or components identical or similar in function or shape are given identical reference numerals as far as distinguishable, and redundant descriptions are omitted. FIG.1is a schematic view of an image forming apparatus100according to an embodiment of the present disclosure. As illustrated inFIG.1, the image forming apparatus100according to the present embodiment includes a document conveyance device1, an image reading device2, an image thrilling device3, a sheet feeding device4, a cartridge mount5, a sheet ejection portion7, and a bypass sheet feeding device8. Further, a sheet alignment apparatus (sheet jogger)200is disposed adjacent to the image forming apparatus100. The document conveyance device1separates a document one by one from multiple documents on a document tray11and conveys the separated document toward an exposure glass13of the image reading device2. The document conveyance device1includes a plurality of conveyance rollers each functioning as a document conveyor to convey the document. The image reading device2is an image scanner, in other words, a device to scan an image on a document placed on the exposure glass13or an image an a document as the document passes over the exposure glass13. The image reading device2includes an optical scanning, unit12as an image reading unit. The optical scanning unit12includes a light source that irradiates a document placed on the exposure glass13with light, and a charge-coupled device (CCD) as an image reader that reads an image from the reflected light of the document. Alternatively, a close contact-type image sensor (CIS) may be employed as an image reader. The image forming device3includes a liquid discharge device that discharges liquid ink onto a sheet to form an image. The liquid discharge device includes a liquid discharge head14as a liquid discharge unit. Ink cartridges15Y,15M,15C, and15Bk, are removably mounted in the cartridge mount5. The ink cartridges15Y,15M,15C, and15Bk are filled with inks of different colors such as yellow, magenta, cyan, and black, respectively. The ink in each ink cartridge the ink cartridges15Y,15M,15C, and15Bk) is supplied to the liquid discharge head14by a supply pump. The sheet feeding device4includes a plurality of sheet feed trays16each functioning as a sheet container. Each sheet feed tray16loads a bundle of sheets P. Each sheet P on which an image is to be formed is a cut sheet which is previously cut in a predetermined size, e.g., A4 size and B4 size, and is contained in the sheet feed tray16in a corresponding sheet conveyance direction. Further, each sheet feed tray16includes a sheet feed roller17that functions as a sheet feeder and a sheet separation pad18that functions as a sheet separator. As the sheet feed roller17rotates, an uppermost sheet P placed on top of the bundle of sheets P contained in the sheet feed tray16is fed by the sheet feed roller17and the sheet separation pad18while the uppermost sheet P is separated from the other sheets of the bundle of sheets. The bypass sheet feeding device8includes a bypass tray51and a bypass sheet feed roller52. The bypass tray51functions as a sheet loader to load a sheet(s) P. The bypass sheet feed roller52serves as a sheet feeder to feed the sheet P from the bypass tray51. The bypass tray51is attached to the body of the image thrilling apparatus100and is openable and closable with respect to the body of the image forming apparatus100. In other words, the bypass tray51is swingably attached to the body of the image forming apparatus100. When the bypass tray51is open (in the state illustrated inFIG.1), a sheet P or a bundle of sheets P can be loaded on the bypass tray51to feed the sheet P. The sheet alignment apparatus200functions as a post-processing apparatus to align and jog, the sheets P conveyed from the image forming apparatus100. In addition to the sheet alignment apparatus200, another post-processing apparatus such as a stapling apparatus that staples (binds) the sheets P and a punching apparatus that punches holes in the sheet P may be installed. With continued reference toFIG.1, a description is given of an operation of the image forming apparatus100according, to the present embodiment. As the image forming apparatus100receives an instruction to start a printing operation, the sheet P is fed from the sheet feeding device4or the bypass sheet feeding device8. As the sheet P is conveyed to a sheet conveyance passage80facing the image forming device3, the image forming device3forms an image on the sheet P. Specifically, the liquid discharge head14discharges ink to the sheet P based on image data of the document read by the image reading device2or print data transmitted by a terminal device, thereby forming an image on an image formation surface (front face) of the sheet P. Note that the image to be formed on the sheet P may be a meaningful image such as text or a figure, or a pattern that is meaningless. In the duplex printing, the sheet P is conveyed in the opposite direction opposite to the sheet conveyance direction at a position downstream from the image forming device3in the sheet conveyance direction and guided to a sheet reverse passage81. Specifically, after the trailing end of the sheet P has passed a first passage changer71that is disposed downstream from the image forming device3in the sheet conveyance direction, the first passage changer71changes the route to the sheet reverse passage81, and the sheet P is conveyed in the opposite direction. Accordingly, the sheet P is guided to the sheet reverse passage81. As the sheet P passes through the sheet reverse passage81, the sheet P is reversed from the front face to the back face and conveyed to the image forming device3again. Then, the image forming device3repeats the same operation performed to the front face of the sheet P, thereby forming an image on the back face of the sheet P. A second passage changer72is disposed downstream from the first passage changer71. The second passage changer72guides the sheet P, on which the image has been formed, selectively to a sheet conveyance passage82toward the upper sheet ejection portion7or to a sheet conveyance passage83toward the lower sheet ejection portion7. When the sheet P is guided to the sheet conveyance passage82toward the upper sheet ejection portion7, the sheet P is ejected onto the upper sheet ejection portion7. On the other hand, when the sheet P is guided to the sheet conveyance passage83toward the lower sheet ejection portion7, a third passage changer73guides the sheet P selectively to a sheet, conveyance passage84toward the lower sheet ejection portion7or to a sheet conveyance passage85toward the sheet alignment apparatus200. When the sheet P is guided to the sheet conveyance passage84toward the lower sheet ejection portion7, the sheet P is ejected onto the lower sheet ejection portion7. On the other hand, when the sheet P is guided to the sheet conveyance passage85toward the sheet alignment apparatus200, the sheet is conveyed to the sheet alignment apparatus200, and the bundle of sheets P is aligned and stacked. Thus, a series of printing operations is completed. Next, the configuration of the liquid discharge device according to the present embodiment is described with reference toFIG.2. As illustrated inFIG.2, the liquid discharge device (image forming device3) according to the present embodiment includes multiple liquid discharge heads14arranged side by side in sheet width directions B. The sheet width directions B are directions intersecting or perpendicular to a sheet conveyance direction A in which the sheet P is conveyed. Note that the liquid discharge device according to the present embodiment is not limited to a configuration having the multiple liquid discharge heads14as illustrated inFIG.2, and may have a configuration having one liquid discharge head disposed over the entire sheet width directions B. Each liquid discharge head14includes a nozzle row54(four nozzle rows inFIG.2) in which a plurality of nozzles is arranged. In the present embodiment, when the sheet P conveyed to the image forming device3and passes through a region facing the image forming device3, each liquid discharge head14is controlled in response to a drive signal based on image data to discharge ink. Thus, ink of each color is discharged from each liquid discharge head14onto the sheet P, thereby forming an image corresponding to the image data on the sheet P. As described above, the liquid discharge device according to the present embodiment is a so-called line-type liquid discharge device in which each liquid discharge head14discharges ink without moving relative to the sheet P being conveyed. Note that the liquid discharge device according to the present disclosure is not limited to the line-type liquid discharge device and may be a serial-type liquid discharge device described later in which the liquid discharge head discharges ink while moving in a maw scanning direction (sheet width direction). As illustrated inFIG.2, in the present embodiment, a nozzle surface55of each liquid discharge head14has a parallelogram shape. Specifically, each liquid discharge head14has the nozzle surface55having the parallelogram shape including a pair of short sides55aextending transversely to the sheet width directions B and a pair of long sides55bextending in the sheet width directions B. The nozzle rows54on the nozzle surface55are arranged parallel to the long sides55bof the nozzle surface55. Further, end portions of the nozzle rows54of the adjacent liquid discharge heads14are disposed so as to overlap each other as viewed in the sheet conveyance direction A. Thus, ink can be discharged without interrupting an image between the liquid discharge heads14adjacent to each other in the sheet width directions B. In the inkjet image forming device that discharges ink from the liquid discharge head to form an image on a sheet, a maintenance device is generally provided to maintain and recover the function of the liquid discharge head. The maintenance device includes, for example, a cap that covers the nozzle surface of the liquid discharge head and a cleaner that cleans the nozzle surface. Hereinafter, a maintenance operation according to the present embodiment is described with reference toFIGS.3to6. As illustrated inFIG.3, in the image forming device3, the posture of the liquid discharge head14is switchable between a state of being disposed obliquely with respect to the horizontal direction as illustrated by the solid line inFIG.3and a state of being disposed in the horizontal direction (also referred to as a position retracted from the sheet conveyance passage80) as illustrated by the long dashed double-short dashed line inFIG.3. When an image is formed on the sheet P, the liquid discharge head14is obliquely disposed and faces the sheet conveyance passage80. On the other hand, when the image forming operation is finished and the maintenance operation of the liquid discharge head14is performed, the liquid discharge head14is disposed in the horizontal direction. When the maintenance operation is performed, as illustrated inFIG.4, a maintenance device40approaches the liquid discharge head14switched to the horizontal posture. The maintenance device40is included in the liquid discharge device serving as the image forming device3. The maintenance device40moves in the horizontal direction (i.e., a movement direction C which is one of the sheet width directions B) to be arranged below the liquid discharge heads14. The maintenance device40includes a suction wiper41as a cleaner that cleans the nozzle surface55of the liquid discharge head14. The suction wiper41is a tubular member made of an elastic body such as rubber and has a suction port41aat the tip thereof. The suction wiper41is mounted on a carriage42that reciprocates in the sheet width directions B. When the carriage42moves along a guide rail43, the suction wiper41moves together with the carriage42in the movement direction C which is one of the sheet width directions13. Subsequently, as illustrated inFIG.5, the liquid discharge head14is lowered and arranged at a position where the liquid discharge head14can be cleaned. Alternatively, the maintenance device40may be lifted and arranged at a position where the liquid discharge head14can be cleaned without lowering the liquid discharge head14. In this state, as illustrated inFIG.6, the suction wiper41moves along the guide rail43, so that the suction wiper41cleans the nozzle surface55of the liquid discharge head14while contacting the nozzle surface55. Specifically, as the suction wiper41moves while contacting the nozzle surface55, ink remaining in the nozzle (discharge port) is wiped and removed, and the removed ink is sucked and collected from the suction port41aof the suction wiper41. As a result, a cleaning operation by the suction wiper41is finished. After the cleaning operation is finished, the liquid discharge head14is covered with the cap to prevent ink discharge failure due to drying. Thereafter, when the image forming operation is performed again, the cap is separated from the liquid discharge head14, and the maintenance device40is moved and retracted from the position facing the liquid discharge head14in the horizontal direction. Then, the liquid discharge head14is switched to the oblique posture and is ready to form an image. Here, the suction wiper41is formed of an elastic material such as rubber so that the nozzle surface55of the liquid discharge head14is not damaged. However, when the suction wiper41performs the cleaning operation, if the suction wiper41contacts an end or a corner of the liquid discharge head14, the suction wiper41may be damaged or deteriorated due to the contact. Therefore, in the present embodiment, the following measures are taken to suppress damage and deterioration of the suction wiper41. FIG.7is a schematic view of the liquid discharge heads14and the suction wiper41, and a graph illustrating a contact force and a contact pressure of the suction wiper41according to a first embodiment of the present disclosure. As illustrated inFIG.7, the suction wiper41according to the present embodiment moves in the movement direction C (one of the sheet width directions B), thereby performing the cleaning operation while a contact portion41bof the suction wiper41contacts the nozzle surface55from a first end e1toward a second end e2of each liquid discharge head14. At that time, as the contact portion41bof the suction wiper41contacts the first end e1and the second end e2(short sides55a) of each liquid discharge head14intersecting the movement direction C, the contact portion41bof the suction wiper41may be damaged and deteriorated. In the present specification, the “first end of the liquid discharge head” (also referred to as an “intersecting end”) means an end of the liquid discharge head that the cleaner (e.g., the suction wiper41) starts contacting when the cleaner moves relative to the liquid discharge head while contacting, the liquid discharge head, and the “second end of the liquid discharge head” (also referred to as an “intersecting end”) means an end of the liquid discharge head that the cleaner finishes contacting when the cleaner moves relative to the liquid discharge head while contacting the liquid discharge head. In the present embodiment, to suppress such damage and deterioration of the suction wiper41, the contact force (pressing force) of the suction wiper41with each liquid discharge head14is relatively small when the contact portion41bof the suction wiper41passes through one of the first end e1and the second end e2intersecting the movement direction C (i.e., the intersecting ends). That is, as illustrated, inFIG.7, the contact force of the contact portion41bof the suction wiper41contacting one of the first end e1and the second end e2(intersecting ends) of the liquid discharge head14in movement ranges H1is smaller than the contact force of the contact portion41bof the suction wiper41contacting a portion of the liquid discharge head14other than the first end e1and the second end e2in movement ranges H2. As described above, in the present embodiment, when the contact portion41bof the suction wiper41is contacting one of the first end e1and the second end e2(the intersecting ends), the contact force of the suction wiper41is relatively small, so that the contact pressure of the suction wiper41with the liquid discharge head14can be relatively small. In other words, the contact pressure of the contact portion41bof the suction wiper41contacting one of the first end e1and the second end e2(intersecting ends) of the liquid discharge head14in movement ranges H1is smaller than the contact pressure of the contact portion41bof the suction wiper41contacting a portion of the liquid discharge head14other than the first end e1and the second end e2in movement ranges F12. Accordingly, the contact portion41bof the suction wiper41can be prevented from being damaged and deteriorated when the contact portion41bof the suction wiper41passes through one of the first end of e1and the second end e2, thereby maintaining the cleaning function of the suction wiper41for a long time. Further, as illustrated inFIG.7, in the present embodiment, the suction wiper41moves in a movement path avoiding corners v1and v2having an acute angle among four corners (vertices) v1to v4of the nozzle surface55. If the suction wiper41contacts the corners v1and v2having the acute angle, the contact with the corners v1and v2may cause to accelerate damage and deterioration of the suction wiper41. Therefore, in the present embodiment, the movement path of the suction wiper41is set so as to avoid the corners v1and v2having the acute angle, thereby preventing damage and deterioration of the contact portion41bof the suction wiper41due to contact with the corners v1and v2having the acute angle. Thus, damage and deterioration of the suction wiper41can be more electively suppressed. FIG.8is a graph illustrating the contact force and the contact pressure of the suction wiper41according to a second embodiment of the present disclosure. As illustrated inFIG.8, in the present embodiment, when the contact portion41bof the suction wiper41contacts the first end e1and the second end e2of the liquid discharge heads14in the movement ranges H1, the contact force and the contact pressure of the suction wiper41are 0 or substantially 0. As described above, the contact force and the contact pressure when the contact portion41bof the suction wiper41contacts the first end e1and the second end e2are set to 0 or substantially 0, so that damage and deterioration of the contact portion41bof the suction wiper41can be more effectively suppressed. When the contact force and the contact pressure of the suction wiper41are 0 or substantially 0, the suction wiper41may contact the liquid discharge head14without the pressing force or may be separated from the liquid discharge head14in a non-contact state as long as there is no influence on the cleaning operation. FIG.9is a graph illustrating the contact force and the contact pressure of the suction wiper41according to a third embodiment of the present disclosure. As illustrated inFIG.9, in the present embodiment, when the contact portion41bof the suction wiper41contacts the portion of the liquid discharge head14other than the first end e1and the second end e2of the liquid discharge heads14in the movement ranges H2, the contact force of the suction wiper41progressively increases to keep the contact pressure of the suction wiper41constant. In the present embodiment, the basic configuration of the suction wiper41and the liquid discharge head14is the same as that of the above-described embodiment illustrated inFIG.7, and a third end e3(the long side55b) of each liquid discharge head14is oblique with respect to the movement direction C. Accordingly, when the suction wiper41moves from the first end e1to the second end e2of the liquid discharge head14, the contact area of the suction wiper41with the liquid discharge head14progressively increases. For this reason, similarly to the above-described embodiment illustrated inFIG.7, when the contact three in the movement ranges H2does not largely change after the contact portion41bof the suction wiper41passes through the first end e1and the second end e2, the contact area of the suction wiper41increases with the movement of the suction wiper41, and the contact pressure of the suction wiper41progressively decreases. On the other hand, in the present embodiment illustrated inFIG.9, while the contact portion41bof the suction wiper41contacts the portion of the liquid discharge head14other than the first end e1and the second end e2of the liquid discharge heads14in the movement ranges H2, the contact force of the suction wiper41increases with the movement of the suction wiper41. Therefore, in the present embodiment, even if the contact area of the suction wiper41progressively increases, the contact pressure of the suction wiper41can be kept constant. As a result, the change of the suction force of the suction wiper41or the wiping action due to the change of the contact pressure can be prevented, thereby stabilizing the cleaning function. Further, in the above-described embodiment illustrated toFIG.7, the contact pressure of the suction wiper41decreases with the movement of the suction wiper41. Therefore, the contact pressure is set larger than a predetermined reference value in advance to maintain the contact pressure equal to or larger than the reference value. On the other hand, in the present embodiment illustrated inFIG.9, the contact pressure can be kept constant, so that the contact pressure of the suction wiper41can be set low overall as compared with the above-described embodiment illustrated inFIG.7. Therefore, in the present embodiment, after the contact portion41bof the suction wiper41passes through the first end e1and the second end e2of the liquid discharge heads14, the contact pressure of the suction wiper41can be reduced when the contact portion41bof the suction wiper41contacts the third end e3(long side55b) of each liquid discharge head14extending in the movement direction C. As described above, in the present embodiment, the contact pressure can be further reduced and kept constant when the contact portion31bof the suction wiper41contacts the long side55b(third end e3extending in the movement direction C) of the liquid discharge head14. Therefore, damage and deterioration of the suction wiper41due to contact with the long side55bcan be suppressed, and the cleaning function of the suction wiper41can be stabilized. FIG.10is a graph illustrating the contact force and the contact pressure of the suction wiper41according to a fourth embodiment of the present disclosure. As illustrated inFIG.10, in the present embodiment, the contact force and the contact pressure of the suction wiper41with the liquid discharge head14in the movement range H2progressively decrease before the contact portion41bof the suction wiper41contacts the second end e2of the liquid discharge head14. As described above, in the present embodiment, the contact force and the contact pressure of the suction wiper41progressively decrease to prevent the contact force and the contact pressure from sharply decreasing. As a result, variations in the cleaning function of the suction wiper41due to sharp changes in the contact force and the contact pressure can be suppressed, and the cleaning function can be stabilized. FIG.11is a schematic view of the liquid discharge heads14and the suction wiper41, and a graph illustrating the contact force and the contact pressure of the suction wiper41according to a fifth embodiment of the present disclosure. Hereinafter, the contact force of the suction wiper41contacting the first end e1of the first liquid discharge head14from a state in which the suction wiper41does not contact the liquid discharge head14is referred to as a “first contact force (F1inFIG.11),” and the contact force of the suction wiper41moving from the second end e2of one liquid discharge head14(e.g., first liquid discharge unit) to the first end e1of another liquid discharge head14(e.g., second liquid discharge unit) is referred to as a “second contact force (F2inFIG.11).” In the above-described embodiment illustrated inFIG.7, the first contact force is set to be the same as the second contact force. On the other hand, in the fifth embodiment illustrated inFIG.11, the first contact force is set to be smaller than the second contact force. That is, in the present embodiment, the contact force of the suction wiper41with the liquid discharge head14is set such that the first contact force is smaller than the second contact force and the second contact force is smaller than the contact force of the suction wiper41contacting the portion other than the first end e1and the second end e2(i.e., the first contact force<the second contact force<the contact force with the portion other than the first end e1and the second end e2). As a result, damage and deterioration of the suction wiper41can be more effectively suppressed, and the cleaning capability can be improved. FIG.2is a schematic view of the liquid discharge heads14and the suction wiper41, and a graph illustrating the contact force and the contact pressure of the suction wiper41according to a sixth embodiment of the present disclosure. Hereinafter, the contact force of the suction wiper41moving from a state in which the suction wiper41contacts the second end e2of the last liquid discharge head14to a state in which the suction wiper41does not contact the liquid discharge head14is referred to as a “third contact force (F3inFIG.12).” In the sixth embodiment illustrated inFIG.12, the third contact force is smaller than the second contact force. That is, in the present embodiment, the contact force of the suction wiper41with the liquid discharge head14is set such that the third contact force is smaller than the second contact force and the second contact force is smaller than the contact force of the suction wiper41contacting the portion other than the first end e1and the second end e2(i.e., the third contact force<the second contact force<the contact force with the portion other than the first end e1and the second end e2). As a result, damage and deterioration of the suction wiper41can be more effectively suppressed, and the cleaning capability can be improved. In each of the above-described embodiments illustrated inFIGS.7to12, the contact area of the suction wiper41with the liquid discharge head14progressively increases as the suction wiper41moves from the first end e1to the second end e2of the liquid discharge head14. In addition, the present disclosure is applicable to a configuration in which the contact area of the suction wiper41with the liquid discharge head14progressively decreases. Therefore, as illustrated inFIG.13, the liquid discharge head14illustrated inFIG.7may be arranged so as to be laterally reversed. In this case, as the suction wiper41moves from the first end e1to the second end e2of the liquid discharge head14in the movement direction C inFIG.13, the contact area of the suction wiper41with the liquid discharge head14progressively decreases. Also in the liquid discharge head14having such a configuration, similarly to each of the above-described embodiments, the contact force or the contact pressure of the suction wiper41contacting one of the first end e1and the second end e2of the liquid discharge head14is smaller than the contact force or the contact pressure of the suction wiper41contacting the portion other than the first end e1and the second end e2, thereby suppressing damage and deterioration of the suction wiper41. Next,FIG.14is a schematic view of the liquid discharge heads14and the suction wipers41, and a graph illustrating the contact force and the contact pressure of the suction wipers41according to a seventh embodiment oldie present disclosure. As illustrated inFIG.14, in the present embodiment, the nozzle surface55of each liquid discharge head14has a rectangular shape. In the present embodiment, the multiple liquid discharge heads14are disposed in multiple rows shifted from each other in the sheet conveyance direction A (the direction intersecting the movement direction C of the suction wiper41), and the multiple liquid discharge heads14are shifted from each other in the sheet width directions B (the movement direction C of the suction wiper41). Further, in the present embodiment, the multiple suction wipers41are disposed (shifted) corresponding to the multiple rows of the liquid discharge heads14in the sheet conveyance direction A, respectively. That is, one of the multiple suction wipers41is disposed corresponding to the liquid discharge head14in an upper row (a) illustrated inFIG.14and, another of the multiple suction wipers41is disposed corresponding to the liquid discharge head14in a lower row (b) illustrated inFIG.14. Note that the suction wipers41and the liquid discharge heads14may be arranged in three or more rows. With such a configuration in the present embodiment, similarly to the above-described embodiments, each suction wiper41moves in the movement direction C to clean the nozzle surface55of the liquid discharge head14in each row. Also in the present embodiment, when the contact portion41bof each suction wiper41contacts the first end e1or the second end e2of each liquid discharge head14, the contact with the first end e1or the second end e2may cause damage or deterioration of the contact portion41bof each suction wiper41. That is, damage and deterioration of the suction wiper41may occur not only in a case in which the first and second ends e1and e2of the liquid discharge head14are substantially perpendicular to the movement direction C of the suction wiper41as in the above-described embodiments, but also in a case in which the first and second ends e1and e2are perpendicular to the movement direction C of the suction wiper41. For this reason, also in the present embodiment, when the contact portion41bof each suction wiper41passes through the first end e1and the second end e2of each liquid discharge head14, the contact three of each suction wiper41in the movement ranges H1is relatively small. Accordingly, similarly to the above-described embodiments, the contact portion41bof the suction wiper41can be prevented from being damaged and deteriorated when the contact portion41bof the suction wiper41passes through one of the first end e1and the second end e2, thereby maintaining the cleaning function of the suction wiper41for a long time. In the present embodiment, when the suction wiper41moves from the first end e1to the second end e2of the liquid discharge head14, the contact area of the suction viper41with the liquid discharge head14is the same (constant). For this reason, when the contact force of the suction wiper41with the liquid discharge head14is constant, the contact pressure of the suction wiper41can also be kept constant, and thus the change of the suction force of the suction wiper41or the wiping action can be prevented. In addition, the cleaning function can be stabilized. Note that the contact pressure of the suction wiper41with the liquid discharge head14is not limited to being kept constant and may change. Any one of the control methods illustrated inFIGS.7to10may be adopted for specific control of the contact pressure of each suction wiper41in the present embodiment. In the present embodiment, the contact forces of the respective suction wipers41are controlled at different timings because the respective suction wipers41reach the corresponding liquid discharge heads14at the different timings. That is, in the present embodiment, as illustrated in timing charts of the contact forces of the rows (a) and (b) illustrated inFIGS.14, first, the contact force of the suction wiper41in the row (b) decreases at the timing when the contact portion41bof the suction wiper41in the row (b) reaches the second end e2of the corresponding liquid discharge head14, and then the contact force of the suction wiper41in the row (a) decreases at the timing when the contact portion41bof the suction wiper41in the row (a) reaches the second end e2of the corresponding liquid discharge head14. As described above, in the present embodiment, the contact forces of the suction wipers41change independently at different timings, so that damage and deterioration of the contact portion41bof each suction wiper41can be suppressed. In an eighth embodiment of the present disclosure illustrated inFIG.15, the relative positions (movement start positions) of the respective suction wipers41relative to the corresponding liquid discharge heads14are set to be the same. Therefore, the timings when the contact portions41bof the respective suction wipers41reach the corresponding liquid discharge heads14are the same. In this case, the contact forces of the respective suction wipers41that contact the corresponding liquid discharge heads14can change in synchronization with each other in the rows (a) and (b). Next, a contact-force changer that changes the contact force of the suction wiper41with the liquid discharge head14is described.FIG.16is a schematic view of a contact-force changer50according to the present embodiment. The contact-force changer50illustrated inFIG.16includes a holder44that holds the suction wiper41, a spring45as an elastic member that presses the suction wiper41, a support46that supports the spring45, and a guide47that guides the support46along the movement direction C of the suction wiper41. The holder44movably holds the suction wiper41toward and away from the liquid discharge head14. In addition, the holder44holds the suction wiper41such that at least the suction port41aat the tip of the suction wiper41projects out of the holder44toward the liquid discharge head14. The spring45is disposed between the suction wiper41and the support46, and an end of the spring45opposite to the suction wiper41is supported by the support46. Since the spring45is compressed between the suction wiper41and the support46, the suction wiper41is pressed toward the liquid discharge head14. The support46has a plurality of projections46athat contacts the guide47. In the present embodiment, to stabilize the posture of the suction wiper41, the support46contacts the guide47via the plurality of projections46a. That is, the support46contacts the guide47at multiple positions that are not on the same straight line, thereby stabilizing the posture of the suction wiper41. In the contact-force changer50having such a configuration, when the suction wiper41moves to perform the cleaning operation, the support46is guided along the guide portion47aof the guide47. As a result, the end of the spring45opposite to the suction wiper41(the end adjacent to the support46) moves toward and away from the liquid discharge head14, thereby changing a compression amount of the spring45. That is, when the support46is guided by the guide portion47aand moves toward the liquid discharge head14as illustrated on the left side inFIG.16, the compression amount of the spring45increases. On the other hand, when the support46is guided by the guide portion47aand moves away from the liquid discharge head14as illustrated on the right side inFIG.16, the compression amount of the spring45decreases. As a result, the contact force of the suction wiper41with the liquid discharge head14changes. As illustrated inFIGS.17A to17D, the guide portion47ais formed in a shape following any one of changes of the contact forces illustrated inFIGS.7to10described above, for example. Accordingly, the contact force of the suction wiper41can be reduced at the first end e1and the second end e2. As a result, damage and deterioration of the suction wiper41can be suppressed. FIG.18is a schematic view of the contact-force changer50according to another embodiment of the present disclosure. The contact-force changer50illustrated inFIG.18does not move the suction wiper41toward and away from the liquid discharge head14. By contrast, the contact-force changer50moves the liquid discharge head14toward and away from the suction wiper41to change the contact force of the suction wiper41with the liquid discharge head14. Specifically, the contact-force changer50according to the present embodiment includes a contact-separation driver48that moves the liquid discharge head14toward and away from the suction wiper41, a position detector49that detects a relative movement position of the suction wiper41relative to the liquid discharge head14, and a controller53that controls the contact-separation driver48based on a detection signal of the position detector49. The position detector49includes an encoder56in which black and white band patterns are arranged alternately, and an optical sensor57including a light emitting unit and a light receiving unit. The optical sensor57is movable together with the suction wiper41. When the suction wiper41moves, the light emitting unit of the optical sensor57irradiates the encoder56with light, and the light receiving unit of the optical sensor57receives the light reflected by the encoder56. At that time, the controller53counts pulse signals to detect the relative movement position of the suction wiper41. Further, the controller53drives the contact-separation driver48based on the detected relative movement position of the suction wiper41. As a result, the contact force of the suction wiper41can be reduced at the timing when the suction wiper41passes through the first end e1and the second end e2of the liquid discharge head14. FIG.19is a schematic view of the contact-force changer50according to yet another embodiment of the present disclosure. In the embodiment illustrated inFIG.19, the controller53controls the contact-separation driver48that moves the suction wiper41toward and away from the liquid discharge head14based on a detection signal of a sensor58(position detector49). The sensor58may be an optical sensor or a magnetic sensor. Instead of the sensor58, a timer may be used to measure the movement time of the suction wiper41, and the relative movement position of the suction wiper41may be acquired based on the measured movement time of the suction wiper41. In still another embodiment, the contact-force changer50may moves both the suction wiper41and the liquid discharge head14toward and away from each other. Various embodiments of the present disclosure have been described above. The above-described embodiments are illustrative and do not limit the present disclosure. It is therefore to be understood that within the scope of the appended claims, numerous additional modifications and variations are possible to the present disclosure otherwise than as specifically described herein. For example, the present disclosure is also applicable to a serial-type liquid discharge device as illustrated inFIG.20. The serial-type liquid discharge device (image forming device3) illustrated inFIG.20includes a carriage9on which the liquid discharge head14is mounted, a guide (guide rod)10that guides the carriage9in the main scanning direction which is the sheet width directions B, and a driver19that moves the carriage9. In the present embodiment, the carriage9includes a liquid discharge head14A for black having a discharge port array for discharging black ink droplets and a liquid discharge head14B for color having a discharge port array for discharging ink of each color of cyan, magenta, and yellow. In the liquid discharge heads14A and14B, the respective discharge port arrays are arranged in a direction intersecting the main scanning direction (i.e., sheet conveyance direction A), and each ink is discharged downward. Note that individual liquid discharge heads may be provided for different colors (e.g., cyan, magenta, and yellow). Alternatively, one liquid discharge head may discharge inks of black and cyan and the other liquid discharge head may discharge inks of magenta and yellow. Further, the color of ink to be used is not limited to the above colors. Each of the liquid discharge heads14A and14B includes an energy generator for discharging ink, for example, a piezoelectric actuator such as a piezoelectric element, a thermal actuator utilizing film boiling of liquid using a thermoelectric conversion element such as a thermal resistor, a shape-memory alloy actuator utilizing metallic phase change due to temperature change, an electrostatic actuator utilizing electrostatic force, and the like. In addition, a plurality of sub-tanks for supplying inks of the respective colors to the liquid discharge heads14A and14B is mounted on the carriage9. The inks are supplied to the sub-tanks from ink cartridges15Y,15M,15C, and15Bk (seeFIG.1) mounted on the body of the image forming apparatus100via ink supply tubes. The driver19includes a motor28serving as a driving source and a timing belt35looped around a drive pulley29and a driven pulley30. As the motor28is driven and the drive pulley29is rotated, the timing belt35circumferentially moves. Accordingly, the carriage9coupled to the timing belt35is moved in the main scanning direction (the sheet width directions B) along the guide10. As the rotation direction of the motor28is switched between one direction and the opposite direction, the carriage9reciprocates in the main scanning direction. As the sheet P is conveyed to the image forming device3, each of the liquid discharge heads14A and14B discharges ink based on image signals while the carriage9moves in the main scanning direction, thereby forming an image for one line on the sheet P not in motion. Then, the sheet P is conveyed by a predetermined amount in the sheet conveyance direction A inFIG.20, and an image for the next line is formed. Subsequently, the conveyance and stop of the sheet P and the reciprocating movement of the carriage9are repeated, and ink is discharged onto the sheet P, thereby forming an entire image. The serial-type liquid discharge device (image forming device3) according to the present embodiment includes the maintenance device40that maintains each of the liquid discharge heads14A and14B. The maintenance device40includes caps36A and36B that cover the liquid discharge heads14A and14B, respectively, a blade wiper37that is a blade-shaped cleaner, and the suction wiper41that has the same function described in the above embodiments. When the maintenance operation is performed, the liquid discharge heads14A and14B move in the main scanning direction (the sheet width directions B) so that the liquid discharge heads14A and148approach the maintenance device40. As the liquid discharge heads14A and14B further move in the main scanning direction, the blade wiper37and the suction wiper41move relative to the liquid discharge heads14A and14B while contacting the liquid discharge heads14A and14B. As a result, ink adhering to the nozzles of the liquid discharge heads14A and14B is removed. Even in such a serial-type liquid discharge device, when the suction wiper41contacts the intersecting ends, which intersect the sheet width direction B, of the liquid discharge heads14A and14B during the cleaning operation, the suction wiper41may be damaged or deteriorated. Therefore, the present disclosure is preferably applied to a serial-type liquid discharge device. As the present disclosure is applied to the serial-type liquid discharge device, damage and deterioration of the suction wiper41due to contact of the suction wiper41with the intersecting ends can be suppressed, and the cleaning function can be maintained for a long time. The damage and deterioration of the cleaner is not limited to the suction wiper41. That is, also in the blade wiper37illustrated inFIG.20, as the blade wiper37moves relative to the liquid discharge heads14A and14B and contacts the intersecting ends of the liquid discharge heads14A and14B, the blade wiper37may be damaged or deteriorated. Therefore, even in such a blade wiper37, the contact force and the contact pressure of the blade wiper37contacting the intersecting, ends are reduced, thereby suppressing damage and deterioration of the blade wiper37. Further, the above-described embodiments of the present disclosure can be applied not only to the image forming apparatus100illustrated inFIG.1but also, for example, to image forming apparatuses100illustrated inFIGS.21and22. Hereinafter, descriptions are given of other examples of the configuration of the image forming apparatus100to which the present disclosure is applicable. Note that the configuration of the image forming apparatus100is mainly described regarding differences from the above-described embodiments, and the other configurations are basically similar to the configurations of the above-described embodiments. Therefore, descriptions of such similar configurations are omitted below. Similarly to the above-described embodiments, the image forming apparatus100illustrated inFIG.21includes the document conveyance device1, the image reading device2, the image forming device3, the sheet feeding device4, the cartridge mount5, and the sheet ejection portion7. However, the image forming apparatus100illustrated inFIG.21does not include the bypass sheet feeding device8. Unlike the image forming device3inFIG.1, the image forming device3inFIG.20is disposed facing a sheet conveyance passage20in which the sheet P is conveyed in the horizontal direction. In the image forming apparatus100illustrated inFIG.21, as a printing operation starts, the sheet P is supplied from the sheet feeding device4and conveyed to the image forming device3. As the sheet P is conveyed to the image forming device3, ink is discharged from the liquid discharge head14onto the sheet P to form an image on the sheet P. In the duplex printing, after the sheet P has passed the image forming device3, the sheet P is conveyed in the opposite direction opposite to the sheet conveyance direction, and a first passage changer31guides the sheet P to a sheet reverse passage21. Then, as the sheet P passes the sheet reverse passage21, the sheet P is reversed front the front face to the back face and conveyed to the image forming device3again, and an image is formed on the back face of the sheet P. A second passage changer32guides the sheet P, on one face or both faces of which the images have been formed, selectively to a sheet conveyance passage23toward the sheet ejection portion7or to a sheet conveyance passage22toward the sheet alignment apparatus200. When the sheet P is guided to the sheet conveyance passage23toward the sheet ejection portion7, the sheet P is ejected onto the sheet ejection portion7. On the other hand, when the sheet P is guided to the sheet conveyance passage22toward the sheet alignment apparatus200, the sheet is conveyed to the sheet alignment apparatus200, and the bundle of sheets P is aligned and stacked. Similarly to the image forming apparatus100illustrated inFIG.1, the image forming apparatus100illustrated inFIG.22includes the document conveyance device1, the image reading device2, the image forming device3, the sheet feeding device4, the cartridge mount5, the sheet ejection portion7, and the bypass sheet feeding device8. Note that, in this case, similarly to the image forming device3inFIG.21, the image forming device3inFIG.22is disposed facing a sheet conveyance passage86in which the sheet P is conveyed in the horizontal direction. In the image forming apparatus100illustrated inFIG.22, as a printing operation starts, the sheet P is supplied from the sheet feeding device4or the bypass sheet feeding device8, and is conveyed to the image forming device3. As the sheet P is conveyed to the image forming device3, ink is discharged from the liquid discharge head14onto the sheet P to form an image on the sheet P. In the duplex printing, after the sheet P has passed the image forming device3, the sheet P is conveyed in the opposite direction opposite to the sheet conveyance direction, and a first passage changer74guides the sheet P to a sheet reverse passage87. Then, as the sheet P passes the sheet reverse passage87, the sheet P is reversed from the front face to the back face and conveyed to the image forming device3again, so that an image is formed on the back face of the sheet P. A second passage changer75guides the sheet P, on one face or both faces of which the images have been formed, selectively to a sheet conveyance passage88toward the sheet ejection portion7or to a sheet conveyance passage89toward the sheet alignment apparatus200. When the sheet P is guided to the sheet conveyance passage88toward the sheet ejection portion7, the sheet P is ejected onto the sheet ejection portion7. On the other hand, when the sheet P is guided to the sheet conveyance passage89toward the sheet alignment apparatus200, the sheet P is conveyed to the sheet alignment apparatus200, and the bundle of sheets P is aligned and stacked. The image forming apparatus100illustrated inFIG.21or22, to which the present disclosure is applied, can attain the same effects as described above. That is, damage and deterioration of the cleaner that cleans the liquid discharge head14are suppressed, and the cleaning function can be maintained for a long time. The present disclosure is not limited to being applied to an inkjet image forming apparatus that discharges ink onto a sheet to form an image on the sheet. The term “liquid discharge device” according to embodiments of the present disclosure includes, in addition to apparatuses to discharge liquid to a material onto which liquid can adhere, apparatuses to discharge liquid into gas (air) or liquid. The “liquid discharge device” may be, for example, an image forming apparatus to form an image on a sheet by discharging ink, or a three-dimensional fabrication apparatus to discharge a fabrication liquid to a powder layer in which powder material is formed in layers to form a three-dimensional fabrication object. The liquid discharge device according to embodiments of the present disclosure may include devices to feed, convey, and eject the material onto which liquid can adhere. The liquid discharge device may further include a pretreatment apparatus to coat a treatment liquid onto the material, and a post-treatment apparatus to coat a treatment liquid onto the material, onto which the liquid has been discharged. The term “material onto which liquid can adhere” represents a material onto which liquid is at least temporarily adhered, a material onto which liquid is adhered and fixed, or a material into which liquid is adhered to permeate. Specific examples of the “material onto which liquid can adhere” include, but are not limited to, a recording media such as a paper sheet, a resin film, or cloth, an electronic component such as an electronic substrate or a piezoelectric element, and a medium such as layered powder, an organ model, or a testing cell. The “material onto which liquid can adhere” includes any materials onto which liquid is adhered, unless particularly limited. Examples of the “material onto which liquid can adhere” include any materials onto which liquid can adhere even temporarily, such as paper, thread, fiber, fabric, leather, metal, plastic, glass, wood, ceramic, construction materials (e.g., wall paper or floor material), and cloth textile. Examples of the liquid include ink, treatment liquid, DNA sample, resist, pattern material, binder, fabrication liquid, and solution or liquid dispersion containing amino acid, protein, or calcium. Examples of the “liquid discharge device” further include a treatment liquid, coating apparatus to discharge a treatment liquid to a sheet to coat, with the treatment liquid, a sheet surface to reform the sheet surface and an injection granulation apparatus in which a composition liquid including raw materials dispersed in a solution is discharged through nozzles to granulate fine particles of the raw materials. As described above, according to the present disclosure, the cleaner is effectively prevented from being damaged and deteriorated. The above-described embodiments are illustrative and do not limit the present disclosure. Thus, numerous additional modifications and variations are possible in light of the above teachings. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted for each other within the scope of the present disclosure. | 54,086 |
11858272 | DESCRIPTION OF THE EMBODIMENTS Referring to the exemplary embodiments of the invention in detail, the examples of the exemplary embodiments of the invention are described in the accompanying drawings. Whenever possible, the same reference numerals are used in the drawings and descriptions to indicate the same or similar parts. Referring toFIG.1, an ink circulation system100of the invention is suitable for an inkjet printer. The inkjet printer accurately sprays tiny ink droplets on a paper, a transparent film, a billboard, or a similar plane medium to be printed through a printer head to form texts and patterns on the plane medium. The ink circulation system100of the invention is not limited to ink with one color. By combining multiple sets of the ink circulation systems100, ink with multiple colors may be output in the inkjet printer, thereby being mixed to form color effects. Referring toFIG.1, the ink circulation system100of the invention includes an ink cartridge110, an ink tank120, an ink pump130, a first valve140, a second valve150, a third valve160, a printer head170, a heating assembly180, and a positive-negative pressure assembly190. The ink cartridge110is used to store an ink200and has an output pipeline111and an ink cartridge valve112. The ink cartridge valve112is disposed on the output pipeline111and is suitable for controlling whether the ink of the ink cartridge110can flow into the output pipeline111. The ink tank120is disposed on one side of the ink cartridge110and is connected to the output pipeline111of the ink cartridge110. The ink tank120serves as a relay node of the ink200and provides a gas pressure to stabilize the ink200to facilitate the storage and output of the ink200. The ink pump130is connected to the output pipeline111and the ink tank120through an ink pipeline131. The first valve140is connected to the ink tank120through a first pipeline141. The second valve150is disposed on the output pipeline111and is arranged side by side with the ink pump130. The second valve150is used to control the formation of a closed circuit or an open circuit between the output pipeline111and the ink tank120. The third valve160is connected to the output pipeline111and the ink pipeline131through a return pipeline161. The printer head170is connected to an ink tank pipeline121of the ink tank120and the return pipeline161. The heating assembly180is disposed in the ink tank120. The heating assembly180is disposed in the ink tank120. The heating assembly180is used to heat the ink200of the ink tank120to reduce the viscosity of the ink200, thereby improving the fluidity of the ink200and preventing the viscosity of the ink200from increasing due to low temperature, which causes the ink to be clogged in the ink tank120and the printer head170. The positive-negative pressure assembly190is connected to the first pipeline141through a gas pressure pipeline191. Further, the ink pump130is used to extract the ink200from the ink cartridge110and fill the ink200into the ink tank120along the output pipeline111and the ink pipeline131. The positive-negative pressure assembly190provides a positive pressure or a negative pressure to the ink tank120to squeeze or absorb the ink200in the ink tank120. Referring toFIG.1, in the embodiment, the positive-negative pressure assembly190has a positive pressure pump192, a negative pressure pump193, and a gas pressure valve194. The positive pressure pump192and the negative pressure pump193are respectively connected to the gas pressure pipeline191, and the gas pressure valve194is disposed between the gas pressure pipeline191and the first pipeline141. The gas pressure valve194is used to switch the first pipeline141to be connected to the positive pressure pump192or the negative pressure pump193and provide a stable positive pressure/negative pressure. The positive pressure pump192and the negative pressure pump193may also adjust a pressure range of the positive-negative pressure. In addition, providing the positive pressure represents that the positive pressure pump192extracts an air300from the outside and transmits the air300from the gas pressure pipeline191and the first pipeline141to the ink tank120, thereby squeezing the ink200in the ink tank120, so that the ink200is transmitted to the printer head170through the ink tank pipeline121. Providing the negative pressure represents that the negative pressure pump193extracts the air300in the ink tank120and discharges the air300from the first pipeline141and the gas pressure pipeline191to the outside, so that the ink tank120, the first pipeline141, and the gas pressure pipeline191form a vacuum, thereby adsorbing the ink200in the ink tank120and preventing the ink200from leaking from the printer head170. In other embodiments, when combining multiple sets of the ink circulation systems100, the single positive-negative pressure assembly190can provide the positive-negative pressure to multiple sets of the ink circulation systems100without adopting multiple positive-negative pressure assemblies190. Referring toFIG.1, the ink cartridge110includes a weight sensor113, which is disposed at a bottom of the ink cartridge110and is used to detect an ink volume of the ink cartridge. The weight sensor113determines whether an ink reserve of the ink cartridge110is sufficient through weight detection. If a weight of the ink cartridge110is lower than a default value, the ink reserve of the ink cartridge is insufficient, and a notification is issued to remind the user to replace the ink cartridge110with a new one. Referring toFIG.1, the ink tank120also has multiple level sensors122. The level sensors122are disposed on an outer surface of the ink tank120and are used to detect an ink level of the ink tank120, thereby identifying the ink reserve in the ink tank120. If the ink reserve is normal, the ink pump130is not activated. If the ink reserve is too low, the ink pump130is activated to replenish the ink in the ink tank120. The ink tank120further includes a pressure sensor123, which is disposed on the first pipeline141, is connected to the ink tank120through the first pipeline141, and is used to detect a gas pressure value between the ink tank120and the printer head170. When the gas pressure value of the ink tank120reaches the default value, bubbles or the ink in the printer head170have been removed and the printer head170is released from a clogged state. Further, the ink tank120and the ink cartridge110are made of metal materials (such as aluminum and stainless steel), which are suitable for resisting acid and alkali of the ink200. The output pipeline111, the ink pipeline131, the return pipeline161, and the first pipeline141are made of teflon. Since the teflon has excellent high-low temperature resistance and chemical stability, the teflon does not generate chemical reactions with the ink200when the ink200flows in the output pipeline111, the ink pipeline131, the return pipeline161, and the first pipeline141. Furthermore, the ink cartridge110, the ink tank120, the output pipeline111, the ink pipeline131, the return pipeline161, and the first pipeline141are all made of opaque materials to prevent the ink200from being deteriorated by irradiation of an external light source. Referring toFIG.1,FIG.2A, andFIG.2B, when the ink circulation system100is in the ink filling mode, the purpose is to fill the ink200in the ink cartridge into the ink tank120and a corresponding pipeline. The weight sensor113is used to detect whether the ink volume of the ink cartridge110is sufficient (Step A1). If the weight of the ink cartridge110is lower than the default value, a notification is issued to replace the ink cartridge110with a new one (Step A2). If the weight of the ink cartridge110is higher than the default value, the first valve140and the ink cartridge valve112are opened and the second valve150is closed (Step A3). The ink pump130is activated to fill the ink200into the ink tank120along the output pipeline111and the ink pipeline131(Step A4). Multiple level sensors122are used to sense whether the ink level of the ink tank120meets a standard (Step A5). If a sensing result is negative, Step A4is re-executed. If the sensing result is positive, the gas pressure valve194switches the first pipeline141to be connected to the negative pressure pump193and activates the negative pressure pump193to provide the negative pressure to the ink tank120(Step A6), so that the ink tank120, the first pipeline141, and the gas pressure pipeline191form the vacuum. Next, the ink cartridge valve112is closed and the second valve150is opened (Step A7), so that the ink200circulates among the ink tank120, the output pipeline111, and the ink pipeline131. Then, the ink pump is closed (Step A8) to stop the fluidity of the ink200. Then, Step A5is repeated to sense whether the ink level of the ink tank meets the standard. If the sensing result is negative, the ink pump130is activated to fill the ink200into the ink tank120. If the sensing result is positive, the second valve150is closed and the third valve160is opened (Step A9) and the ink pump130is activated (Step A10), so that the ink200circulates among the ink tank120, the return pipeline161, and the ink pipeline131, and the ink200passes through the printer head170. Further, the third valve160is closed and the second valve150is opened (Step A11), and Step A5is repeated again to sense whether the ink level of the ink tank meets the standard. If the sensing result is negative, the ink pump130is activated to fill the ink200into the ink tank120. If the sensing result is positive, the heating assembly180is activated to heat the ink200in the ink tank120and the printer head170(Step A12). Then, whether an ink temperature in the ink tank120and the printer head170meets the standard is sensed. If the sensing result is negative, Step A12is executed again until the ink temperature meets the standard. If the sensing result is positive, the ink circulation system100has completed ink filling and finishes the operation. Referring toFIG.1,FIG.3A, andFIG.3B. When the ink circulation system100is in the loop printing mode, the purpose is to ensure whether the ink200in the ink tank120is sufficient before printing, and maintain the fluidity of the ink200, so that the printer head170may print smoothly. First of all, the gas pressure valve194switches the first pipeline141to be connected to the negative pressure pump193and activates the negative pressure pump193(Step B1). Then, the first valve140is opened (Step B2) to provide the negative pressure to the ink tank120, so that the ink tank120, the first pipeline141, and the gas pressure pipeline191form the vacuum. Multiple level sensors122are used to sense whether the ink level of the ink tank120meets the standard (Step B3). If the sensing result is negative, the ink cartridge valve112is opened and the second valve150is closed (Step B4), and the ink pump130is activated to fill the ink200into the ink tank120along the output pipeline111and the ink pipeline131(Step B5). If the sensing result is positive, the ink cartridge valve112is closed and the second valve150is opened (Step B6). Then, the ink pump130is activated to fill the ink200into the printer head170(Step B7), and the heating assembly180is activated to heat the ink200in the ink tank120and the printer head170(Step B8). Next, whether the ink temperature in the ink tank120and the printer head170meets the standard is sensed (Step B9). If the sensing result is negative, Step B8is executed again until the ink temperature meets the standard. If the sensing result is positive, the printer head170starts printing and outputting the ink200(Step B10). Referring toFIG.1,FIG.4A, andFIG.4B, when the ink circulation system100is in the ink removal mode, the purpose is to remove the printer head170clogged by the ink. Multiple level sensors122are used to sense whether the ink level of the ink tank120meets the standard (Step C1). If the sensing result is negative, the ink cartridge valve112is opened and the second valve150is closed (Step C2), and the ink pump130is activated to fill the ink200into the ink tank120along the output pipeline111and the ink pipeline131(Step C3). If the sensing result is positive, the ink cartridge valve112is closed and the second valve150is opened (Step C4). Then, the first valve140is closed (Step C5) and the negative pressure pump193is closed (Step C6) to stop providing the negative pressure. Next, the gas pressure valve194switches the first pipeline141to be connected to the positive pressure pump192and opens the first valve140(Step C7), and the ink pump130is activated to fill the ink200into the ink tank120along the output pipeline111and the ink pipeline131(Step C3). The positive pressure pump192is activated to extract the air300from the outside and transmit the air300from the gas pressure pipeline191and the first pipeline141to the ink tank120, thereby squeezing the ink200in the ink tank120, so that the ink200is transmitted to the printer head170through the ink tank pipeline121(Step C8) to remove the ink200clogged in the printer head170. Next, the pressure sensor123is used to detect whether the gas pressure value between the ink tank120and the printer head170declines to the default value (Step C9). If the sensing result is negative, Step C8is repeated. If the sensing result is positive, the ink200in the printer head170has been removed and the printer head170is released from the clogged state. Then, the positive pressure pump192is closed (Step C10) and the gas pressure valve194switches the first pipeline141to be connected to the negative pressure pump193(Step C11). Step C1is repeated again, if the sensing result is negative, the ink cartridge valve112is opened and the second valve150is closed (Step C2), and the ink pump130is activated to fill the ink200into the ink tank120along the output pipeline111and the ink pipeline131(Step C3). If the sensing result is positive, the ink cartridge valve112is closed and the second valve150is opened (Step C12). Finally, the negative pressure pump193is activated to provide the negative pressure to the ink tank120to extract the air (Step C13), so that the ink tank120, the first pipeline141, and the gas pressure pipeline191form the vacuum to prevent the ink200from leaking from the printer head170. In short, when the ink200dries out and becomes clogged in the printer head170, the ink removal mode may be used to provide the positive pressure, so that the ink200with fluidity is transmitted to the printer head170to remove the dried ink200, thereby maintaining the smooth flow of the printer head170. Referring toFIG.1,FIG.5A, andFIG.5B, when the ink circulation system100is in the bubble removal mode, the purpose is to remove the bubbles from the printer head170. Multiple level sensors122are used to sense whether the ink level of the ink tank120meets the standard (Step DD. If the sensing result is negative, the ink cartridge valve112is opened and the second valve150is closed (Step D2), and the ink pump130is activated to fill the ink200into the ink tank120along the output pipeline111and the ink pipeline131(Step D3). If the sensing result is positive, the ink cartridge valve112is closed and the second valve150is opened (Step D4). Then, the first valve140is closed (Step D5) and the negative pressure pump193is closed (Step D6) to stop providing the negative pressure. The second valve150is closed and the third valve160is opened (Step D7). Next, the gas pressure valve194switches the first pipeline141to be connected to the positive pressure pump192and opens the first valve140(Step D8), and the ink pump130is activated to fill the ink200into the ink tank120along the output pipeline111and the ink pipeline131(Step D3). The positive pressure pump192is activated to extract the air300from the outside and transmit the air300from the gas pressure pipeline191and the first pipeline141to the ink tank120, thereby squeezing the ink200in the ink tank120, so that the ink200passes through the printer head170and the third valve160(Step D9), and the ink200circularly flows in the return pipeline161, the ink pipeline131, and the ink tank pipeline121to remove the bubbles from the printer head170. Then, the pressure sensor123is used to detect whether the gas pressure value between the ink tank120and the printer head170declines to the default value (Step D10). If the sensing result is negative, Step D9is repeated. If the sensing result is positive, the bubbles in the printer head170have been removed. Then, the positive pressure pump192is closed (Step D11). The second valve150is opened and the third valve160is closed (Step D12), and the gas pressure valve194switches the first pipeline141to be connected to the negative pressure pump193(Step D13). Step D1is repeated again, if the sensing result is negative, the ink cartridge valve112is opened and the second valve150is closed (Step D2), and the ink pump130is activated to fill the ink200into the ink tank120along the output pipeline111and the ink pipeline131(Step D3). If the sensing result is positive, the ink cartridge valve112is closed and the second valve150is opened (Step D14). Finally, the negative pressure pump193is activated to provide the negative pressure to the ink tank120to extract the air (Step D15), so that the ink tank120, the first pipeline141, and the gas pressure pipeline191form the vacuum to prevent the ink200from leaking from the printer head170. In short, when the ink200contains the bubbles and enters the printer head170, the bubble removal mode may be used to provide the positive pressure, so that the ink200circularly flows and passes through the printer head170to remove the bubbles from the printer head170and the ink200. Based on the above, the ink pump of the ink circulation system of the invention is used to extract the ink from the ink cartridge and fill the ink into the ink tank along the output pipeline and the ink pipeline to achieve the purpose of replenishing the ink. Further, the negative pressure may be provided to the ink tank through the positive-negative pressure assembly to absorb the ink in the ink tank, thereby preventing the ink from leaking from the printer head. The positive-negative pressure assembly is suitable for providing the positive pressure to the ink tank to squeeze the ink in the ink tank, so that the ink is transmitted to the printer head to release the printer head from the clogged situation or remove the bubbles from the printer head by enabling the ink to pass through the printer head and the third valve. In addition, the heating assembly of the invention is suitable for heating the ink in the ink tank and the printer head to reduce the viscosity of the ink, thereby improving the fluidity of the ink and reducing the clogging of the printer head by the ink. | 18,842 |
11858273 | Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. DETAILED DESCRIPTION When producing printing fluid containers, it is important to ensure that the printing fluid containers are simple to manufacture and are easy for the ultimate customer to use. It also is desirable to employ designs whereby application of a cover onto a container body may be automated, either by press-fitting or by threading. Injection molding threaded components can require complicated molding, particularly when there is a need for both internal and external threads. The present printing fluid container employs a molded closure assembly that may be installed using conventional screw on methods, but that minimizes complexity of the molds. The present printing fluid container also provides for faster opening of the container and provides an improved customer experience. As will now be described in detail, the closure assembly includes a cap that may be removed either by twisting it off or snapping it off. This dual release mechanism provides a quick and easy uncap experience. Regardless of the removal method employed, removal is achieved with relatively little user effort. In accordance with the aforementioned principals, a printing fluid container is provided for a printing system, the printing fluid container including a container body for holding printing fluid and a closure assembly configured to selectively close access to the container. The closure assembly includes a collar that may be fluidically connected to the container body, and a cap that may be separately applied to and removed from the collar to selectively close and open the printing fluid container. According to examples described herein, the cap and collar may have complementary surface features that provide for quick cam-actuated removal of the cap from the collar upon rotation of the cap in a first direction. The cap may be removed upon rotation of not more than 90 degrees rotation relative to the collar under a torque of not more than 1.0 Nm. Referring initially toFIG.1, a printing fluid container10is shown in exploded view, the printing fluid container including a container body100, a collar200, and a cap300. The container body may take virtually any form, but is shown here as a cylindrical bottle for use in filling/refilling an onboard printing fluid source of a printing system, as will be described in greater detail below. Printing fluid container10thus may be used, for example, in connection with a so-called continuous ink supply system CISS (also referred to as continuous ink system CIS) of a printer. As shown, container body100includes a hollow base110defining an interior chamber112. The internal chamber is suited for holding a printing fluid F for use in printing. Hollow base110has a closed bottom portion114, a top shoulder portion116, and a cylindrical side-wall portion118extending therebetween. The top shoulder portion opens into a neck120, which in turn defines a neck passage122and a neck opening124that provides access to the interior chamber. Printing fluid F may be introduced into interior chamber112via neck opening124and neck passage122(e.g., during manufacture). Printing fluid F also may be expelled from interior chamber112via neck passage122and neck opening124(e.g., during fill/refill of an onboard printing source of a printing system as will be described further below). Referring now toFIGS.1and2, it will be noted that collar200is configured for selected attachment to container body100. In some examples, the collar includes a spout210with an exterior spout surface212and a spout opening214. The spout opening serves as the container opening when the collar is attached to the container body. The collar further includes a peripheral collar body220that defines a collar passage222that is accessible via a collar opening224to selectively fluidically connect the neck opening to the spout. The spout thus is fluidically connected to interior chamber112when the collar is attached to the container body. Accordingly, printing fluid may be dispensed through spout210to fill/refill an onboard printing fluid source of a printing system as is herein described. Although collar200is depicted as being configured for selected application to the container body100, it will be understood that the collar may be fixed to the neck or may form an integral part of the neck. Where the collar and container body are separable, the printing fluid container may be provided with attachment features to provide for selected attachment of the collar to the container body. In some examples, the attachment features take the form of complementary threads to provide for threaded attachment of the collar to the container body. In the depicted implementation, the container body is provided with first threads126on an exterior neck surface128to define a threaded neck. Correspondingly, the collar is provided with complementary second threads226on an interior collar body surface228to define a threaded collar. Collar200thus may be applied to container body100by aligning the collar body with the neck along longitudinal axis A, and rotating the collar in a first direction, typically clockwise, about the longitudinal axis. Although the container body is depicted herein as having threads on an exterior surface, and the collar is depicted as having threads on an interior surface of the collar body, it will be understood that the container body may have interior surface threads and the collar may have exterior surface threads. Referring now toFIGS.1-3, it will be noted that cap300is configured to removably engage collar200, and thereby, to selectively close the printing fluid container. More particularly, the cap includes a lid310configured to cover spout210, sealing the container opening when the cap is in place. More particularly still, the lid includes a cap clip312that extends from an undersurface thereof to mate with spout210. The cap clip may employ a peripheral ridge314that frictionally engages the exterior spout surface to resist removal of the cap from the collar. An O-ring also may be employed to form a seal between the cap clip and the spout. The cap thus may be press-fit (or snap-fit) onto the collar to hold the cap in place. As shown, ridge314may be formed on the cap clip at a distance D from the undersurface of lid, and engages the spout at a corresponding distance D from the spout opening such that the cap will be fully released upon traversing a distance D along longitudinal axis A. A torque of between 0.2 Nm and 1.0 Nm preferably will be sufficient to overcome the frictional engagement between the cap clip and spout, and thus will be sufficient to remove the cap from the collar. Although ridge314is shown herein as projecting from the cap clip, it will be appreciated that the ridge may project from the spout to the same effect. It also will be appreciated that other frictional features similarly may be employed to releasably secure the cap to the collar. Focusing now onFIGS.2and3, it will be noted that cap300further includes a peripheral skirt320defining a cap opening324. In accordance with the principals described herein, the peripheral skirt320is configured to closely interfit with collar body220. More particularly, the peripheral skirt and collar body define a pair of cylinders with complementary interior/exterior surface features that promote concentric alignment thereof. The aforementioned complementary interior/exterior surface features may take the form of teeth disposed on respective interior/exterior surfaces of the cap and collar. Collar200thus may include a plurality of collar teeth230evenly distributed around the collar body. Cap300correspondingly may include a plurality of cap teeth330evenly distributed around the cap. The collar teeth and cap teeth are configured for cammed interfitment along longitudinal axis A such that the cap teeth are interleaved with the collar teeth upon application of the cap to the collar body. Upon rotation of the cap in a first direction, the cap teeth engage the collar teeth to effect cam-actuated removal of the cap from the collar. To promote cam-actuated removal of the cap from the collar, collar teeth230define a plurality of collar cam surfaces232(also referred to as collar ramps), and cap teeth330define a plurality of cap cam surfaces332(also referred to as cap ramps). The collar cam surfaces and cap cam surfaces are configured to cammingly engage one another upon rotation of the cap in a first rotational direction, resulting in sliding passage of the cap cam surfaces over the collar cam surfaces to effect removal of the cap from the collar. Each cam surface has surface characteristics to accommodate cap removal under a torque of not more than 1.0 Nm, and preferably, a torque of between 0.2 Nm and 1.0 Nm. As shown, collar cam surfaces232form collar ramps that are inclined peripherally toward the spout opening214in a first rotational direction, preferably at an angle of less than 45 degrees. Cap cam surfaces332correspondingly form cap ramps that are inclined peripherally toward the cap opening324at an angle corresponding to the incline angle of collar cam surfaces232, but in a second rotational direction opposite the first rotational direction. The collar ramps (and/or the cap ramps) define a longitudinal span of at least a distance D such that the ridge will clear the collar upon not more than 90 degrees rotation of the cap the in a first rotational direction about the longitudinal axis. Stated otherwise, the cap will travel a distance D along a path parallel to longitudinal axis A upon not more than 90 degrees rotation of the cap in the first rotational direction. In some examples, the collar ramps are inclined toward spout210in a counterclockwise direction (as viewed from the spout) and the cap ramps are inclined toward cap opening324in a clockwise direction (as viewed from the cap lid). The cap thus may be removed from the collar by relative rotation in a counterclockwise direction (as viewed from the cap, looking toward the collar). Collar teeth230also may define a plurality of collar stop surfaces234(also referred to as collar risers), and cap teeth330may define a plurality of cap stop surfaces334(also referred to as cap risers). The collar stop surfaces234and cap stop surfaces334are configured to fixedly engage each other upon rotation of the cap in a second rotational direction, opposite the first rotational direction. The collar thus may be locked relative to the cap during rotation of the cap in the second rotational direction. Rotation of the cap about longitudinal axis A in the second rotational direction thus will result in corresponding rotation of the collar with the cap. As shown, collar stop surfaces234form collar risers, each of which extends in a direction substantially parallel to longitudinal axis A. Cap stop surfaces334similarly form cap risers, each of which extends in a direction substantially parallel to a longitudinal axis A. Rotation of the cap about the longitudinal axis in a second rotational direction thus effects engagement of the cap risers and collar risers to rotatably tighten the collar onto the container body (e.g., where a threaded collar is to be attached to a threaded neck of a container body). As described herein, the collar teeth are surface features that rise radially outwardly from an exterior collar body surface240. Similarly, the cap teeth are surface features that rise radially inwardly from an interior cap surface340. The ramps and risers may be canted radially inwardly to help maintain sliding contact between the collar teeth and cap teeth during rotation of the cap relative the collar. The collar ramps and collar risers intersect in rounded collar teeth tips236, and the cap ramps and cap risers intersect in rounded cap tips336, thereby promoting alignment of the cap teeth and collar teeth when the cap is applied to the collar. Although the collar is depicted herein as having collar teeth on an exterior collar body surface, and the cap is depicted as having cap teeth on an interior cap surface, it will be understood that the collar may have interior surface teeth and the cap may have exterior surface teeth without departing from the principals herein described. The depicted printing fluid container10includes a collar with twelve collar teeth230equally distributed along an exterior collar body surface (also referred to as the collar periphery), each collar tooth having a cam ramp and a cam riser as described above to define substantially triangular collar teeth. Printing fluid container10also includes a cap with twelve cap teeth equally distributed along an interior cap surface (also referred to as the cap periphery), each cap tooth having a cam ramp and a cam riser as described above to define substantially triangular cap teeth. This arrangement of collar teeth and cap teeth has been found to be well-suited for application and removal of the cap relative to the collar of a printing fluid container. With substantially triangular teeth on each of the collar body and cap, the collar teeth and cap teeth substantially entirely overlap when the cap is applied to the collar body. Accordingly, the cap ramps will fully traverse the collar ramps upon 30 degrees rotation of the cap about the longitudinal axis, effecting removal of the cap from the collar. This rotational span provides the desired ease of cap removal, while still providing the desired tactile feedback to the user, and still allowing rapid alignment and seating of cap on the collar during application/reapplication of the cap to the collar. It will be appreciated that fewer teeth generally will correspond to the need for more rotation to remove the cap, and will complicate alignment and seating of the cap. More teeth generally will allow quicker removal with less rotation of the cap, but will undesirably reduce the longitudinal span (also referred to as throw) achieved by rotation of the cap, and/or may make cammed passage of the cap teeth over the collar teeth more difficult (e.g., if the slope of the collar and cap ramps were increased to increase throw). Increasing the number of teeth thus could unacceptably increase the effort required to remove the cap. Furthermore, where too little rotation effects cap removal, tactile feedback to the user may be insufficient. While the depicted printing fluid container has been described with twelve collar teeth and twelve cap teeth, other arrangements may be employed in accordance with the principals described herein. The collar may include between four and twenty-four collar teeth. The cap correspondingly may include between four and twenty-four cap teeth. It will be appreciated that the cap of a printing fluid container employing twenty-four collar teeth and twenty-four cap teeth (in the configuration described above) would be removable upon 15 degrees rotation. Similarly, the cap of a printing fluid container employing four collar teeth and four cap teeth (in the configuration described above) would be removable upon 90 degrees rotation. The slope and size of the teeth would vary depending on the number of teeth, as could the surface characteristics employed. In any event, the collar teeth and cap teeth preferably are configured such that the cap may be removed upon rotation of the cap in a first rotational direction under a torque of not more than 1.0 Nm. Referring still toFIGS.2and3, it will be appreciated that collar teeth230may be considered to collectively define a sawtooth collar lip250disposed on a periphery of the collar. Cap teeth330similarly may be considered to collectively define a sawtooth cap lip350on a periphery of the cap. More particularly, collar body220has a sawtooth collar lip on an exterior collar body surface240, and cap skirt320has a sawtooth cap lip350on an interior cap surface340. Sawtooth collar lip250defines a plurality of interleaved collar ramps232and collar risers234such that the sawtooth collar lip extends around the collar to with undulating surface profile. Sawtooth cap lip350similarly defines a plurality of cap ramps and cap risers such that the sawtooth cap lip extends around the cap with an undulating surface profile complementary to the surface profile of sawtooth collar lip250. Therefore, when cap300is applied to collar200, sawtooth cap lip350and sawtooth collar lip250collectively define a peripheral ring of consistent radial depth. Movement of cap300in the first rotational direction (e.g., counterclockwise) thus effects engagement between the cap ramps and the collar ramps. More particularly, rotating the cap in the first rotational direction effects cammed engagement of the cap ramps and collar ramps to separate the cap from the collar. The rotation required to effect cap removal is dependent on the size and shape of the ramps employed, but should be accomplished upon rotation of the cap by a release rotation of not more than 90 degrees. For example, where the sawtooth collar lip includes twelve ramps equally distributed around a collar periphery and spanning the collar periphery (as shown inFIGS.1-3), the cap ramps will completely traverse the collar ramps upon 30 degrees rotation of the cap. Complete traverse of the collar ramps by the cap ramps, in turn, will move the cap a from its seated position (shown inFIG.3) by a distance corresponding to the longitudinal span of the collar ramps (a distance D). Where the cap is press-fit (or snap-fit) onto the collar and held in place using an attachment feature (such as peripheral ridge314), the longitudinal span of the collar ramps will be sufficient to allow the attachment feature to clear the collar (or cap) upon effecting a release rotation of the cap. To apply/reapply cap300to collar200, the cap and collar may be positioned along longitudinal axis A with the sawtooth cap lip350and sawtooth collar lip250generally aligned, and the cap press-fit (or snap-fit) onto the collar. It will be appreciated that some misalignment between the sawtooth cap lip and sawtooth collar lip may be addressed by rounded collar tips236and cap tips336at the intersections between the ramps and risers. Once the cap is applied to the collar, movement of cap300in a second rotational direction (e.g., clockwise) effects engagement between the cap risers and the collar risers. More particularly, rotating the cap in the second direction thus effects fixed engagement of the cap risers and collar risers to effect rotation of collar200with cap300. Rotation of the cap in the second rotation direction thus translates rotational torque from the cap to the collar, which in turn may be used to tighten collar200onto container body100. More particularly still, cap300and collar200may be effectively locked together such that rotation of the cap in the second rotational direction correspondingly threads collar body220onto correspondingly threaded neck120of container body100, typically through multiple revolutions of the cap/collar combination. The cap may employ frictional grip features360on an exterior surface thereof to enhance user grip such that adequate torque may be applied when rotating the cap/collar combination. It will be appreciated that rotation of the cap in the first or second rotational direction will not remove the collar from the container body because the cap and collar are only locked together during rotation in the first rotational direction. To remove the collar, the collar itself is rotated in the first rotational direction, typically through multiple revolutions of the collar. In some examples, container body100may be provided with peripheral tabs160, and the collar provided with corresponding tab seats260configured to lock the collar onto the container body. As shown inFIG.4, printing fluid container10may be used in connection with a printing system20to fill/refill an onboard printing fluid source22with printing fluid from the printing fluid container. To do so, cap300is removed from collar200, thereby exposing spout210and providing fluidic access to the interior chamber112of container body100. With the cap removed, printing fluid container10may be positioned to align spout210with a fluidic input24of onboard printing fluid source22, and printing fluid may be poured into the onboard printing fluid source, either by gravity or under an applied force. Once filling/refilling is complete, printing fluid container10may be removed from printing system20, cap300may be applied/replied to collar200, and the printing fluid container10may be stored for future use. The preceding description has been presented to illustrate and describe examples of the principles described. This description is not intended to be exhaustive or to limit these principles to any precise form disclosed. Many modifications and variations are possible in light of the above teaching. | 21,015 |
11858274 | DESCRIPTION OF THE EMBODIMENTS An embodiment of the present teaching will be described below. Note that, however, the embodiment described below is merely an example of the present teaching; it goes without saying that it is possible to make any appropriate changes in the embodiment of the present teaching without departing from the gist and scope of the present teaching. Upward and downward are each a component of an up-down direction7and are opposite to each other; leftward and rightward are each a component of a left-right direction9and are opposite to each other; and frontward and rearward are each a component of a front-rear direction8and are opposite to each other. Furthermore, in the embodiment, the up-down direction7corresponds to the vertical direction, and each of the front-rear direction8and the left-right direction9corresponds to the horizontal direction. Moreover, the up-down direction7is defined with a state that a multi-function peripheral10is usably installed or a posture in which the multi-function peripheral10is usably installed, as the reference. Note that the state that the multi-function periphery10is usably installed as depicted inFIGS.1A to1Cwill be referred to as a “usable state”. Moreover, the posture in which the multi-function peripheral10is usably installed as depicted inFIGS.1A to1Cwill be referred to as a “usable posture”. Further, the front-rear direction8is defined such that a side on which an opening13of the multi-function peripheral10is provided is designated as the front side (front surface), and the left-right direction9is defined as viewing the multi-function peripheral10from the front side (front surface). The front-rear direction8is an example of a first direction, and the left-right direction9is an example of a second direction. <Overall Configuration of Multi-function Peripheral10> As depicted inFIGS.1A and1B, the multi-function peripheral10is formed to have a substantially rectangular parallelepiped shape. The multi-function peripheral10includes, at a lower portion of a casing thereof, a printer unit11which records an image onto a paper12(seeFIG.2) by an ink-jet recording method. As depicted inFIG.2, the printer unit11includes a feeding section15, a feeding tray20, a discharge tray21, a conveyance roller section54, a recording section24, a discharge roller section55, a platen42, and an ink tank100(an example of a tank). Further, the multi-function peripheral10has various functions such as a facsimile function and a print function. The multi-function peripheral10is an example of a liquid discharging apparatus or a liquid consuming apparatus. <Feeding Tray20, Discharge Tray21> As depicted inFIGS.1A and1B, the feeding tray20is inserted into and removed from the multi-function peripheral10by a user, in the front-rear direction8through the opening13. The opening13is formed in a central portion in the left-right direction9of the front surface of the multi-function peripheral10. The feeding tray20is capable of supporting a plurality of sheets of the paper12that are stacked in the feeding tray20. The discharge tray21is arranged at the upper side of the feeding tray20, and is inserted or removed together with the feeding tray20. The discharge tray21supports the paper12discharged through a space between the recording section24and the platen42by the discharge roller section55. <Feeding Section15> The feeding section15feeds the paper12supported by the feeding tray20to a conveyance route65. As depicted inFIG.2, the feeding section15includes a feeding roller25, a feeding arm26, and a shaft27. The feeding roller25is rotatably supported by the feeding arm26at a front end thereof. The feeding roller25rotates in a direction for causing the paper12to be conveyed in a conveyance direction16when a conveyance motor (not depicted in the drawings) is reversely rotated. In the following description, the rotations of the feeding roller25, a conveyance roller60, and a discharge roller62in the direction for causing the paper12to be conveyed in the conveyance direction16are each referred to as “normal rotation”. The feeding arm26is pivotably supported by the shaft27supported by the frame of the printer unit11. A bias is applied to the feeding arm26by an elastic force of a spring, etc. or by the self-weight of the feeding arm26such that the feeding arm26is pivoted and urged toward the feeding tray20. <Conveyance Route65> As depicted inFIG.2, in the interior of the printer unit11, a space is defined by an outer guide member18and an inner guide member19which are arranged to face with each other with a predetermined gap intervened therebetween. This space constructs a portion of the conveyance route65. The conveyance route65is a route or path that is extended from a rear-end portion of the feeding tray20toward the rear side of the printer unit11. Further, the conveyance route65makes a U-turn while being extended from the lower side to the upper side, at the rear side of the printer unit11; and then the conveyance route65reaches the discharge tray21via a space between the recording section24and the platen42. As depicted inFIGS.2and3, a portion of the conveyance route65between the conveyance roller section54and the discharge roller section55is provided at a substantially central portion in the left-right direction9of the multi-function peripheral10, and is extended in the front-rear direction8. Note that inFIG.2, the conveyance direction16of the paper12in the conveyance route65is indicated by an arrow of a dashed-dotted line. <Conveyance Roller Section54> As depicted inFIG.2, the conveyance roller section54is arranged at the upstream side of the recording section24in the conveyance direction16. The conveyance roller section54includes the conveyance roller60and a pinch roller61which are facing each other. The conveyance roller60is driven by a conveyance motor. The pinch roller61rotates following the rotation of the conveyance roller60. The paper12is conveyed in the conveyance direction16by being pinched between the conveyance roller60and the pinch roller61which are rotated positively by the normal rotation of the conveyance motor. <Discharge Roller Section55> As depicted inFIG.2, the discharge roller section55is arranged at the downstream side of the recording section24in the conveyance direction16. The discharge roller section55includes the discharge roller62and a spur63which are facing each other. The discharge roller62is driven by the conveyance motor. The spur63rotates following the rotation of the discharge roller62. The paper12is conveyed in the conveyance direction16by being pinched between the discharge roller62and the spur63which are rotated positively by the normal rotation of the conveyance motor. <Recording Section24> As depicted inFIG.2, the recording section24is arranged between the conveyance roller section54and the discharge roller section55in the conveyance direction16. Further, the platen42and the recording section24are arranged to face each other in the up-down direction7, while sandwiching the conveyance route65therebetween. Namely, the recording section24is arranged at a position at which the recording section24is located above the conveyance route65in the up-down direction7and at which the recording section24faces the conveyance route65. The recording section24includes a carriage23and a recording head39(an example of a head or a liquid consuming section). As depicted inFIG.3, the carriage23is supported by guide rails43and44which are extended in the left-right direction9, respectively at positions separated in the front-rear direction8. The guide rails43and44are supported by the frame of the printer unit11. The carriage23is connected to a known belt mechanism disposed on the guide rail44. The belt mechanism is driven by a carriage motor (not depicted in the drawings). Namely, the carriage23connected to the belt mechanism reciprocates in the left-right direction9by being driven by the carriage motor. As depicted by alternate long and short dash lines inFIG.3, the range of movement of the carriage23spans beyond the left and right end sides of the conveyance route65in the left-right direction9. Further, an ink tube32which connects the ink tank100and the recording head39and a flexible flat cable33which electrically connects the recording head39and a control circuit board having a controller (not depicted in the drawings) mounted thereon are extended from the carriage23. The ink tube32supplies an ink stored in the ink tank100to the recording head39. More specifically, four ink tubes32B,32M,32C, and32Y via which inks of respective colors (which are black, magenta, cyan, and yellow colors) are distributed are extended from the ink tank100, and are connected to the carriage23in a bundled form. In the following description, these four ink tubes32B,32M,32C, and32Y will be collectively referred to as “ink tube(s)32” in some cases. The flexible flat cable33transmits a control signal output from the controller to the recording head39. As depicted inFIG.2, the recording head39is installed on the carriage23. A plurality of nozzles40is formed in the lower surface of the recording head39. End portions (tip portions) of the nozzles40are exposed from the lower surface of the recording head39and from the lower surface of the carriage23on which the recording head39is installed. In the following description, the surface through which the end portions of the nozzles40are exposed will be referred to as a “nozzle surface” in some cases. The recording head39jets or discharges the ink as fine ink droplets (minute ink droplets) through the nozzles40. In a process of movement of the carriage23, the recording head39jets the ink droplets toward the paper12supported by the platen42. Accordingly, an image, etc. is recorded on the paper12. <Platen42> As depicted inFIGS.2and3, the platen42is arranged between the conveyance roller section54and the discharge roller section55in the conveyance direction16. The platen42is arranged so as to face the recording section24in the up-down direction7, and supports the paper12, conveyed by the conveyance roller section54, from therebelow. <Ink Tank100> As depicted inFIGS.1A to1C, the ink tank100is accommodated inside the multi-function peripheral10. The ink tank100is fixed to the multi-function peripheral10such that the ink tank100cannot be easily removed from the multi-function peripheral10. More specifically, the ink tank100is accommodated in the inside of the multi-function peripheral10via an opening22formed in the front surface of the casing of the multi-function peripheral10, at the right end of the front surface in the left-right direction9. The opening22is adjacent to the opening13in the left-right direction9. Note that, however, the front surface (a portion of a base wall101A and a portion of an inclined wall101B which will be described later on) of the ink tank100is located in front of the opening22in the front-rear direction8(more specifically, located in front of a portion of the front wall of the casing defining the opening22). Further, the multi-function peripheral10is provided with a box-shaped cover70capable of covering the front surface, of the ink tank100, located in front of the opening22. The cover70is supported by the casing of the multi-function peripheral10to be rotatable between a cover position at which the cover70covers the opening22and a front wall101of the ink tank100(seeFIG.1A), and an exposure position at which the cover70allows the opening22and the front wall101of the ink tank100to be exposed to the outside of the multi-function peripheral10at which the cover70does not cover the opening22and the front wall101of the ink tank100(seeFIG.1B). The upper surface of the cover70in the cover position is substantially horizontal. Note that, alternatively, the upper surface of the cover70at the cover position may be inclined obliquely downward from the side of the rotational base end of the cover70toward the rotational distal end of the cover70. As depicted inFIGS.1A,1B,7and8, the cover70in this embodiment is supported by the casing of the multi-function peripheral10to be rotatable about a rotational axis71extended in the left-right direction9at a lower end portion in the up-down direction7. The rotational axis71in this embodiment is located in front of the front wall101in the front-rear direction8(namely, is located on the side opposite to an ink chamber111(to be described later on) with respect to the front wall101), and below the ink tank100in the up-down direction7. Note that, however, it is sufficient that the position of the rotational axis71is at least below an inlet112(to be described later on), and further that the ink tank100and the rotational axis71have the above-described positional relationship under a condition that the ink tank100is in an inflow posture at which the liquid can be poured into the ink tank100. As depicted inFIGS.4and5, the ink tank100has an outer shape that is substantially rectangular parallelepiped. The ink tank100has a front wall101, a right wall102, a left wall103, an upper wall104, and a lower wall105. On the other hand, the rear surface of the ink tank100is opened or uncovered. Further, by fixing a film106by welding to rear-end surfaces of the right wall102, the left wall103, the upper wall104and the lower wall105, the rear surface of the ink tank100is sealed. Namely, the film106forms the rear wall of the ink tank100. The ink tank100having the above-described configuration is molded or shaped as an integrated part or component by, for example, performing injection-molding with a resin material. For example, the inner shape or profile of the ink tank100(to be described later on) is defined by an unillustrated mold (metal mold) which is pulled out in the rearward direction from the uncovered rear surface of the ink tank100. The upper wall104defines or demarcates the upper end of the ink chamber111in the up-down direction7. The lower wall105defines the lower end of the ink chamber111in the up-down direction7. The front wall101, the right wall102and the left wall103each as an example of the erected wall are provided upstandingly between the upper wall104and the lower wall105in a direction crossing the upper and lower walls104and105. Further, each of the walls101to105has at least light transmitting property or translucency to such an extent that the ink inside the ink chamber111is visually observable or recognizable from the outside of the ink tank100. The front wall101is constructed of a base wall101A extending from the lower wall105substantially in the up-down direction7and an inclined wall101B which is connected or continued to the upper end of the base wall101A and which is inclined relative to the up-down direction7and the front-rear direction8. The inclined wall101B is formed with an inlet112penetrating through the inclined wall101B in the thickness direction thereof. The inclined wall101B is inclined rearward relative to the base wall101A (namely, inclined toward the ink chamber111). <Ink Chamber111> As depicted inFIG.5, a plurality of partition walls107,108and109which define or demarcate the internal space of the ink tank100is provided in the interior of the ink tank100. Each of the partition walls107,108and109is extended in the up-down direction7and the front-rear direction8, and is connected to the front wall101, the upper wall104, the lower wall105and the film106. Further, the partition walls107,108and109are disposed to be separated and away from one another in the left-right direction9. As a result, the internal space of the ink tank100is partitioned into four ink chambers111B,111M,111C and111Y that are adjacent in the left-right direction9. The ink chambers111B,111M,111C and111Y are each an example of a liquid storage chamber for storing ink to be jetted through the nozzles40. The ink chamber111B is a space demarcated by the front wall101, the right wall102, the upper wall104, the lower wall105, the film106and the partition wall107. The ink chamber111M is a space demarcated by the front wall101, the upper wall104, the lower wall105, the film106and the partition walls107and108. The ink chamber111C is a space demarcated by the front wall101, the upper wall104, the lower wall105, the film106and the partition walls108and109. The ink chamber111Y is a space demarcated by the front wall101, the left wall103, the upper wall104, the lower wall105, the film106and the partition wall109. In the following description, the ink chambers111B,111M,111C, and111Y are collectively referred to as “ink chamber(s)111” in some cases. Further, reference numerals having different alphabetic suffixes (B, M, C, and Y) are assigned to four components provided while corresponding to the ink chambers111B,111M,111C and111Y, respectively; in a case that these components are collectively referred to, then these components are assigned with a reference numeral(s) while omitting the respective alphabetic suffixes, in some cases. Inks of different colors are stored in the ink chambers111, respectively. Specifically, black ink is stored in the ink chamber111B, cyan ink is stored in the ink chamber111C, magenta ink is stored in the ink chamber111M, and yellow ink is stored in the ink chamber111Y. Each of the color inks is an example of a liquid. However, the number of ink chambers111and the colors of the inks are not restricted to the number and the colors in the above-described example. The ink chambers111are arranged along the left-right direction9. Further, among the four ink chambers111B,111M,111C and111Y, the ink chamber111B is arranged at the rightmost side and the ink chamber111Y is arranged at the leftmost side. Namely, the ink chambers111B,111M1111C and111Y are arranged such that the ink chamber111B storing the black ink is located to be most separated away from the ink chamber111Y storing the yellow ink. Furthermore, the ink chamber111B has a volume larger than the any other ink chambers111M,111C and111Y. <Inlet112> The inclined wall101B of the ink tank100is provided with inlets112B,112M,112C, and112Y (hereinafter, collectively referred to as “inlet(s)112”) via which the inks are allowed to flow into the ink chambers111, respectively. The inlet112penetrates through the inclined wall101B in a direction of the thickness of the inclined wall101B, and makes the corresponding ink chamber111communicate with the outside of the ink tank100. The inner surface of the inclined wall101B faces the ink chamber111, and the outer surface of the inclined wall101B faces the outside of the ink tank100. The inclined wall101B is inclined such that the outer surface thereof is located at a position above the inner surface of the inclined wall101B. Consequently, the inlet112allows the ink chamber111and the outside of the ink tank100to directly communicate with each other. Namely, between the inlet112and the ink chamber111, there is no channel which is bent or curved and which has a cross-sectional area smaller than the cross-sectional area of the inlet112. Further, it is allowable that the inlet112is formed in the upper wall104, rather than in the inclined wall101B. The inclined wall101B and the inlet112provided on the inclined wall101B are exposed to the outside of the multi-function peripheral10by locating the cover70at the exposure position under a condition that the cover70is located at the exposure position as depicted inFIG.1B. Further, the inlet112is provided on the inclined wall101B to be in front of the opening22. In the present embodiment, the posture of the ink tank100at which the ink can be flowed into the ink chamber111through the inlet112(inflow posture) coincides with the posture of the ink tank100when the multi-function peripheral10is in the usable state. Namely, when the multi-function peripheral10is in the usable state, the ink is poured into the ink chamber111through the inlet112. Although the inlet112in this embodiment is circular-shaped, the shape of the inlet112is not limited to this; the inlet112may be oval-shaped, polygonal-shaped, etc. The ink tank100has caps113B,113M,113C and113Y (hereinafter collectively referred to as “cap(s)113” in some cases) that are detachably attached with respect to the inlets112. As depicted inFIG.1A, the cap113attached to the inlet112blocks or closes the inlet112by making a tight contact with the periphery of the inlet112. On the other hand, as depicted inFIG.1B, in a case that the cap113is removed from the inlet112, the inlet112is open or released. The cap113is attached to and removed from the inlet112in a state that the cover70is located at the exposure position. Further, by removing the cap113from the inlet112, the ink can be poured into the ink chamber111via the inlet112. Note that an ink outflow channel (not depicted in the drawings) is provided in each of the ink chambers111B,111M,113C and113Y. The ink outflow channel is a channel that allows the ink stored in the corresponding ink chamber111to flow out of the ink tank100. An end of the ink outflow channel is connected to the ink chamber111corresponding thereto; the other end of the ink outflow channel is connected to the ink tube32corresponding thereto. With this, the ink stored in each of the ink chambers111is supplied to the recording head39via one of the ink outflow channels and one of the ink tubes32which correspond to the ink chamber111. Further, atmosphere communicating holes (not depicted in the drawings) are provided on the ink chambers111B,111M,111C and111Y, respectively. The atmosphere communicating hole allows the ink chamber corresponding thereto to communicate with the atmosphere. With this, the internal pressure in each of the ink chambers111is maintained at the atmospheric pressure. As a result, any excessive supply of the ink due to the increase in inner pressure in the ink chamber111or any backflow of the ink due to the decrease in inner pressure in the ink chamber111, etc. are suppressed. Further, the atmosphere communicating hole is provided with a semipermeable membrane, etc. configured to suppress any leaking of the ink. <Cover70> As depicted inFIG.6, the cover70is a box-shaped member having a main wall72having a substantially rectangular-shape and side walls73,74and75projecting from the outer periphery of the main wall72in the thickness direction of the main wall72. The side wall73is disposed on the cover70at the rotational distal end thereof, so as to extend along the outer periphery of the main wall72. The side wall74is disposed to extend along the outer periphery of the main wall72from an end portion, of the side wall73, at one side in the left-right direction9. The side wall75is disposed to extend along the outer periphery of the main wall72from an end portion, of the side wall73, at the other side in the left-right direction9. Namely, the side walls74and75are arranged to face each other in the left-right direction9. The outer surface of the cover70(in other words, the outer surfaces of the main wall72and of the side walls73to75) are continued to the outer surface of the multi-function peripheral10. Namely, the outer surface of the cover70constructs a portion of the outer surface of the multi-function peripheral10. Further, the cover70is provided with a transparent window76. The transparent window76allows the front wall101, of the ink tank100, to be visually observable from the outside of the multi-function peripheral10in a state that the cover70is located at the cover position. The transparent window76is an example of the transmitting section configured to optically transmit information to a user of the multi-function peripheral10. In this embodiment, the term “information to be optically transferred” means the position of the liquid surface (liquid level) of the ink which can be visually observed through the front wall101. Namely, the transmitting section in the embodiment is configured such that the transmitting section itself does not possess any information to be transmitted, but allows an object (the front wall101in the embodiment) having the information to be transmitted to be visually observable from the outside. The transparent window76has an opening77having a substantially rectangular shape and penetrating through the main wall72in the thickness direction thereof, and a film78closing the opening77. The film78is formed of a light-transmitting or translucent material. The film78in this embodiment is adhered to the periphery of the opening77, on the side of the outer surface of the main wall72(namely, the surface of the cover70on the opposite side to the inner surface thereof which faces the front wall101). Further, the side walls74and75are provided with bearings79and80, respectively. The bearings79and80are arranged on the rotational axis71in a state that the cover70is attached to the casing. Furthermore, as depicted inFIG.1C, a portion, of the casing, which demarcates the lower portion of the opening22is provided with a pair of spindles91and92projected in mutually separating directions on the rotational axis71. In the state that the cover70is attached to the casing, the bearings79and80receive the spindles91and92, respectively. With this, the cover70is made to be rotatable around the rotational axis71with respect to the casing. Moreover, as depicted inFIG.6, a rib81is provided on the inner surface of the main wall72at a position surrounding the periphery of the opening77. The rib81is formed to project from the inner surface of the main wall72and to extend along the periphery of the opening77. The term “inner surface of the main wall72” means a surface on a side facing the ink tank100under a condition that the cover70is located at the cover position. In other words, the inner surface of the main wall72means the upper surface, of the main wall72, under a condition that the cover70is located at the exposure positon. Further, the rib81is an example of the checking section configured to prevent the ink moving on the upper surface of the cover70, under the condition that the cover70is located at the exposure positon, from arriving at the transparent window76. The rib81is constructed of a first rib82arranged on the rotational base end side of the cover70, a second rib83arranged on the rotational distal end side of the cover70, a third rib84arranged on the side of the side wall74, and a fourth rib85arranged on the side of the side wall75. The end portions of the first and second ribs82and83are connected to the end portions of the third and fourth ribs84and85. The first and second ribs82and83are formed to extend in the left-right direction9(an example of the extending direction). The third and fourth ribs84and85are formed to extend in the up-down direction7(another direction of the extending direction) under the condition that the cover70is located at the cover position, and are formed to extend in the front-rear direction8(yet another direction of the extending direction) under the condition that the cover70is located at the exposure position. The first to fourth ribs82to85project rearward from the inner surface of the main wall72under the condition that the cover70is located at the cover position (for example, seeFIGS.7and8). Accordingly, a projection amount at which the first to fourth ribs82to85project is set to such a range that the first to fourth ribs82to85do not make contact with the front wall101of the ink tank100under the condition that the cover70is located at the cover position. Further, as depicted inFIG.8, the first to fourth ribs82to85project upward from the inner surface of the main wall72under the condition that the cover70is located at the exposure position. Note that the first rib82is formed to extend substantially vertically with respect to the main wall72. On the other hand, the second rib83is inclined with respect to the main wall72. In such a manner, the angle of the rib81with respect to the main wall72is not particularly limited. Further, the thickness of the first rib82is gradually thinned (namely, is tapered) from the projection base end side toward the projection distal end side. On the other hand, the thickness of the second rib83is substantially same or uniform in the projection direction. In such a manner, the thickness of the rib81in the projection direction is not particularly limited. In the multi-function periphery10of the embodiment as described above, in a case that a user attempts to replenish or recharge the ink to the ink tank100, the user causes the cover70to rotate to the exposure position, removes the cap113from the inlet112, and pours the ink from the released inlet112. In this situation, the ink not poured into the inlet112or the ink overflowed from the inlet112moves on the front wall101and flows downward, and adheres to the inner surface (upper surface) of the cover70in the inflow posture. However, according to the above-described embodiment, the ink adhered to the inner surface of the cover70is checked or stopped by the rib81and is guided to the extending direction of the rib81. As a result, it is possible to suppress the lowering in visibility of the front wall101due to the contamination of the transparent window76with the ink. Note that in the embodiment, the explanation has been given, by way of example, about the rib81having the first to fourth ribs82to85surrounding the periphery of the transparent window76. With this, it is possible to effectively suppress the adhesion of the ink to the transparent window76. Further, the rib81functions also as a reinforcing section configured to reinforce the rigidity, of the cover70, lowered due to the provision of the opening77. As a result, it is possible to suppress any twisting of the cover70when the cover70is pivoted or rotated. The arrangement of the rib81, however, is not limited to this. For example, it is sufficient that only the first rib82is disposed, such that the first rib82is located between the front wall101and the transparent window76in the front-rear direction8in the state that the cover70is at the exposure position. With this, it is possible to cut off any route via which the liquid mainly moves or flows on the cover70. Further, it is allowable to omit the second rib83located at the farthest from the ink tank100under the condition that the cover70is located at the exposure position, and to construct the rib81with the first rib82, the third rib84and the fourth rib85. Further, in the embodiment, the explanation has been made regarding the rib81as an example of the checking section. However, the specific example of the checking section is not limited to this. For example, it is allowable to provide a groove, a stepped portion, etc. in the inner surface of the main wall72, instead of providing the rib81.FIG.11illustrates an example groove281, where the groove281is realized by recessing the inner surface of the main wall72, or the groove281may be formed between a pair of ribs provided upstandingly and parallel to each other in the inner surface of the main wall72. The stepped portion may be such a stepped portion181as shown inFIG.10, in which that a side thereof closer to the transparent window76is greater in height. Furthermore, the checking section may be configured by a combination of the rib, groove and stepped portion, etc. Moreover, an ink absorbing member configured to absorb the ink may be arranged around the checking section. The ink absorbing member may be formed of a porous material such as foamed polyurethane. In a case that the checking section is the rib81or the stepped portion, the ink absorbing member may be arranged along the rib81or the stepped portion. Further, in a case that the checking section is the groove, the ink absorbing member may be filled inside the groove. With this, it is possible to further effectively check and stop the ink moving toward the transparent window76. Furthermore, it is allowable that the checking section may be configured to hold the ink by, for example, surface tension. With this, it is possible to effectively prevent the ink from arriving at the transparent window76. Note that the specific shape of the checking section for holding the ink by the surface tension is appropriately selected depending on the kind of the ink (mainly the viscosity of the ink), the wettability of the surface of the cover70, etc. Moreover, the checking section may be configured to guide the ink in the left-right direction9by, for example, the capillarity. With this, it is possible to reduce the amount of the ink which might flow across the checking section, thereby making it possible to effectively prevent the ink from arriving at the transparent window76. Note that the specific shape of the checking section for causing the capillarity is appropriately selected depending on the kind of the liquid (mainly the viscosity of the liquid), the wettability of the surface of the cover70, etc. The checking section configured to cause the capillarity is preferably realized by a groove. Further, although the ink tank100according to the embodiment has the four ink chambers111B,111M,111C and111Y which store the four color inks, respectively, the specific configuration of the ink tank100is not limited to this. For example, the ink tank may be configured to store only the black ink. Furthermore, in the embodiment, the explanation has been given about the transparent window76as an example of the transmitting section. However, the specific example of the transmitting section is not limited to this. For example, as shown inFIG.9, a transmitting section according to a modification may be a letter, figure or symbol, etc.176, drawn in the inner surface of the main wall72. In the following, the letter, figure, symbol, etc., will be collectively referred to as “letter, etc.”. More specifically, the transmitting section may be configured to be visible by the user when the cover70is located at the exposure position and may have a procedure for replenishing the ink, a precaution when replenishing the ink, etc. described therein, etc. Namely, the transmitting section according to the modification is different from the transmitting section of the embodiment in that the transmitting section itself has the information to be transmitted. Further, the transmitting section according to the modification optically transmits, to the user, the information that the transmitting section itself has, under the condition that the cover70is located at the exposure position. In other words, the user can see the letter, etc. drawn in the transmitting section by locating the cover70according to the modification at the exposure position. By checking and stopping the ink moving toward the letter, etc. drawn in the main wall72by the above-described checking section, it is possible to suppress the lowering in visibility of the letter, etc. Note that the letter, etc., may be expressed by concave/convex portions formed in the inner surface of the main wall72, or may be drawn in a sticker adhered to the inner surface of the main wall72. Further, in the above embodiment, although the explanation has been given about the ink as an example of the liquid, the present teaching is not restricted to this. Namely, instead of the ink, the liquid may be a pretreatment liquid which is to be discharged onto a recording paper before discharging an ink at the time of printing, or may be water, etc. which is to be sprayed in the vicinity of the nozzles40of the recording head39for preventing drying of the nozzles40of the recording head39. Note that the present teaching is particularly effective by being applied to a liquid consuming apparatus provided with a tank storing a color liquid. | 35,764 |
11858275 | DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of inkjet printing apparatus will be described hereinafter. Embodiment 1 Embodiment 1 of this invention will be described hereinafter with reference to the drawings. FIG.1is a schematic overall view of an inkjet printing system according to Embodiment 1. The inkjet printing system according to Embodiment 1 includes a sheet feeder1, an inkjet printing apparatus3, and a takeup roller5. The sheet feeder1holds web paper WP in a roll form to be rotatable about a horizontal axis. The sheet feeder1unwinds the web paper WP and feeds it to the inkjet printing apparatus3. The inkjet printing apparatus3prints images by dispensing ink to the web paper WP, and feeds the web paper WP to the takeup roller5. The takeup roller5winds on a horizontal axis the web paper WP printed in the inkjet printing apparatus3. Here, the direction in which the web paper WP is fed by the sheet feeder1and transported is regarded as transport direction X. A horizontal direction perpendicular to the transport direction X is regarded as width direction Y. The above sheet feeder1is located upstream of the inkjet printing apparatus3in the transport direction X. The above takeup roller5is located downstream of the inkjet printing apparatus3in the transport direction X. The inkjet printing apparatus3includes a drive roller7disposed in an upstream position for taking in the web paper WP from the sheet feeder1. The web paper WP unwound from the sheet feeder1by the drive roller7is fed in the transport direction X and transported toward the takeup roller5by a plurality of transport rollers9. A drive roller11is disposed between the most downstream transport roller9and the takeup roller5. This drive roller11feeds the web paper WP transported on the transport rollers9forward toward the takeup roller5. The inkjet printing apparatus3includes, between the drive roller7and drive roller11, a printing unit13, a drying section15, and an inspecting device17arranged in the stated order from upstream. The printing unit13performs printing on the web paper WP. The drying section15dries the web paper WP printed by the printing unit13. In the case of inkjet apparatus that uses UV ink, the drying section15includes a UV lamp or UV-LED. In the case of inkjet apparatus that uses water-based ink, the drying section15includes a heat roller and/or a hot air machine. The inspecting device17checks whether portions printed on the web paper WP have stains, omissions or other defects. The printing unit13includes an inkjet head19having a plurality of nozzles for dispensing the ink to the web paper WP. Generally, a plurality of inkjet heads19are arranged along the transport direction X of the web paper WP. For example, four printing units13are provided for black (K), cyan (C), magenta (M), and yellow (Y). In the following description, however, a construction having only one printing unit13will be taken for example. The printing unit13has a length in the width direction Y of the web paper WP that exceeds the width of the web paper WP. The printing unit13has the inkjet head19that can print on a printing area in the width direction of the web paper WP without moving in the width direction Y. The inkjet head19is supplied with the ink through a subtank21from an ink feeder23. The inkjet printing apparatus3includes a controller25for performing overall control of the drive rollers7and11, printing unit13, drying section15, inspecting device17, and ink feeder23. The controller25has, directly or indirectly connected thereto, a counter27, a storage unit29, and a computing unit31. The controller25is constructed of a CPU and memory, for example. The counter27measures, for example, time when the inkjet printing apparatus3suspends a printing process. The storage unit29stores a relationship between still time and backflow amount which will be describe in detail hereinafter. The computing unit31, based on the time measured by the counter27and the relationship between still time and backflow amount, performs mathematical operations for determining an operating time of backward drive for operating the ink feeder23. The above web paper WP corresponds to the “printing medium” in this invention. The ink feeder23will now be described with reference toFIG.2.FIG.2is a block diagram of the ink feeder23in the inkjet printing system according to Embodiment 1. The ink feeder23includes a main tank33, a switch valve35, a supply pipe37, a pump39, a filter41, a degassing filter43, and a liquid feed amount detector45. The main tank33is a receptacle that stores ink. The operator of this apparatus replenishes the main tank33with ink at appropriate times. The switch valve35opens and closes under control of the controller25. The switch valve35permits or blocks circulation of the ink through the supply pipe37. The supply pipe37communicatively connects the main tank33and inkjet head19. The supply pipe37serves as passage of the ink. The pump39feeds under pressure the ink present in the main tank33and supply pipe37. This pump39preferably is a tube pump (also called a roller pump, peristaltic pump, and tubing pump). The pump39has an inlet47, an outlet49, a tube51, a rotating element53, a housing55, and a motor57. The inlet47and outlet49are connected to the supply pipe37for communication therewith. The inlet47and outlet49are connected to opposite ends of the tube51. The inlet47is connected to an upstream portion of the supply pipe37as seen in time of normal ink feeding operation of the pump39. The time of normal ink feeding operation is a time of printing operation, for example, and it refers to an operation for feeding the ink from the main tank33toward the inkjet head19. The outlet49is connected to a downstream portion of the supply pipe37as seen in time of normal ink feeding operation of the pump39. The tube51is made into a U-shape and connects the inlet47and outlet49. The tube51is formed of an elastic body. Therefore, when the tube51is pressed from outside, its flow passage cross-section area will be reduced. When the pressure is removed, it will return to a usual flow passage cross-section area. The tube51has the rotating element53located centrally of the U-shape. The tube51is fitted in the housing55so that its U-shaped outer circumferential surface may extend along and in contact with an inner circumferential surface of the housing55. The rotating element53has a cross-shaped rotating frame59and a plurality of rollers60. Each roller60is rotatably attached to one distal end of the rotating frame59. The rotating element53rotates with each roller60pressing on the inner circumferential surface of the tube51toward the outer circumferential surface, thereby squeezing and diminishing the flow passage cross-section area of the tube51. This rotating operation in one direction of the rotating element53feeds the ink in the tube51from the inlet47to the outlet49. A rotating operation in the other direction of the rotating element53feeds the ink in the tube51from the outlet49to the inlet47. The rotating element53is driven to rotate by the motor57. The motor57has its direction of rotation and rotating speed controlled by the controller25. The above pump39is capable of continuous liquid feeding, and is therefore suitable for feeding a large amount of ink. With this pump39, the rotational frequency of the rotating element53and the flow rate are basically proportional. When the rotational frequency of the rotating element53is constant, the flow rate will also become constant. This provides an advantage of facilitating a fixed quantity liquid delivery. The filter41is mounted on a portion of the supply pipe37downstream of the pump39as seen in time of normal ink feeding operation. The filter41is provided for removing particles mixed into the ink which do not contribute to image formation but can cause choking of the inkjet head19. However, this filter41will capture part of the ingredients of the ink included in the main tank33. The ink is composed of ingredients such as pigment, dispersant, stabilizer, and so on, which are present in a dispersed state. Particularly pigment and monomer among these ingredients can be loosely flocculated in the ink. Then, the pigment and monomer will form larger flocculated masses than when in the dispersed state. The filter4may capture the flocculated masses of the ink ingredients rather than the particles which should intrinsically be removed, and get blocked by these masses together with the particles. In this embodiment, the filter41is attached to the supply pipe37in a position for allowing the ink to flow upward from below during the normal ink feeding operation. Consequently, at a time of backward drive which will be described hereinafter, the filter41will easily release the captured masses, with gravity also acting on the masses. The degassing filter43is mounted on a portion of the supply pipe37downstream of the filter41as seen in time of normal ink feeding operation. The degassing filter43removes bubbles included in the ink flowing through the supply pipe37. When bubbles are included in the ink, there is a possibility of a fault that the ink is not dispensed appropriately from the inkjet head19. Since this degassing filter43removes even bubbles included in the ink, printing is performed with high quality. The subtank21is mounted on a portion of the supply pipe37downstream of the degassing filter43as seen in time of normal ink feeding operation. The subtank21has a level sensor (not shown) installed therein. When the amount of ink in the subtank21falls below a fixed value as a result of consumption of the ink at the inkjet head19, the controller25will detect this and supply the ink from the main tank33to bring the amount of ink in the subtank21back to the fixed value. The liquid feed amount detector45is disposed between the filter41and degassing filter43. This liquid feed amount detector45detects the amount of ink that flows through the supply pipe37. The main tank33noted above corresponds to the “tank” in this invention. Reference is made back toFIG.1. The counter27measures a time the ink flow stands still in the supply pipe37. Specifically, the controller25operates the counter27to start measuring time at a point of time the liquid feed amount detector45shows zero liquid feed amount. And at a point of time the liquid feed amount exceeds zero again, the controller25operates the counter27to reset the time measurement. The storage unit29will be described. Reference is made here toFIGS.3to5.FIG.3is a graph showing a relationship between still time and flow rate decrease rate.FIG.4is a table showing a relationship between still time and backflow amount.FIG.5Aschematically shows a state of the filter in time of printing operation.FIG.5Bschematically shows a state of the filter in time of functional recovery operation.FIG.5Cschematically shows a state of the filter after a functional recovery process, Here, an elapsed time in a state where the ink feed amount is zero is regarded as a still time.FIG.3shows one example of relationship between the still time and a flow rate decrease rate indicating a rate of decrease of flow rate due to choking of the filter41. As seen fromFIG.3, when the still time increases, the flow rate decrease rate will increase. Specific numerical values of the still time and flow rate decrease rate at this time are shown inFIG.4. The fact that when the still time increases, the flow rate decrease rate will increase, is especially because, the longer becomes the still time in which the ink does not flow, part of the pigment and monomer which should be dispersed in the ink will be the more likely to flocculate loosely. And it is a main cause that the pigment and monomer having flocculated into large masses are captured by the filter41. The ink will be consumed when the apparatus operates to dispense the ink from the inkjet head19to the web paper WP. Then, as shown inFIG.5A, the filter41captures the particles having mixed into the ink and the masses of part of the ingredients in the ink having loosely flocculated. Consequently, the filter41undergoes a pressure loss which decreases the flow rate of the ink passing through the filter41. When the flow rate immediately after changing of the filter41is set to 100, and thereafter the still time for suspending the ink feeding increases, the flow rate decrease rate of the ink will increase. Inventors have done an experiment on what amount of ink should be made to flow backward through the filter41in order to resolve the choking of the filter41when the flow rate lowers. As a result, as shown in the backflow amount column inFIG.4, for example, it has been found that the choking of the filter41can be improved by choosing a backflow amount according to the still time. Based on the result, the storage unit29stores, written in beforehand, data showing a relationship between the still time and backflow amount. When the apparatus is started, or when the printing process of a printing job is restarted from a state where the printing job is stopped, the controller25reads a still time occurring on that occasion from the counter27. Next, the controller25gives the read still time to the computing unit31. The computing unit31calculates a backflow amount based on the still time received and the relationship between the still time and backflow amount in the storage unit29. The backflow amount calculated by the computing unit31is given to the controller25. The controller25operates the pump39to realize the backflow amount received from the computing unit31. The controller25operates the pump39, and there are the following two types of operation. That is, the two types are forward drive in a printing operation, and backward drive in a functional recovery operation. The forward drive is driving of the pump39to feed the ink to the inkjet head19through the supply pipe37in a normal way, that is to feed the ink from the main tank33through the filter41to the inkjet head19. The backward drive is driving of the pump39to feed the ink in a direction opposite to the ink flowing direction for feeding the ink in time of forward drive. To define the backward drive in other words, the pump39is operated in the direction for returning the ink to the main tank33so that the ink may flow backward in the filter41. Then, in the filter41, as shown inFIG.5B, the particles and the masses of ink ingredients captured in the upstream side of the filter41are moved back upstream in the filter41, riding on the ink flow, thereby to be agitated. Consequently, the materials captured in the filter41are washed away into the ink in the portion of the supply pipe47upstream of the filter41. This substantially eliminates the pressure loss in the filter41.FIG.5Cshows this state. When the apparatus starts up, the controller25, as described hereinafter, determines whether or not the functional recovery operation is necessary. Further, the controller25, while performing a printing process, checks whether or not the liquid feed amount is below a threshold, based on a relationship between operation amount of the pump39and liquid feed amount detected by the liquid feed amount detector45. This is done in order to determine, while performing the printing process, whether the filter41is choked or not. A liquid feed amount short of the operation of the pump39means that a choke has occurred to the filter41. A determination is therefore made with reference to the threshold on whether or not the liquid feed amount is short of what it should be relative to the operation amount of the pump39. It is preferable that the controller25determines based on the still time whether or not the functional recovery operation is necessary, at a point of time when the ink flow through the filter41is changed from suspension to resumption during operation of the apparatus, and at a point of time when the apparatus starts up. Next, an operation of the inkjet printing system having the above construction will be described with reference toFIG.6.FIG.6is a flow chart showing a processing sequence. Step S1 The apparatus is started up. That is, the power source of the apparatus is turned on for enabling the inkjet printing system to execute a printing process. Step S2 The process is branched depending on whether or not a functional recovery operation is necessary. Specifically, the controller25reads a measured time of the counter27and gives it to the computing unit31. The computing unit31calculates a backflow amount based on the relationship between still time and backflow amount in the storage unit29, and the measured time corresponding to the still time. The calculated backflow amount is given to the controller25. The controller25determines from the backflow amount whether or not the functional recovery operation is necessary. If the backflow amount is 0, for example, it is not necessary to execute the functional recovery operation. On the other hand, if the backflow amount exceeds 0, the functional recovery operation is determined necessary. Whether or not a functional recovery operation is necessary may be determined only from the still time. Further, a functional recovery operation may certainly be executed in time of startup of the apparatus without determining whether the functional recovery operation is necessary. This can shorten time until a shift is made to the printing operation. Step S3 Assume here that the functional recovery operation is unnecessary. The controller25carries out forward drive of the pump39for the printing operation. Specifically, the controller25opens the switch valve35and operates the pump39to feed the ink from the main tank33to the inkjet head19. This operation is performed according to the ink storage capacity of the subtank21. Step S4 The process is branched depending on whether or not all the printing process is completed. Step S5 The apparatus is stopped if all the printing process is completed. Consequently, the counter27begins to measure a still time of the apparatus. Here, description will be made of the case where the functional recovery process is determined necessary in the above step S2. Step S6 (Functional Recovery Operation Step) The controller25executes the functional recovery process. Specifically, the pump39is driven backward. Consequently, the ink flows through the filter41in the direction opposite to the time of printing operation. This improves the choking of the filter41. When part of the ingredients of the ink are captured as masses by the filter41, the part of the ingredients of the ink will disperse in the ink again. When back-driving the pump39, it is preferable that, in the portion of the supply pipe37connecting the subtank21and degassing filter43, a gas-liquid interface of the ink is located adjacent the subtank21rather than the degassing filter43. That is, the pump39is driven backward so that the gas-liquid interface of the ink may not be located inside the degassing filter43. Although the controller25conducts the functional recovery process with the backflow amount calculated from the still time, when the gas-liquid interface of the ink is located adjacent the subtank21rather than the degassing filter43, the calculated backflow amount alone may not be able to realize the ink backflow. In that case, what is necessary is to repeat the backward drive and forward drive of the pump39a plurality of times in order to gain the backflow amount. Step S7 will be described, which is executed when one printing job is completed and whether or not all printing process is determined in the above step S4, and before printing in the next printing job is performed. Step S7 The controller25checks for choking of the filter41when one printing job is completed and before shifting to the next printing job. Specifically, during the printing process in step S3, the controller25determines with reference to the threshold whether or not the liquid feed amount is short of what it should be relative to the operation amount of the pump39. When the liquid feed amount is less than the threshold, the operation returns to step S6 to carry out the functional recovery process noted above. On the other hand, when the liquid feed amount is larger than the threshold, a determination is made that the situation is normal, and a shift is made to step S3 to perform the printing process of the next printing job. Instead of executing step S7 for every printing job, it may be executed for every two or more printing jobs, or every predetermined time elapse of the printing process. There are types of prints that consume less ink than others. In such a case, the amount of ink flow through the supply pipe37can easily decrease even during a printing process. Then, there is a possibility that the ingredients of the ink flocculate even during the printing process. Choking of the filter41thereby occurring during the printing process can easily be detected by executing step S7 every predetermined time. According to this embodiment, the controller25provides the forward drive of the pump39in time of printing operation. The controller25provides the backward drive of the pump39in time of functional recovery operation. This feature can re-disperse, in the ink within the supply pipe37, the masses of the ingredients of the ink captured by the filter41during the printing operation. The choking of the filter41can thereby be improved, which can reduce operation cost due to changing of the filter41. As a result, the filter41can be used to the best advantage for its intrinsic purpose of removing particles that do not contribute to image formation, but cause choking of the inkjet head19. The controller25, in time of functional recovery operation, provides the backward drive until the gas-liquid interface of the ink in the portion of the supply pipe37adjacent the inkjet head19is located on the side of the degassing filter43adjacent the inkjet head19. Consequently, the gas-liquid interface of the ink is not located in the degassing filter43. The degassing filter43can therefore remain filled with the ink during the functional recovery operation. This prevents bubbles mixing into the ink. Further, the controller25, in time of functional recovery operation, repeats the forward drive and backward drive a plurality of times. Consequently, the ink in the supply pipe37can fully be agitated through the filter41. The masses of the ingredients of the ink captured by the filter41can therefore be re-dispersed reliably. The controller25back-drives the pump39according to the backflow amount calculated by the computing unit31. Thus, there is no need to back-drive the pump39more than necessary. The functional recovery operation can be done with a minimum amount of backflow. The functional recovery operation can therefore be performed efficiently. Embodiment 2 Next, Embodiment 2 of this invention will be described with reference to the drawing. FIG.7is a block diagram of an ink feeder in an inkjet printing system according to Embodiment 2. Components identical to those of Embodiment 1 are shown with the same signs, and will not particularly be described. In Embodiment 2, a first sensor61and a second sensor63are attached to the supply pipe37of the ink feeder23. Specifically, the first sensor61is attached to the portion of the supply pipe37between the degassing filter43and subtank21, and is disposed adjacent the subtank21. The second sensor63is disposed in a position on the supply pipe37adjacent the degassing filter43. These first sensor61and second sensor63detect the gas-liquid interface of the ink present in the supply pipe37. In the construction of Embodiment 2, in time of functional recovery process described above, the controller25operates to back-drive the pump39so that the gas-liquid interface of the ink in the supply pipe37may settle between the first sensor61and second sensor63. Consequently, there is no possibility of bubbles mixing in the ink or the backward drive being done to excess. Thus, the functional recovery operation can be carried out reliably. This invention is not limited to the foregoing embodiments, but may be modified as follows: (1) Each of Embodiments 1 and 2 described above provides the degassing filter43and subtank21between the filter41and inkjet head19. However, this invention does not require these components as indispensable. (2) Each of Embodiments 1 and 2 has been described taking a tube pump as an example of the pump39. This invention is not limited to this type as the pump39, but a pump39of a different type may be employed. In that case, a switch valve, a check valve, and so on may be included in the supply pipe37, and the ink flowing directions described hereinbefore may be realized by means of the forward drive and backward drive. (3) In each of Embodiments 1 and 2 described above, in time of normal ink feeding operation, the pump39is located in a position upstream of the filter41to intervene between the portions of the pipe37. However, this invention is not limited to this. That is, in time of normal ink feeding operation, the pump39may be located in a position downstream of the filter41to intervene between the portions of the pipe37. In this case also, in time of functional recovery operation, the masses of the ingredients of the ink captured by the filter41during printing operations can be re-dispersed in the ink within the supply pipe37by back-driving the pump39. Consequently, the choking of the filter41can be improved. (4) Each of Embodiments 1 and 2 has been described that the forward drive and backward drive are repeated a plurality of times in time of functional recovery process. However, this invention does not necessarily need to repeat the forward drive and backward drive of the pump39a plurality times in time of functional recovery process. That is, there is no need to solve the choking of the filter41completely by back-driving the pump39, but what is necessary is just to be able to improve the choking of the filter41from a state before the functional recovery operation. Further, in order to aim at achieving the functional recovery to a maximum degree by one-time backward drive, the length of supply pipe37between the degassing filter43and subtank21may be increased. (5) In each of Embodiments 1 and 2 described above, a determination is made in step S2, after the start-up of the apparatus, whether or not a functional recovery operation is necessary. However, as in step S7, a determination is made whether or not the functional recovery operation should be carried out between the printing processes according to a checking based on the flow rate. This makes it unnecessary to determine whether or not the functional recovery operation is needed at every startup of the apparatus. Conversely, instead of determining between the printing processes whether or not the functional recovery process should be carried out according to the checking based on the flow rate, a determination may be made whether or not the functional time operation is necessary only in time of startup of the apparatus. (6) In each of Embodiments 1 and 2 described above, step S2 ofFIG.6checks after a startup of the apparatus whether or not the functional recovery operation is necessary, and step S7 determines in intervals between the printing processes whether or not the functional recovery process should be carried out according to the checking based on the flow rate. However, this invention may carry out the functional recovery operation at regular intervals, without checking or determining whether or not the functional recovery operation is necessary in the first place, or whether or not the functional recovery process is necessity. That is, the controller25may control the pump39to carry out the functional recovery operation immediately after feeding the ink to the subtank21. In this case, immediately after feeding the ink to the subtank21, the gas-liquid interface of the ink in the supply pipe37is located near an inlet port of the subtank21. Note here that a known amount of ink is present from this position of the gas-liquid interface of the ink to a position adjacent the inkjet head19of the degassing filter43, i.e. an outlet port, not shown, of the degassing filter43filled with the ink. So, in executing the functional recovery operation, an amount of ink not exceeding the above known amount of ink may be fed backward. Further, the controller25may control the pump39to carry out the functional recovery operation at every fixed time interval, e.g. once every 30 minutes, with the knowledge of the position of the gas-liquid interface of the ink in the supply pipe37. An increase in the frequency of the functional recovery operation will secure a constantly stable ink feed amount. (7) In Embodiments 1 and 2 described above, the filter41is attached to the supply pipe37in a position for allowing the ink to flow upward from below in time of normal use. However, this invention is not limited to such attaching position. That is, the filter41may be attached in a position for allowing the ink to flow downward from above, or in a position for allowing the ink to flow horizontally from one side toward the other side. (8) In Embodiments 1 and 2 described above, the functional recovery process is done only by operating the pump39. However, the switch valve35may also be operated as follows. That is, when carrying out the functional recovery process, the switch valve35is closed first. Then, the pump39is back-driven. This raises the pressure of the ink in the interior of supply pipe37between the degassing filter43and switch valve35. Subsequently, the switch valve35is opened. This releases the pressure in the supply pipe37between the degassing filter43and switch valve35at a stroke. This increases a backward ink flow velocity, thereby facilitating improvement in the choking of the filter41. The masses formed in the ink can also be re-dispersed in a short time. This invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. | 30,364 |
11858276 | It should be noted that some details of the figures have been simplified and are drawn to facilitate understanding of the present teachings rather than to maintain strict structural accuracy, detail, and scale. DETAILED DESCRIPTION Reference will now be made in detail to exemplary implementations of the present teachings, examples of which are illustrated in the accompanying drawings. Wherever convenient, the same reference numbers will be used throughout the drawings to refer to the same or like parts. As used herein, unless otherwise specified, the word “printer” encompasses any apparatus that performs a print outputting function for any purpose. As discussed above, the level of liquid print material in a reservoir of a printer, for example liquid metal in a metal printer, can be monitored using a laser that directs a laser beam onto an upper surface of the liquid metal and a photosensor that detects a position of the laser beam that is reflected from the upper surface of the metal onto the photosensor. As the level of the liquid metal decreases and increases, the position of the reflected laser beam on the photosensor changes, and the position can be used to calculate the level of the liquid metal within the reservoir. One impediment that can interfere with the accurate measurement of the level of liquid metal within the reservoir is the formation of dross on the upper surface of the liquid metal. Dross can be, for example, impurities, contaminants, chemical by-products, or another material that can be introduced from contamination on or within the metal supply. Further, the dross may form from a chemical reaction of two or more reactants within the reservoir of the printer. The dross can be or include, for example, a solid or mostly solid material. The dross can be or include, for example, magnesium oxide (MgO), aluminum oxide (Al2O3), another material that forms on at least a portion of the upper surface of liquid print material within the reservoir, or combinations thereof. The dross is generally less dense (i.e., lighter) than the liquid print material and thus floats on an upper surface of the liquid print material. One major source of the dross is the supply metal stock. The more material that has run through the system, the more dross can potentially accumulate. In other words, the amount of dross that accumulates within the printer is directly proportional to the amount of print material that has been melted within the reservoir. The dross can build up and accumulate within the reservoir, particularly on the walls that form the reservoir and across the upper surface of the liquid print material, and can interfere with the ability of the print system to determine the height of the liquid pool within the reservoir. While the level of the liquid print material drops during printing, the position and level of the dross remains fixed within the reservoir. If laser beam reflects from the dross rather than the liquid print material, the position of the laser beam on the photoreceptor does not change with the changing level of the print material. Thus the position of the laser beam on the photoreceptor indicates the fixed position of the dross and not the changing level of the print material. The printer can, for example, stop feeding solid wire into the print reservoir because the position of the reflected laser beam incorrectly indicates that the reservoir is full while, in fact, the level of the liquid metal is dropping. As the printer reservoir empties, liquid metal is no longer available or ejected from the nozzle and printing ceases. An implementation of the present teachings includes a printer component that helps mitigate dross buildup and the problems associated therewith, as discussed below. FIG.1is a schematic cross section of a printer100such as a metal printer that uses magnetohydrodynamic (MHD) technology to eject droplets102such as metal droplets102onto a surface104. Use of various aspects and structures according to the present teachings with other ejection technologies is contemplated. Further, it will be appreciated that the figures depict generalized example schematic illustrations, and an actual printer in accordance with the present teachings can include other structures that are not depicted for simplicity, while various depicted structures can be removed or modified. The printer100ofFIG.1includes a block106that defines a reservoir108, a supply inlet110, and an ejection chamber112. While the block106is depicted as a single structure, it will be appreciated that the block106can include two or more sections that are attached together. The block106can be or include, for example, boron nitride, graphite, or another material that resists physical changes and damage from high temperatures encountered during use. The printer100further includes a nozzle118, such as a replaceable nozzle118. The nozzle118includes an orifice120from which the metal droplets102are ejected during printing. The printer100further includes an ejector122that is engaged to eject the metal droplet102from the nozzle118. The ejector122can be, for example, an electromagnetic coil122that encircles the ejection chamber112, or another type of ejector122. FIG.1further depicts a metal supply130which, in this implementation, is a supply reel132that supplies a metal wire134in solid form to the reservoir108. The metal wire134is heated and melted within the reservoir108and becomes a liquid metal136. The liquid metal136flows from the reservoir108, through the supply inlet110, into the ejection chamber112, to the nozzle118, and is ejected from the orifice120using the ejector122. Printers including other flow paths for the liquid metal136are contemplated. To eject a metal droplet102from the orifice120of the nozzle118, a current is applied to the coil122which develops and creates a pulsed magnetic field through the coil122. This pulsed magnetic field induces an MHD-based force density within the liquid metal136within the ejection chamber112, which overcomes capillarity and/or surface tension of the liquid metal136within the nozzle118, thereby ejecting the metal droplet102from the orifice120of the nozzle118. It will be appreciated that contours of the supply inlet110and/or the ejection chamber112can be designed to improve, customize, and/or optimize flow dynamics of the liquid metal136therewithin. As liquid metal136is ejected from the nozzle118in the form of the metal droplet102, a level “L” of the liquid metal136within the reservoir108is monitored using, for example, a laser142that emits a laser beam144onto an upper surface146of the liquid metal136. The laser beam144reflects from the upper surface146of the liquid metal136and onto a photosensor150. When the upper surface146of the liquid metal136is at level L1, the laser beam144is reflected onto position P1of the photosensor150. As depicted inFIG.2, as the level of the liquid metal136decreases during printing, the position of the reflected laser beam144on the photosensor150changes. For example, when the upper surface146of the liquid metal136drops from level L1to level L2, the laser beam144reflects from the upper surface146of the liquid metal136onto position P2of the photosensor150. FIG.3depicts a printer300within which dross302has built up on sidewall(s)304of the block106within the reservoir108. (It will be appreciated that a reservoir108having a circular or oval perimeter includes one continuous sidewall, while a reservoir108having a square or rectangular perimeter includes four connected sidewalls.) As depicted, the liquid metal136has dropped during printing from level L1to level L2, and the laser beam144reflects from the dross302rather than from the upper surface146of the liquid metal136. As such, the printer300has not detected that the level of the liquid metal136has dropped and the liquid metal136requires replenishment. In the structure ofFIG.3, the liquid metal136will eventually be depleted and printing will cease. Referring back toFIG.1, the printer100according to an implementation of the present teachings includes an inner shell160(i.e., an inner sleeve or liner). The inner shell160can be a substructure of the printer that can be replaced by the user, for example, between printing sessions and/or during routine maintenance. The inner shell160can be or include graphite, ceramic, or a metal (e.g., tungsten) or a metal alloy that has a higher melting point than the metal used as the print material. The dimensions and shape of the inner shell160may depend, at least in part, on the dimensions and shape of the reservoir108formed by the block106of the printer100. For example, in plan view, the reservoir108may have a generally circular shape; thus, as depicted at400ofFIG.4, which depicts a plan view of the inner shell160, the inner shell160may also have a generally circular shape. In other implementations, the reservoir108may have a generally square or rectangular shape, or another shape, and thus the inner shell160can have a generally square or rectangular shape, or another shape, respectively (not individually depicted for simplicity). In some implementations, the inner shell160may physically contact the sidewalls304and/or a bottom162that define, at least in part, the reservoir108. In another implementation, the inner shell160may be free from contact with the sidewalls304that define the reservoir108but may physically contact the bottom162. In some implementations as described below, the inner shell160may physically contact the bottom162during a period of use, and be free from contact with the bottom during other periods of use. FIG.4depicts the plan view400, and further depicts a side view430and a bottom view450of an implementation of the inner shell160. In this implementation, the inner shell160includes a first, lower surface432at a first end of the inner shell160and a second, upper surface434opposite the lower surface432at a second end of the inner shell160where the second end is opposite the first end. The inner shell160further includes one or more interior sidewall(s)436and one or more exterior sidewall(s)438opposite the interior sidewall(s)436. (It will be appreciated that an inner shell160having a circular or oval perimeter includes one continuous interior sidewall436and one continuous exterior sidewall438, while an inner shell160having a square or rectangular perimeter includes four connected interior sidewalls436and four connected exterior sidewalls438.) The lower surface432intersects the interior sidewall436and the exterior sidewall438at the first end of the inner shell160. The upper surface434intersects the interior sidewall436and the exterior sidewall438at the second end of the inner shell160. The inner shell160further defines one or more notches or slots440that extend through the inner shell160from the interior sidewall436to the exterior sidewall438proximate the first end of the inner shell160. The slots440allow liquid metal136to flow from an inner vessel442that is defined, at least in part, by the interior sidewall436of the inner shell160to an exterior of the inner shell160and into the inlet110. Various flow paths “FP” of the liquid metal136from the inner vessel442, through the one or more slots440, to the exterior the inner shell, and then to the inlet110are depicted in the side view430. The inner shell160can be either a single-piece structure or a multi-piece structure. Multi-piece implementations can include two or more structures that are either separate (e.g., physically spaced) or physically connected together. The inner shell160can have a thickness, from the interior sidewall436to the exterior sidewall438, of from about 0.05 millimeters (mm) to about 5.0 mm, or from about 0.5 to about 3.0 mm. During printing, the inner shell160can be maintained in a fixed position during the entire printing process. In this implementation, referring back toFIG.2, dross302is deposited at generally a fixed location (i.e., at a fixed height) on the inner shell160during the printing session. However, during a maintenance or repair procedure between printing sessions, the reservoir108of the printer100is accessed and the inner shell160is removed and replaced. Because the contaminated inner shell160is replaced before a large deposit of dross302is allowed to form, the problem represented inFIG.3is avoided. In some cases, the interval for removal and/or replacement of the inner shell160is not sufficient for one work shift and some job printing may be interrupted. In another implementation of the present teachings, the position of the inner shell160can be changed and/or adjusted during a printing session. For example, the inner shell can be repositioned200, e.g., raised, lowered, or otherwise repositioned200, relative to the bottom162of the reservoir108as depicted inFIG.2, during the printing process so that only a thin coating of dross302forms on the interior sidewall436of the inner shell160. In other words, the same volume of dross302forms on the surface of the inner shell160, but the dross302forms over a larger surface area of the inner shell160due to the repositioning of the inner shell160in the vertical direction during the printing process. Repositioning of the inner shell160can be performed using an actuator210such as a mechanical actuator210or an electromechanical actuator210that, at least in part, physically contacts and/or is physically connected to the inner shell160. For example, the actuator210can include the use of one or more rotating wheels210that, in conjunction with an electric motor (not depicted inFIG.2for simplicity), is configured to raise and/or lower, and/or otherwise reposition, the inner shell160relative to the bottom162of the reservoir108during printing. One major source of the dross302is the supply metal stock (e.g., the metal wire134). The more material (e.g., supply metal stock) that has run through the system, the more dross302that can potentially accumulate. Therefore, the amount of dross302is generally proportional to the amount of metal (e.g., the metal wire134) that is fed through the printer100. Since the dross302floats to the top surface146of the liquid metal136, the dross302is mostly above the liquid metal136and is contained by the sidewalls304that enclose the supply metal stock. In a conventional printer300without the inner shell160, the dross302can attached to, and accumulate on, the sidewalls304and can permanently change the surface properties, including the electrical resistivity, of the sidewalls304. In a printer100using the inner shell160, the dross attaches to, and accumulates on, the interior sidewall(s)436of the inner shell160, which can be cleaned and/or replaced. In an aspect of the present teachings, the inner shell160divides the reservoir108into two sections. A first section of the reservoir108is provided by the inner vessel442and is defined, at least in part, by the interior sidewall436of the inner shell160. A second section of the reservoir is provided between the exterior sidewall(s)438of the inner shell160and the sidewall(s)304of the block106that define, at least in part, the reservoir108. During use of the printer100, as depicted inFIG.1, the metal supply130, e.g., the metal wire134, is fed into the reservoir108within the first section of the reservoir108. In other words, the metal wire134is introduced into the reservoir108within and through the inner vessel442and between opposite portions of the interior sidewall436of the inner shell160. Introducing the solid metal wire134into the reservoir108within the inner vessel442of the inner shell160ensures that the dross302, which is less dense than the liquid metal136, is contained within the inner vessel442as long as the upper surface146of the liquid metal136remains below the upper surface434of the inner shell160. The printer100including the inner shell160are thus designed so that the upper surface146of the liquid metal136, at its highest point, remains below the upper surface434of the inner shell160. This ensures that any buildup of dross302occurs on the interior sidewall(s)436of the inner shell160and not on the sidewalls304that define the reservoir108. The dross302can thus be removed by replacing the inner shell160, or by removing the dross302from the inner shell160, during repair or maintenance of the printer100. The second section of the reservoir108between the exterior sidewall(s)438of the inner shell160and the sidewall(s)304of the reservoir108has minimal buildup of dross302. Some dross302may be introduced into this section, for example, during an initial fill of the reservoir108with the metal wire134. During replenishment of liquid metal136that has been printed as metal droplets102, added dross302is contained within the inner vessel442. During printing, the majority of liquid metal136provided to the nozzle118originates from the first section of the reservoir108(i.e., from the inner vessel442) rather than from the second section of the reservoir108(i.e., from between the exterior sidewall438of the inner shell160and the sidewall304of the block106that define, at least in part, the reservoir108). This occurs, in part, because the large majority of the volume of liquid metal136that is supplied to the nozzle118originates within the first section of the reservoir108. The volume of liquid metal136within the second section of the reservoir108is mostly stagnant, and only a very small volume of the liquid metal136is supplied to the nozzle118from the second section. FIG.5depicts a method500that can be used to form a printed structure. For simplicity of explanation, and without limiting the present teachings, the method500ofFIG.5is described with reference to the structures depicted inFIGS.1,2, and4, although it is contemplated other implementations can include structures and method acts that are not depicted for simplicity, while various depicted structures and method acts may be removed or modified. The method500can including providing a print fluid136, such as a liquid metal136, within a reservoir108of a printer100as at502. This can include, for example, melting a metal wire134supplied from a supply reel132within the reservoir108, or another subprocess. The reservoir108can be defined by, or provided by, a block106of the printer100. At504, the print fluid136is ejected from a nozzle118of the printer100, thereby decreasing a volume of the print fluid136within the reservoir108. For example, the volume of the print fluid136can decrease from a first level L1to a second level L2. In an optional implementation, during the printing, a first replaceable inner shell160can be raised, lowered, and/or otherwise repositioned200relative to a bottom162of the reservoir108as at506. After printing has been completed or at some other processing stage, the ejection of the print fluid136from the nozzle118is halted as at508. The first replaceable inner shell160is removed from the reservoir108as at510. This may require partial disassembly of the printer100during, for example, a maintenance or repair process. The first replaceable inner shell160can be cleaned, reconditioned, or otherwise processed to partially or completely remove dross302that has collected on the first inner shell160, then reinstalled into the printer100as at512. In an alternative to removing the dross302, the first replaceable inner shell160can be discarded or recycled, and a second replaceable inner shell160can be installed into the printer100as at512. Subsequently, the printer100can be reassembled. After reassembling the printer, printing can continue, for example, by ejecting at least a portion of the print fluid136from the nozzle118of the printer100as at514. An implementation of the present teachings thus mitigates problems associated with the formation of dross302within the printer100. The inner shell160is positioned within the printer100such that the dross302forms on the removable inner shell160rather than on other parts of the printer100. The inner shell160can then be removed for cleaning, reconditioning, or replacement. Because the dross302is removed from the printer100before excessive buildup occurs, various problems such as incorrect measurement of the print fluid136within the reservoir108as depicted inFIG.3can be avoided. Another implementation of the present teachings is depicted inFIGS.6and7. This implementation includes a resistor subsystem602that measures the level “L” of the liquid print fluid136within the reservoir108of a printer600, where the resistor subsystem602is less susceptible to incorrect readings due to dross302than the measurement system that uses the laser142and the photosensor150. The resistor subsystem602can replace the laser142and the photosensor150of the implementation ofFIG.1, and thus the laser142and the photosensor150are not depicted inFIG.6. FIG.6depicts a schematic cross section of the printer600including the resistor subsystem602, where the resistor subsystem602measures the level “L” of the liquid print fluid136within the reservoir108. InFIG.6, the print fluid136is at level “L1,” within the reservoir108. The resistor subsystem602includes a first resistive electrode604(i.e., a first electrode604) and a second resistive electrode606(i.e., a second electrode606) that is paired with the first electrode604. The first electrode604is spaced from the second electrode606by a gap607. The resistor subsystem602further includes an ohmmeter608, where the first electrode604and the second electrode606are separately electrically coupled with the ohmmeter608using a first lead610and a second lead612respectively. The electrical resistance between the electrodes604,606is proportional to the length of the segment of the electrodes604,606that is above the liquid metal136. In other words, as less of the first and second electrodes604,606are submerged within the print material136as the level “L” decreases, the electrical resistance between the first and second electrodes604,606increases. Conversely, as the level “L” increases, the electrical resistance measured between the electrodes604,606decreases. The electrical resistance measured between the electrodes604,606can be used to determine the level of the liquid metal136within the reservoir108. Thus, a method that uses the resistor subsystem602can provide a continuous level measurement without requiring a line of site sight from the upper surface146. Further if the level of the liquid metal136drops below a bottom of the electrodes604,606, the resistor subsystem602can be designed to issue an alarm. The ohmmeter608is thereby configured to measure the different electrical resistances between the first electrode604and the second electrode606as the level of the print fluid136within the reservoir108changes. It will be appreciated that while a particular design of ohmmeter608is depicted inFIG.6for purposes of illustration, other types of instruments (e.g., a circuit, an integrated circuit, a sensor, an ohmmeter having another design, etc.) that measure the electrical resistance between the first electrode604and the second electrode606are contemplated. As depicted inFIG.6, the liquid print fluid136physically contacts the first electrode604and the second electrode606. Particularly, the print fluid136fills a large portion of the gap607between the first electrode604and the second electrode606. This results in the electrical resistance measured between the first electrode604and the second electrode606being at first resistance, where the first resistance measured by the ohmmeter608is relatively low and indicates that the liquid print fluid136within the reservoir108is at the high level “L1.” During printing, the level of the print fluid136within the reservoir108may drop from level “L1” as depicted inFIG.6to level “L2” as depicted inFIG.7. As depicted inFIG.7, as the level of the print fluid136drops, the print fluid136fills a smaller portion of the gap607between the first electrode604and the second electrode606than in the full state ofFIG.6. As depicted inFIGS.6and7, as the level “L” drops, the relatively low resistance print material136(e.g., aluminum) becomes increasingly replaced in the gap607by a relatively high resistance gas609(e.g., air) that is within the reservoir108of the printer. This results in the electrical resistance between the first electrode604and the second electrode606being at a second resistance that is higher than the first resistance, and indicates that the liquid print fluid136within the reservoir108is at the low level “L2.” As the dross can accumulate on the sidewalls, the dross can also accumulate on the electrodes, thereby resulting in defective electrical contact and decreasing the accuracy of the resistivity measurements. To address the problem of electrode contamination by the formation of dross, the use of one or more hollow electrodes is proposed. Similar to the function of the inner shell proposed for dross removal, the hollow electrode(s) will provide an enclosed pool of liquid metal that is less susceptible to dross contamination, thereby providing more reliable and accurate measurements of the level of the print material. Electrical contact between the liquid metal and the inner surfaces of the electrodes (i.e., the portions of the electrodes that form the hollow center) will be the preferred electrical path for the sensing of the liquid metal within the reservoir during measurements of the level “L” of the liquid metal136print material. FIG.8depicts a magnified upper end view800and magnified cross section850of the first electrode604, the second electrode606, and the gap607that spaces the two electrodes604,606of the resistor subsystem602. The location of the cross section850is shown in the depiction of the end view800. In an implementation, the electrodes604,606can each be or include a material selected from the group consisting of a graphite, a ceramic, a graphite-ceramic composite, or another suitable material. In the orientation ofFIG.8, each electrode can have a width of from about 0.2 mm to about 2.0 mm, or from about 0.5 mm to about 1.0 mm, and a height of from about 2.0 centimeters (cm) to about 10.0 cm. The resistor subsystem602can include a first face700defined by the first electrode604and a second face702defined by the second electrode606. The first face700and the second face702are adjacent to, and facing, each other and are separated by the gap607. In an implementation, the gap can be from about 0.3 cm to about 2.0 cm wide. In an optional implementation, the first and second electrodes604,606can be coated with an electrical insulator704at locations other than the first and second faces700,702; in other words, the first face700and the second face702are at least partially exposed and free or generally free from the electrical insulator704. The electrical insulator704can isolate the resistance measurement to only the first and second faces700,702, and may improve the measurement of the resistance value by the ohmmeter608. The electrical insulator704can be or include a coating of, for example, silicon dioxide (SiO2), a ceramic, or another suitable material. As depicted atFIG.8, the first electrode604can be physically and electrically separated from the second electrode606by spacers802, where the spacers802are formed from an electrical insulator. The electrical insulator that forms the spacers802can be the same or different than the electrical insulator704. The first electrode604, the second electrode606, the electrical insulator704, the leads610, and the spacers802, in an implementation, form an electrode subassembly870. It will be appreciated that an actual electrode subassembly870in accordance with the present teachings can include other structures that are not depicted for simplicity, while various depicted structures can be removed or modified. The various elements of the electrode subassembly870, including the first electrode604, the second electrode606, the electrical insulator704, the leads610,612, and the spacers802, should be manufactured from materials that can withstand the high temperatures they will encounter from the liquid metal136within the reservoir108during printing. In one particular implementation, aluminum has a melting point of about 660° C., and thus the first electrode604, the second electrode606, the electrical insulator704, the leads610,612, and the spacers802should be sufficiently heat resistant to withstand exposure to temperatures of over 660° C., for example, temperatures of from about 900° C. to about 1000° C., or greater than about 900° C. In an implementation, the electrode subassembly670, including the first electrode604and the second electrode606, together with the spacers802, may form a cylinder having a generally circular cross section. The cylinder includes a hollow center defined at least partially by the first electrode604and the second electrode606as depicted, for example, inFIG.8. Shapes other than a cylinder are contemplated, such as structures with three cross-sectional sections or legs, four cross-sectional sections or legs, or five or more cross sectional legs, where the cross-sectional sections or legs provide a hollow center, where the hollow center includes the gap607. In other implementations, a first electrode604and a second electrode606that are paired but do not define a hollow center can be used to provide a resistance measurement. While filling the reservoir108with liquid metal136, a majority of the liquid metal136that fills the gap607flows from beneath the upper surface146of the liquid metal136, as the bottom ends of the electrodes that form the hollow cylinder are below the upper surface146of the liquid metal136. Because the dross302may, in some instances, be a material that is lower in density than the liquid metal136, the dross302floats on the upper surface146of the liquid metal136. Forming first electrode604, the second electrode606, and the spacers802as a hollow cylinder reduces the amount of dross302within the gap607. Dross302within the gap607, and particularly on the faces700,702, may reduce the accuracy of the resistance measurement obtained by the ohmmeter608. FIG.9depicts a method900that can be used to form a printed structure. For simplicity of explanation, and without limiting the present teachings, the method900ofFIG.9is described with reference to the structures depicted inFIGS.6-8, although it is contemplated other implementations can include structures and method acts that are not depicted for simplicity, while various depicted structures and method acts may be removed or modified. As depicted at902, a print fluid136such as a liquid metal is provided within a reservoir108of a printer600. When the print fluid136is provided within the reservoir108, the print fluid136is also provided between a first electrode604and a second electrode606that is physically and electrically spaced from the first electrode604by a gap607. For example, the print fluid may be provided on (e.g., in physical and electrical contact with) the first face700and the second face702. In some implementations, the first electrode604and the second electrode606can, at least in part, define a hollow center. At906, at least a portion of the print fluid136is ejected from the nozzle118, which decreases the volume of the print fluid136within the reservoir108. The electrical resistance between the first electrode604and the second electrode606is measured as the level “L” of the print fluid136drops within the reservoir108as at908. An estimation of the level “L” of the print fluid136within the reservoir108is made using the resistance measurement, as at910. Responsive to the measurement indicating that the level “L” of the print fluid136reaches a target minimum level, a volume of the print fluid136within the reservoir is replaced as at912. In some instance, for example, depletion of the metal wire134from the supply reel132or a printer malfunction, the level “L” of the print fluid136can drop below the bottom of the first electrode604and/or the second electrode606. When this occurs, the electrical resistance measured between the first electrode604and the second electrode606suddenly increases or spikes. This state can be used to trigger a printer alarm to indicate to an operator that the level or volume of the print fluid136is low, as at914. FIG.10is a side view of a printer100that employs both of the inner shell160ofFIG.1and the electrode subassembly870ofFIG.8. In this implementation, the electrode subassembly870, including the first electrode604and the second electrode606, are positioned outside (i.e., exterior to) the inner vessel442defined by the inner shell160. As depicted inFIG.10, the metal wire134is fed from the metal supply130into the inner vessel442during the supply or resupply of the print material136to the reservoir108. This generally contains any dross302within the vessel442. Because the electrode subassembly870is positioned outside the vessel442, and most or all of the dross302will be deposited within the vessel442of the inner shell160, the dross302is less likely to interfere with the resistance measurements obtained from the electrode subassembly870as read by the ohmmeter608. FIG.11depicts side view of a printer1100that includes the resistor subsystem602, the laser142, and the photosensor150. In an implementation, the printer1100can use both the laser142and the resistor subsystem602to periodically or continuously measure the level of the print fluid136within the reservoir108. Using two different types of systems to measure the level “L” of the print fluid136provides redundancy in the measurement of the level of the print fluid136and can improve the accuracy of the print fluid level measurement. In another implementation of theFIG.11printer, the laser142can periodically or continuously measure the level of the print fluid136, while the resistor subsystem602is used to ensure that the level of the print fluid136does not drop below a minimum level. In this implementation, the resistor subsystem602detects a sudden increase or spike in the electrical resistance between the first electrode604and the second electrode606, which would indicate that the print fluid level “L” has dropped below the bottom of either/both of the first electrode604and/or the second electrode606. This spike in the electrical resistance can be used to trigger a printer alarm to indicate to an operator that the level or volume of the print fluid136is low. FIG.12depicts a side view of another implementation of the present teachings that includes a printer1200having a resistor subsystem1202. This implementation includes a first resistive electrode1204(i.e., a first electrode1204) and a second electrode1206. An electrical resistance is measured by an ohmmeter608to determine a level “L” of the print fluid136within the reservoir108as described with respect to some other implementations above. In the implementation ofFIG.12, the first electrode1204can be a single solid element. The first electrode1204can be any suitable shape, for example, a block of material or an electrode with a hollow center. In cross section, the first electrode1204can have an outer perimeter shape such as, or including, a square, a rectangle, an oval, a polygon, etc. The first electrode1204can have a solid center, or can have a hollow center. A first electrode1204that defines a hollow center can have the advantages as described above, for example, a reduction in the amount of dross302that forms within the hollow center. Additionally, the second electrode1206is provided by one of the sidewalls304formed by the block106that defines the reservoir108. The first electrode1204can be electrically coupled to the ohmmeter608using a first lead610and the second electrode1206(i.e., the sidewall304provided by the block106) can be electrically coupled to the ohmmeter608using a second lead612. FIG.13is a magnified perspective depiction of an implementation of the first electrode1204ofFIG.12. In this implementation, the first electrode1204is in the form of a cylinder having a hollow center1300. The first electrode1204can be formed from any suitable material able to withstand the high temperatures of print material136which can be, for example, molten aluminum or another liquid metal. Suitable materials include, for example, graphite, ceramic, and graphite-ceramic composites. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present teachings are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein. For example, a range of “less than 10” can include any and all sub-ranges between (and including) the minimum value of zero and the maximum value of 10, that is, any and all sub-ranges having a minimum value of equal to or greater than zero and a maximum value of equal to or less than 10, e.g., 1 to 5. In certain cases, the numerical values as stated for the parameter can take on negative values. In this case, the example value of range stated as “less than 10” can assume negative values, e.g., −1, −2, −3, −10, −20, −30, etc. While the present teachings have been illustrated with respect to one or more implementations, alterations and/or modifications can be made to the illustrated examples without departing from the spirit and scope of the appended claims. For example, it will be appreciated that while the process is described as a series of acts or events, the present teachings are not limited by the ordering of such acts or events. Some acts may occur in different orders and/or concurrently with other acts or events apart from those described herein. Also, not all process stages may be required to implement a methodology in accordance with one or more aspects or implementations of the present teachings. It will be appreciated that structural components and/or processing stages can be added or existing structural components and/or processing stages can be removed or modified. Further, one or more of the acts depicted herein may be carried out in one or more separate acts and/or phases. Furthermore, to the extent that the terms “including,” “includes,” “having,” “has,” “with,” or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” The term “at least one of” is used to mean one or more of the listed items can be selected. As used herein, the term “one or more of” with respect to a listing of items such as, for example, A and B, means A alone, B alone, or A and B. Further, in the discussion and claims herein, the term “on” used with respect to two materials, one “on” the other, means at least some contact between the materials, while “over” means the materials are in proximity, but possibly with one or more additional intervening materials such that contact is possible but not required. Neither “on” nor “over” implies any directionality as used herein. The term “conformal” describes a coating material in which angles of the underlying material are preserved by the conformal material. The term “about” indicates that the value listed may be somewhat altered, as long as the alteration does not result in nonconformance of the process or structure to the illustrated implementation. Finally, “exemplary” indicates the description is used as an example, rather than implying that it is an ideal. Other implementations of the present teachings will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the present teachings being indicated by the following claims. Terms of relative position as used in this application are defined based on a plane parallel to the conventional plane or working surface of a workpiece, regardless of the orientation of the workpiece. The term “horizontal” or “lateral” as used in this application is defined as a plane parallel to the conventional plane or working surface of a workpiece, regardless of the orientation of the workpiece. The term “vertical” refers to a direction perpendicular to the horizontal. Terms such as “on,” “side” (as in “sidewall”), “higher,” “lower,” “over,” “top,” and “under” are defined with respect to the conventional plane or working surface being on the top surface of the workpiece, regardless of the orientation of the workpiece. | 40,859 |
11858277 | DETAILED DESCRIPTION The following description is directed to various examples of the disclosure. In the foregoing description, numerous details are set forth to provide an understanding of the examples disclosed herein. However, it may be understood by those skilled in the art that the examples may be practiced without these details. While a limited number of examples have been disclosed, those skilled in the art may appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover such modifications and variations as fall within the scope of the examples. Throughout the present disclosure, the terms “a” and “an” are intended to denote at least one of a particular element. In addition, as used herein, the term “includes” means includes but not limited to, the term “including” means including but not limited to. The term “based on” means based at least in part on. In the present disclosure reference is made to a printing system, printing apparatus, printing device, and/or printer. The terms “printing system”, “printing apparatus”, “printing device”, and/or “printer” should be read in their broad definition, therefore being any image recording system that uses at least one printhead. In an example, the printing apparatus may be a two-dimensional (2D) desk printer. In another example, the printing apparatus may be a 2D large format printer. In another example, the printing apparatus may be a printing press, for example, an offset printing press. In yet another example, the printing apparatus may be a three-dimensional (3D) printer and/or an additive manufacturing system. Some examples of printers comprise a plurality of nozzles distributed across a single or a plurality of printheads, wherein each nozzle is assigned to a single printing fluid. In the present disclosure, the term “nozzle” should be interpreted as any cylindrical or round spout at the end of a pipe, hose, or tube used to control a jet of printing fluid. The plurality of nozzles may eject a printing fluid. In an example, the printing fluid may comprise a colorant and/or dye with a liquid carrier; e.g., cartridges and/or liquid toners. Some printing fluids may be dye based printing fluids, where dyes may be understood as a coloring solution. Other printing fluids may be pigment based printing fluids, where pigments may be understood as coloring particles in suspension. In another example, the printing fluid may comprise ink particles and an imaging oil liquid carrier; e.g., liquid toner ink commercially known as HP ElectroInk from HP Inc. In another example, the printing fluid is an additive manufacturing fusing agent which may be an ink-type formulation comprising carbon black, such as, for example, the fusing agent formulation commercially known as V1Q60A “HP fusing agent” available from HP Inc. In an additional example such a fusing agent may additionally comprise an infra-red light absorber. In another additional example, such a fusing agent may additionally comprise a visible light absorber. In yet another additional example such fusing agent may additionally comprise a UV light absorber. Examples of inks comprising visible light enhancers are dye-based colored ink and pigment-based colored ink; e.g., inks commercially known as CE039A and CE042A available from HP Inc. In yet another example, the printing fluid may be a suitable additive manufacturing detailing agent; e.g., formulation commercially known as V1Q61A “HP detailing agent” available from HP Inc. A plurality of examples of the printing fluid that may be propelled by a nozzle has been disclosed, however any other chemical printing fluid comprising an agent in a liquid solvent or in a liquid carrier that may evaporate in contact with ambient air may be used without departing from the scope of the present disclosure. As mentioned above, in some cases, the printing fluid container comprising some printing fluids may be desired to move regularly due to the nature of the printing fluid composition. Failing to do so may lead to deficient print job quality or image quality (IQ). Some of these printing fluids may comprise composition with heavy and/or big particles which may deposit at the bottom of the container by the effect of gravity. As an example, some printing fluids comprising white pigments may be wanted to be in movement, which may be either a constant or a periodic movement, since the white pigments size is big (e.g., particle size of about 275 microns) as opposed to some other color pigments size (e.g., particle size of about 140 microns). Referring now to the drawings,FIGS.1A and1Bare a diagram illustrating an example of an apparatus100comprising a rotating housing.FIG.1Ais an example of an isometric view of the apparatus100.FIG.1Bis an example of a top view of the apparatus100. The apparatus100comprises a rotating housing110or rotating wheel. The rotating housing comprises a side wall120and a back wall125. The rotating housing comprises an open end (i.e., opening) at the opposite side from the back wall125indicated by arrow140. In the illustration example ofFIGS.1A and1B, the rotation housing walls are designed as a composition of a rectangular prism and a cylindrical prism. However, many other shapes could be used to define the rotating housing110walls. In an example, the rotating housing110walls may be designed as a rectangular prism. In another example, the rotating housing110may be designed as a circular prism. In some examples, the side wall120and the back wall125are different walls and, thereby, the side wall120and the back wall125may be formed from different material, thickness, pattern, finishing, and the like. In other examples, the side wall120and the back wall125are the same wall, thereby being formed from the same material, thickness, pattern, finishing, and the like. The side wall120and the back wall125have an inner side and an outer side. At least a wall from the rotating housing (e.g., back wall125), comprises a bore160communicating the inner side and the outer side. The bore may have any cross-section pattern, for example, circular, squared, triangular, pentagonal, and the like. The inner side of the walls of the rotating housing110defines a chamber comprising a volume therein. The chamber is to receive a fluid container through the opening section indicated by the arrow140. In the examples herein, a printing fluid container or fluid container, may comprise any repository capable of containing an amount of liquid printing fluid. In an example, the printing fluid container may be a printing fluid supply, capacity of which may range from about 2 liters to about 10 liters, for example, 5 liters. In another example, the printing fluid container may be a printing fluid supply, capacity of which may be over 10 liters. In another example, the printing fluid container may be a printing fluid supply, capacity of which may be less than 2 liters, for example 1 liter. In other examples, the printing fluid container may comprise a printhead containing an amount of printing fluid. In other examples, the printing fluid container may comprise a receptacle containing slots suitable for the introduction of a plurality of printheads container an amount of printing fluid. The apparatus100also comprises a fix frame130to hold the rotating housing110so that the rotating housing110can rotate. In the present disclosure, the term fix frame may be used as a reference to interpret the rotation of the rotation housing100element, which rotates with respect to the fix frame. The rotating housing110may rotate clockwise and/or counterclockwise with respect to axis X. The rotating housing110may rotate as indicated with arrow145. The fix frame130, however, is static and may be attached to a structure. In one example, the fix frame may be attached to a wall of a container to store the apparatus100therein. In another example, the fix frame130may be attached to an image recording system or printer. In some examples, the fix frame130has a contact point with the back wall125from the rotating housing110. Additionally, the contact point between the back wall125and the fix frame130is designed in such a way that it reduces the friction and other movement opposing strengths between the back wall125and the frame130. The apparatus100also comprises an optical sensor150. The optical sensor150may be a single element or a plurality of elements. The optical sensor150may be any device capable of emitting and/or receiving light beams and to detect the beam intensity from the received light beams. The optical sensor150comprises an emitter to issue a detecting optical signal through the bore160. The optical sensor150also comprises a receiver to receive a detected optical signal associated to the detecting optical signal. In the examples herein, the term “detecting signal” may be referred to as the signal emitted by an emitter, and the term “detected signal” may be referred to as the signal received by a receiver and is associated to the detecting signal. In additional examples, the sensor may be a sensor other than an optical sensor, for example a hall-effect sensor. In an example, the detecting optical signal may be a light beam emitted from the emitter that is to travel through the bore160and to the chamber defined by the inner wall of the rotating housing110. In another example, the detecting signal may be a light beam emitted from the emitter that is to travel through the chamber and to the bore160. In the example that there may not be any fluid container in the chamber, the light beam may travel all the way through the opening indicated by arrow140. In the example that there is a fluid container in the chamber, the light beam may be blocked by a wall from the housing of the fluid container at a predetermined distance and reflected to the receiver. In other examples, the light beam may be blocked by the back wall125of the rotating housing110due to its rotation. In an example, the light beam emitted by the emitter and the reception or lack of reception of a light beam by the receiver may be used to determine the position of the rotating housing110. In an example, the bore160may be designed in such a way that the bore160is associated with a predetermined position (i.e., predetermined orientation) of the rotating housing110, for example, a vertical position. In the example, the vertical position may be the position in which a fluid container may be installed (e.g., load position). In an example, as the rotating housing110rotates, the detecting signal may be blocked and reflected at the back wall125from the rotating housing110, the reflection of which may be received by the receiver and may be used as a detected signal. The intensity of the detected signal is indicative that the rotating housing110is not in the predetermined position of the rotating housing110. In another example, as the rotating housing110rotates, the detecting signal may not be blocked by the back wall125from the rotating housing110and may travel through the bore160. Based on the presence of the fluid container in the chamber, the receiver may (or may not) receive a reflected beam as detected optical signal, being the detected optical signal indicative of the presence of the fluid container in the chamber. The detected optical signal reflected from the back wall125may have a different intensity than other detected optical signals, thereby being indicative of different situations (e.g., rotating housing110not in the predetermined—vertical—position, fluid container installed in the chamber, etc.). Based on the previous examples, the reception of lack of reception of a light beam by the receiver may be used to determine whether the fluid container is present in the rotating housing110. In one of the examples above, if the chamber does not have a fluid container therein, the light beam may not be reflected back through the opening and not received by the receiver thereby the lack of reception of the light beam being indicative of an empty chamber. In another example, if there is a fluid container in the chamber, the light beam may be blocked and reflected by a wall from the housing of the fluid container, reflection of which may be received by the receiver, thereby the reception of the light beam being indicative of the presence of the fluid container in the chamber. Alternatively, the receiver may be placed in the wall of the housing of the fluid container, thereby being no reflection. The reception of the light beam from the receiver being indicative of the fluid container in the chamber. In an example, the detecting optical signal is issued by an emitter, and the detected optical signal is received by a receiver. The emitter and the receiver may be part of an optical sensor150. In some examples, the emitter and the receiver may be included in a single optical sensor150. In other examples, the emitter and the receiver may be included in the same or in separate housings. Furthermore, the emitter and the receiver may be located close to each other. In an example, the emitter may be attached to the fix frame130and the receiver may be attached to the rotating housing110. In another example, the emitter may be attached to the rotating housing110and the receiver may be attached to the fix frame130. In yet another example, the emitter and the receiver and attached in the fix frame130. Following with the examples above, the detected signal is sent to a controller to determine whether the fluid container is present in the rotating housing110. In some examples, the controller may also determine whether the rotating housing110is in a determined position. FIG.2is a block diagram illustrating an example of a printing apparatus200comprising a rotating housing110. The apparatus200may include apparatus100comprising a rotating housing110, a side wall120, a fix frame130, an optical sensor150, and a bore160. The rotating housing110, the side wall120, the fix frame130, the optical sensor150, and the bore160may be the same as or similar to the corresponding elements fromFIGS.1A and1B. The apparatus200additionally comprises or may be coupled to a controller270. The controller270may be a combination of hardware and programming that may be implemented in a number of different ways. For example, the programming of modules may be processor-executable instructions stored on at least one non-transitory machine-readable storage medium and the hardware for modules may include at least one processor to execute those instructions. In some examples described herein, multiple modules may be collectively implemented by a combination of hardware and programming. In other examples, the functionalities of the controller270may be, at least partially, implemented in the form of electronic circuitry. As mentioned above, the detected signal may be sent to the controller270. The controller270may determine whether a fluid container is present in the rotating housing110or not. Additionally, or alternatively, in some examples, the controller270may determine whether the rotating housing110is in a determined position. The controller270may further control the rotating housing110to rotate to a position corresponding to the determined position. In an example, the determined position may be a vertical orientation corresponding to a load orientation of the fluid container. In some examples, the controller270may further control the rotating housing110to rotate the load orientation of the fluid container if the controller270previously determined that the fluid container is not present in the rotating housing110. In other examples, the controller270may be to execute the method300ofFIG.3for issuing an alert signal. Additionally, or alternatively, the controller270may be to execute method500fromFIG.5and/or method600fromFIG.6. FIG.3is a flowchart of an example method300for issuing an alert signal. Method300may be described below as being executed or performed by a controller, such as the controller270ofFIG.2. In some implementations of the present disclosure, method300may include more or less blocks than are shown inFIG.3. In some implementations, some of the blocks of method300may, at certain times, be performed in parallel and/or may repeat. Method300may be performed by a controller (e.g., controller270fromFIG.2). In some examples, the controller may be part of a printing apparatus. In other examples, the controller may be part of the rotating housing100. At block320, the controller may control the optical sensor (e.g., optical sensor150fromFIGS.1A and1B) to detect whether the fluid container is present in the rotating housing (e.g., rotating housing110fromFIGS.1A and1B). In some examples, the controller may detect whether the fluid container is present in the rotating housing based on the detected optical signal from the receiver. At block340, the controller may issue an electrical alert signal to notify if the fluid container is not present in the rotating housing. The electrical alert signal may be sent to an alert device to inform the user that the rotating housing is not present in, for example, apparatus100. In some examples, the alert device may issue a visual alert device, for example a Light Emitting Diode (LED), screen, tablet or any suitable visual emitting device. In other examples, the alert device may issue an auditive alert device, for example a speaker or any other auditive alert device. The following examples are disclosed with reference toFIGS.4A and4B.FIG.4Ais a diagram illustrating an example of a back view of an apparatus comprising a rotating housing110to receive a fluid container.FIG.4Bis a diagram illustrating an example of an isometric view of the fluid container400. FIG.4Ashows an example rotating housing110that rotates as indicated by arrow145. The rotating housing comprises a side wall120and a back wall125. In some examples, the back wall125of the rotating housing110is to be connected to a fix frame (e.g., fix frame130fromFIGS.1A and1B). FIG.4Bshows an example of a fluid container400. The fluid container400comprises a side wall420at a side of the fluid container400, and a back wall425at the back side of the fluid container400. The fluid container400comprises a base at the bottom part of the fluid container400. In some examples, the fluid container400may also comprise a lid490to close the container from a top opening. The fluid container400is to be introduced in the chamber defined by the inner wall of the rotating housing110through an opening (e.g., opening indicated by arrow140fromFIGS.1A and1B). In some examples, for ease of the introduction and/or removal of the fluid container400to the rotating housing110, the fluid container400may further comprise a handle495. In an example, once the fluid container400is installed in the rotating housing110, the side wall420from the fluid container400may be associated with the side wall120from the rotating housing110, and the back wall425from the fluid container400may be associated with the back wall125from the rotating housing110. In an example, the fluid container400may comprise a slot to host a printhead therein. The printhead may be introduced in a slot of the fluid container400through an opening. In additional examples, the fluid container400may comprise a plurality of slots to host a plurality of printheads therein. For example, the fluid container400may comprise a first printhead slot480A to host a first printhead and a second printhead slot480B to host a second printhead. The rotating housing110fromFIG.4Acomprises a plurality of bores460. In the illustrated example, the first plurality of bores460comprises first bore460A, a second bore460B, and a third bore460C. An example of plurality of bores460has been illustrated, however the plurality of bores460may comprise more or less bores than the ones illustrated without departing from the scope of the present disclosure. As disclosed above, the fluid container400fromFIG.4Bmay be introduced into the rotating housing110fromFIG.4A. In some examples, the fluid container400may have a plurality of bores415(illustrated as dotted lines on the back wall425from the fluid container400), corresponding to the first plurality of bores. In an example, a bore from the first plurality of bores460from the back side125of the rotating housing110, may be associated with a bore from the plurality of bores415from the fluid container400, in such a way that a detecting signal and/or a detected signal may be allowed to travel through the bore from the first plurality of bores460and the bore from the plurality of bores415. In other examples, the fluid container400may not have a back side425, thereby being an open end in which a detecting signal and/or a detected signal may be allowed to travel though the bore from the plurality of bores460and the open end respective to the back side425. In some examples, the back wall425from the fluid container400may comprise a bore associated with a printhead slot, in such a way that a detecting signal may travel through the bore to be blocked and/or reflected by the back side of the printhead housing (not shown). In the examples in which there is not any printhead in the printhead slot, the detecting signal may travel through the bore and through the printhead slot to be blocked and/or reflected by the inner side of the front wall of the fluid container400. The detected optical signal associated with the detecting signal of the previous examples may enable a controller (e.g., controller270fromFIG.2) to determine whether the printhead is present in the printhead slot or if the printhead is not present in the printhead slot. In additional examples, the back wall425from the fluid container400may comprise a plurality of bores415associated with a plurality of printhead slots. In an example, the plurality of bores415from the back side425of the fluid container400may comprise a first bore associated with the first printhead slot480A, and a second bore associated with the second printhead slot480B. The plurality of bores460on the back side125of the rotating housing110causes the detected optical signal to include a plurality of signal pulses indicative of a position (i.e. orientation) of the rotating housing, for example, Additionally, the back side125of the rotating housing110may, for example, further comprise an additional plurality of bores465illustrated in dotted lines. The additional plurality of bores465may be located in a symmetrical location with respect to a horizontal axis from the plurality of bores460. The additional plurality of bores465enables the detected signal to be received by a controller (e.g., controller270fromFIG.2) in such a way that the controller is to control or determine the position of the rotating housing110(e.g., a vertical position corresponding to the printhead loading position) in a more precise way. FIG.5is a flowchart of an example method500for determining if a fluid container (e.g., fluid container400fromFIG.4B) is in a rotating housing (e.g., rotating housing110fromFIGS.1A and1B). Method500may be described below as being executed or performed by a controller, such as the controller270ofFIG.2. At block520, the controller may instruct the rotating housing (e.g., rotating housing110fromFIGS.1A and1B). The rotating housing comprises a wall with a bore therethrough (e.g., wall125and bore160fromFIGS.1A and1B). At block540, the controller may instruct an emitter sensor (e.g., optical sensor150fromFIGS.1A and1B) to emit a detecting optical signal through the bore. At block560, the controller may instruct a receiver sensor to detect an optical signal associated with the detecting signal. In some examples, the receiver may be integrated in the same sensor as the emitter. At block580, the controller may determine if the fluid container is present in the rotating housing based on the detected optical signal. FIG.6is a flowchart of an example method600for rotating a rotating housing. Method600may be described below as being executed or performed by a controller, such as the controller270ofFIG.2. At block620, the controller may issue an alert signal if the fluid container (e.g., fluid container400fromFIG.4B) is not present in the rotating housing (e.g., rotating housing110fromFIGS.1A and1B). At block640, the controller may instruct the rotating housing to rotate to a load position (e.g., position inFIG.4A) so that the fluid container can be received in the rotating housing. The above examples may be implemented by hardware, or software in combination with hardware. For example, the various methods, processes and functional modules described herein may be implemented by a physical processor (the term processor is to be implemented broadly to include CPU, SoC, processing module, ASIC, logic module, or programmable gate array, etc.). The processes, methods and functional modules may all be performed by a single processor or split between several processors; reference in this disclosure or the claims to a “processor” should thus be interpreted to mean “at least one processor”. The processes, method and functional modules are implemented as machine-readable instructions executable by at least one processor, hardware logic circuitry of the at least one processors, or a combination thereof. As used herein, the terms “about” and “substantially” may be used to provide flexibility to a numerical range endpoint by providing that a given value may be, for example, an additional 20% more or an additional 20% less than the endpoints of the range. The degree of flexibility of this term can be dictated by the particular variable and would be within the knowledge of those skilled in the art to determine based on experience and the associated description herein. In some examples herein, the terms “about” and “substantially” may be used to provide flexibility to a relative position and/or an absolute position. The drawings in the examples of the present disclosure are some examples. It should be noted that some units and functions of the procedure may be combined into one unit or further divided into multiple sub-units. What has been described and illustrated herein is an example of the disclosure along with some of its variations. The terms, descriptions and figures used herein are set forth by way of illustration. Many variations are possible within the scope of the disclosure, which is intended to be defined by the following claims and their equivalents. Example implementations can be realized according to the following sets of features: Feature set 1: An apparatus comprising:a rotating housing comprising a wall with an inner side defining a chamber and an outer side, the wall having a bore communicating the inner side and the outer side, the chamber being to receive a fluid container;a fix frame holding the rotating housing;an optical sensor comprising an emitter to issue a detecting optical signal through the bore and a receiver to receive a detected optical signal associated to the detecting optical signal; andwherein the detected signal is sent to a controller to determine whether the fluid container is present in the rotating housing. Feature set 2: An apparatus with feature set 1, further comprising the controller to:control the optical sensor to detect whether the fluid container is present in the rotating housing; andissue an electrical alert signal to notify if the fluid container is not present in the rotating housing. Feature set 3: An apparatus with feature set 1 or 2, further comprising the fluid container and wherein the fluid container comprises a slot to host a printhead. Feature set 4: An apparatus with any of feature sets 1 to 3, wherein the rotation wheel further comprises a plurality of slots, each slot to host a printhead; and a plurality of bores, wherein each bore is associated with a slot. Feature set 5: An apparatus with any of feature sets 1 to 4, wherein the plurality of bores causes the detected optical signal to include a plurality of signal pulses indicative of a position of the rotating housing. Feature set 6: An apparatus with any of feature sets 1 to 5, further comprising an additional plurality of bores on the wall, being the additional plurality of bores symmetrical with respect to the plurality of bores. Feature set 7: An apparatus with any of feature sets 1 to 6, further comprising a controller to control the rotating housing to rotate to a position corresponding to a load orientation of the fluid container. Feature set 8: An apparatus with any of feature sets 1 to 7, wherein one of the emitter or the receiver is attached to the fix frame and the other of the emitter or the receiver is attached to the rotating housing. Feature set 9: An apparatus with any of feature sets 1 to 8, wherein the emitter and the receiver are attached to the fix frame. Feature set 10: An image recording system comprising:a rotating wheel comprising a wall defining a chamber to receive a printing fluid container; anda sensing device comprising an emitter to emit a detecting optical signal through a bore on the wall and a receiver to receive a detected optical signal associated with the detecting signal to detect that the printing fluid container is present in the rotating wheel. Feature set 11: An image recording system with feature set 10, further comprising a controller to: control the sensing device to detect whether the printing fluid container is present in the rotating wheel; and issue an electrical alert signal to notify if the printing fluid container is not present in the rotating wheel. Feature set 12: An image recording system with any of feature sets 10 to 11, further comprising the printing fluid container and wherein the printing fluid container comprises a slot to host a printhead. Feature set 13: An image recording system with any of feature sets 10 to 12, wherein the rotating wheel comprises: a plurality of slots, each slot to host a printhead; a plurality of bores, wherein each bore is associated with a slot; and wherein the plurality of bores causes the detected optical signal to include a plurality of signal pulses indicative of a position of the rotating wheel. Feature set 14: A method comprising:rotating a rotating housing comprising a wall with a bore therethrough;emitting, by an emitter, a detecting optical signal through the bore;receiving, by a receiver, a detected optical signal associated with the detecting signal; anddetermining if a fluid container is present in the rotating housing based on the detected optical signal. Feature set 15: A method with feature set 14, further comprising: issuing an alert signal if the fluid container is not present in the rotating housing; and rotating the rotating housing to a load position so that the fluid container can be received in the rotating housing. | 30,955 |
11858278 | DESCRIPTION OF EXEMPLARY EMBODIMENTS With reference to the accompanying drawings, a liquid supplying apparatus and a liquid ejecting apparatus according to an exemplary embodiment will now be explained. The liquid ejecting apparatus disclosed in the embodiment below is, for example, an ink-jet printer that performs printing by ejecting liquid such as ink onto a medium such as paper. In the drawings, it is assumed that a liquid ejecting apparatus11is installed on a horizontal plane, and, based on this assumption, the direction of gravity is indicated by a Z axis, and the directions along the horizontal plane are indicated by an X axis and a Y axis. The X, Y, and Z axes are orthogonal to one another. In the description below, the direction along the X axis may be referred to as a width direction X, the direction along the Y axis may be referred to as a depth direction Y, and the direction along the Z axis may be referred to as a vertical direction Z. Configuration of Liquid Ejecting Apparatus As illustrated inFIG.1, the liquid ejecting apparatus11includes a liquid ejecting head20capable of ejecting liquid, a liquid supplying apparatus30for supplying the liquid to the liquid ejecting head20, and a control unit25. The liquid supplying apparatus30includes a supply flow passage35that is in communication with the liquid ejecting head20. The liquid supplying apparatus30includes a mounting unit31into which a plurality of liquid containers40can be detachably mounted by insertion. The mounting unit31includes a housing case32capable of housing the plurality of liquid containers40inside. The housing case32has slots32A. The slots32A are respective housing spaces into which the plurality of liquid containers40can be inserted individually. The mounting unit31includes engagement portions33configured to be engaged with the liquid containers40inserted in the slots32A. The engagement portion33is provided on the housing case32individually for each of the plurality of slots32A. The engagement portion33has a locking function for preventing the liquid container40from being detached by the user during printing. The liquid container40contains liquid that is to be supplied to the liquid ejecting head20. That is, the liquid container40is a liquid supplying source from which the liquid is supplied to the liquid ejecting head20. The liquid ejecting head20according to this example ejects ink or the like as an example of the liquid. Therefore, the liquid container40contains ink as an example of the liquid. The liquid container40is, for example, a liquid cartridge such as an ink cartridge. The liquid container40may be any other type of liquid container as long as it can be detachably mounted into the mounting unit31. For example, the liquid container40may be a liquid tank such as an ink tank which can be refilled with liquid by the user. The liquid ejecting head20according to the present embodiment ejects more than one kind of liquid. Groups each consisting of a plurality of liquid containers40containing the same kind of liquid, among the plural kinds of liquid which the liquid ejecting head20is capable of ejecting, can be detachably mounted by insertion into the mounting unit31. For example, N pairs or sets, each containing the same kind of liquid (three pairs in the example illustrated inFIG.1), of the liquid containers40can be detachably mounted by insertion into the mounting unit31. The number of the N pairs or sets, each containing the same kind of liquid, of the liquid containers40may be one, or two or more. If the liquid is ink, though not limited thereto, the kinds of the liquid are, for example, the kinds of the ink. The kinds of the ink are, for example, ink-color types. As illustrated inFIG.1, the liquid ejecting apparatus11includes a cabinet13housing the liquid ejecting head20inside. The cabinet13may be supported by a pair of legs12. The liquid supplying apparatus30may be provided separately from the cabinet13as illustrated inFIG.1. Alternatively, the liquid supplying apparatus30may be provided integrally with the cabinet13. In the liquid ejecting apparatus11according to the present embodiment, the liquid ejecting head20ejects liquid toward a medium14. If the liquid is ink, though not limited thereto, the liquid ejecting apparatus11performs printing on the medium14by ejecting ink from the liquid ejecting head20. Therefore, the liquid ejecting apparatus11may be equipped with a transportation unit23configured to transport the medium14. The medium14may have a long shape, or may be a cut sheet having a predetermined length. If the medium14is paper, though not limited thereto, the medium14may be roll paper or cut-sheet paper. As illustrated inFIG.1, the transportation unit23may use a roll transportation scheme of transporting the medium14having a long shape from a medium roll (not illustrated). The transportation unit23may include an unreeling portion15configured to unreel and feed the medium14from the medium roll, a guiding portion16for guiding the medium14ejected out of the cabinet13after printing, and a taking-up portion17configured to reel and take up the medium14. The transportation unit23may include a tensioning mechanism18configured to apply tension to the medium14that is to be taken up onto the taking-up portion17. The transportation unit23includes transportation rollers (not illustrated) configured to transport the medium14toward a recording position where the medium14is to face the liquid ejecting head20. The liquid ejecting head20performs printing on the medium14by ejecting liquid such as ink toward the medium14transported by the transportation unit23. The recording scheme of the liquid ejecting head20may be serial recording illustrated inFIG.1or line recording. The liquid ejecting apparatus11using the serial recording scheme includes a carriage21configured to move the liquid ejecting head20. The liquid ejecting apparatus11alternates recording operation, in which liquid is ejected from the liquid ejecting head20while the carriage21moves in the width direction X intersecting with the transportation direction of the medium14, and transportation operation, in which the transportation unit23transports the medium14to the next recording position. By this alternate execution of the recording operation and the transportation operation, the liquid ejecting apparatus11performs printing on the medium14. If the line recording scheme is used, the liquid ejecting head20is configured as a line head or a multiple-type head having a plurality of nozzles for making it possible to perform recording throughout the entire width of the medium14at a time. The liquid ejecting apparatus11performs printing on the medium14by ejecting liquid from the nozzles of the liquid ejecting head20onto the medium14transported at a predetermined transportation speed. The term “line head” as used herein means a single elongated head. The term “multiple-type head” as used herein means a head array made up of a plurality of unit heads arranged throughout the entire width of the medium14. The liquid ejecting apparatus11may be equipped with a maintenance unit22configured to perform maintenance on the liquid ejecting head20. The maintenance unit22performs maintenance operation of discharging liquid from the nozzles of the liquid ejecting head20forcibly. When an image is formed by print operation of the liquid ejecting head20, some of the nozzles are used for ejecting liquid therefrom, and the others are not used for ejecting liquid therefrom. The viscosity of the liquid inside the nozzles that are not used increases gradually. Moreover, in some instances air goes into the liquid inside a nozzle. Air dissolved into liquid by permeation through the supply flow passage35made of a tube grows gradually into an air bubble over a long period of time, and in some instances such an air bubble reaches a nozzle. The presence of such thickened liquid or an air bubble inside a nozzle might result in poor liquid ejection therefrom. The maintenance unit22prevents or troubleshoots poor liquid ejection by performing maintenance operation of letting out such thickened liquid or air bubbles present inside nozzles of the liquid ejecting head20together with the liquid. As described here, not only during print operation but also during maintenance operation, the liquid ejecting head20consumes liquid supplied from the liquid supplying apparatus30. Therefore, in the present embodiment, the operation of the liquid ejecting head20including print operation and maintenance operation will be referred to as liquid-consuming operation, which involves liquid consumption. As illustrated inFIG.1, the liquid ejecting apparatus11may be equipped with an operation panel24that is operated by the user. In this example, the facade which the user who operates the operation panel24faces with is the front of the liquid ejecting apparatus11. The control unit25receives input information which the user enters by operating the operation panel24. One of pieces of the input information is print instruction information for instructing the liquid ejecting apparatus11to execute liquid ejecting operation (for example, print operation). The operation panel24includes a power operation unit that is operated for turning the power of the liquid ejecting apparatus11ON/OFF. The operation panel24may include a display unit configured to display a menu and operation information of the liquid ejecting apparatus11. In this case, the display unit may be a touch panel having an operation function. The liquid ejecting apparatus11may be connected to a host apparatus80(seeFIG.4) such that communication can be performed therebetween. For example, the user instructs the liquid ejecting apparatus11to execute liquid ejecting operation (for example, print operation) by operating the input interface of the host apparatus80. That is, based on the print instructions inputted via the operation panel24or sent from the host apparatus80, the liquid ejecting apparatus11performs print operation to print an image onto the medium14. The control unit25controls the liquid supplying apparatus30, the liquid ejecting head20, and the transportation unit23. Upon receiving the print instructions, the control unit25controls the liquid ejecting head20and the transportation unit23to cause them to perform printing on the medium14. In addition, the control unit25controls the liquid supplying apparatus30while the power of the liquid ejecting apparatus11is ON. Liquid Supplying Apparatus Next, with reference toFIGS.2and3, the structure of the liquid supplying apparatus30will now be explained in detail. The liquid supplying apparatus30is illustrated inFIGS.2and3, with the exterior armor part of the housing case32detached. In the liquid supplying apparatus30, the direction in which each liquid container40is mounted by insertion into the mounting unit31is defined as “insertion direction ID”, and the direction parallel to the insertion direction ID is defined as “depth direction Y1”. In the liquid supplying apparatus30, when the mounting unit31is viewed from the front (insertion-opening side), the longitudinal direction of the facade of each liquid container40inserted therein is defined as “width direction X1”, and the direction in which the liquid containers40are arranged is defined as “arrangement direction Z1”. In this example, the width direction X1is parallel to the width direction X of the liquid ejecting apparatus11, and the depth direction Y1is parallel to the depth direction Y of the liquid ejecting apparatus11. The arrangement direction Z1is parallel to the vertical direction Z. The faces of the housing case32are made up of a pair of sides, the top, the bottom, and the back. The width direction X1, the depth direction Y1, and the arrangement direction Z1of the liquid supplying apparatus30may be modified as may be necessary. The arrangement direction Z1, in which the liquid containers40mounted by insertion into the mounting unit31are arranged, may be different from the vertical direction Z. Although the liquid supplying apparatus30according to the example illustrated inFIGS.2and3has a vertical container-array configuration, meaning that the arrangement direction Z1is parallel to the vertical direction Z, the liquid supplying apparatus30may have a horizontal container-array configuration, meaning that the arrangement direction Z1is parallel to the width direction X of the liquid ejecting apparatus11. As illustrated inFIG.2, the housing case32of the mounting unit31is compartmentalized into the plurality of slots32A into which the plurality of liquid containers40can be put. The housing case32has a shape like a rectangular parallelepiped. The housing case32is able to house the plurality of liquid containers40inside, with the liquid containers40tiered in the arrangement direction Z1. The housing case32has, at its front, an insertion opening through which the plurality of liquid containers40can be inserted. The liquid containers40are inserted into the respective slots32A through the insertion opening of the housing case32. Each liquid container40has a low-profile rectangular-parallelepiped-like shape so that the liquid containers40can be mounted by insertion, in a state of being arranged in the arrangement direction Z1of the housing case32. As illustrated inFIG.2, the liquid container40has a grip portion40A at a position of being exposed from the slot32A when mounted by insertion. The user is able to hold the grip portion40A with fingers and then attach or detach the liquid container40. The liquid container40includes a container that has the grip portion40A. The liquid container40further includes a liquid pack encased in the container. The container of the liquid container40may be configured to be repeatedly usable, and the user may replace the liquid pack alone with brand-new one. Alternatively, the liquid container40in its entirety, inclusive of the container, may be replaced with brand-new one. In the former case, the container may be a tray. The liquid container40may be a tank whose container having the grip portion40A contains liquid. As illustrated inFIG.2, the engagement portion33includes an operation portion34configured to be operated by the user. The engagement portion33is movable to switch between an engagement state and a non-engagement state. When in the engagement state, the engagement portion33is in engagement with the liquid container40inserted in the slot32A. When in the non-engagement state, the engagement portion33is not in engagement therewith. When the liquid container40needs to be replaced, the user operates the operation portion34to move the engagement portion33from an engagement state into a non-engagement state. Then, after replacing the liquid container40with brand-new one, the user operates the operation portion34to move the engagement portion33from a non-engagement state into an engagement state. The engagement portion33may be urged by an urging member such as a spring (not illustrated) in the direction of engagement with the liquid container40. As illustrated inFIG.2, the mounting unit31is configured such that paired liquid containers40containing the same kind of liquid are mounted by insertion into it. Specifically, the mounting unit31is configured such that a first liquid container(s)41, and a second liquid container(s)42containing the same kind of liquid as the liquid contained in the first liquid container41, are mounted by insertion into it. As described here, there are two kinds of the liquid containers40, namely, the first liquid container(s)41and the second liquid container(s)42, containing the same kind of liquid. Therefore, for each kind of liquid, the plurality of slots32A includes a first slot SL1, into which the first liquid container41is configured to be inserted, and a second slot SL2, into which the second liquid container42is configured to be inserted. The liquid ejecting apparatus11uses the first liquid container41and the second liquid container42while performing switching therebetween as the liquid supplying source from which the liquid is supplied to the liquid ejecting head20. The mounting unit31illustrated inFIG.2includes a switching unit(s)38that performs this switching. Let N be the maximum number of the liquid containers40that are able to be mounted by insertion into the mounting unit31. Given this definition, N includes M pairs each consisting of the first liquid container41and the second liquid container42containing the same kind of liquid, as illustrated inFIG.2. In the example illustrated inFIG.2, there are M kinds of liquid that are able to be supplied to the liquid ejecting head20, and there are the first liquid container41and the second liquid container42for each of the M kinds. In the example illustrated inFIG.2, the N liquid containers40include a first liquid container group43containing first liquid, a second liquid container group44containing second liquid, and a third liquid container group45containing third liquid. The first liquid container group43includes the first liquid container41and the second liquid container42containing the first liquid. The second liquid container group44includes the first liquid container41and the second liquid container42containing the second liquid. The third liquid container group45includes the first liquid container41and the second liquid container42containing the third liquid. If the liquid is ink, the kinds of the liquid are, for example, ink-color types. The first liquid, the second liquid, and the third liquid are ink having respective colors different from one another. For example, the first liquid, the second liquid, and the third liquid are cyan ink, magenta ink, and yellow ink. The ink-color types may be modified as may be necessary. The scope of the present disclosure is not limited to a configuration in which all of the N containers are constituents of plural pairs or sets each containing the same kind of liquid. It is sufficient as long as at least one pair or set containing the same kind of liquid is included. The switching unit38illustrated inFIG.2performs switching to use either one of the first liquid container41and the second liquid container42as the liquid supplying source that is to be in communication with the liquid ejecting head20. The switching unit38is controlled by the control unit25. When one of the two liquid containers40that is currently used as the liquid supplying source, that is, the first liquid container41or the second liquid container42, runs out of liquid (for example, runs out of ink), the switching unit38switches the liquid supplying source to the other of the two liquid containers40. As illustrated inFIG.2, the liquid supplying apparatus30includes a movement restriction unit(s)39. Linked with switching by the switching unit38, the movement restriction unit39is able to restrict the movement of the first liquid container41and the second liquid container42selectively. The movement restriction unit39selectively switches the engagement portion33that is in an engagement state of being in engagement with the liquid container40between a restriction state and a non-restriction state. When in the restriction state, the movement of the engagement portion33from the engagement state into the non-engagement state is restricted. When in the non-restriction state, the movement of the engagement portion33from the engagement state into the non-engagement state is allowed. When in the restriction state, the movement restriction unit39locks the engagement portion33in the engagement state. The movement restriction unit39is controlled by the control unit25. As illustrated inFIGS.2and3, the engagement portion33includes a first engagement portion33A, which is able to be engaged with the first liquid container41, and a second engagement portion33B, which is able to be engaged with the second liquid container42. The first engagement portion33A includes a first operation portion34A operable by the user for disengagement from the state of engagement with the first liquid container41. The second engagement portion33B includes a second operation portion34B operable by the user for disengagement from the state of engagement with the second liquid container42. As described here, the operation portion34includes the first operation portion34A of the first engagement portion33A and the second operation portion34B of the second engagement portion33B. The scope of the present disclosure is not limited to a configuration in which each operation portion34A,34B is formed integrally with the corresponding engagement portion33A,33B. Each operation portion34A,34B may be formed separately from the corresponding engagement portion33A,33B. To sum up, it is sufficient as long as each operation portion34A,34B is able to cause the corresponding engagement portion33A,33B to move between the engagement state and the non-engagement state. The movement restriction unit39includes a first lock mechanism391configured to lock the first engagement portion33A in the engagement state and a second lock mechanism392configured to lock the second engagement portion33B in the engagement state. The first lock mechanism391is selectively switched between a restriction state (lock state) for restricting the movement of the first engagement portion33A from the engagement state into the non-engagement state and a non-restriction state (unlock state) for allowing the movement of the first engagement portion33A from the engagement state into the non-engagement state. The second lock mechanism392is selectively switched between a restriction state (lock state) for restricting the movement of the second engagement portion33B from the engagement state into the non-engagement state and a non-restriction state (unlock state) for allowing the movement of the second engagement portion33B from the engagement state into the non-engagement state. When the first lock mechanism391is in the restriction state, the user is unable to operate the first operation portion34A from the engagement state into the non-engagement state. Therefore, the user is unable to detach the first liquid container41from the first slot SL1. When the first lock mechanism391is in the non-restriction state, the user is able to operate the first operation portion34A from the engagement state into the non-engagement state. Therefore, the user is able to detach the first liquid container41from the first slot SL1and replaces it with brand-new one41. When the second lock mechanism392is in the restriction state, the user is unable to operate the second operation portion34B from the engagement state into the non-engagement state. Therefore, the user is unable to detach the second liquid container42from the second slot SL2. When the second lock mechanism392is in the non-restriction state, the user is able to operate the second operation portion34B from the engagement state into the non-engagement state. Therefore, the user is able to detach the second liquid container42from the second slot SL2and replaces it with brand-new one42. In the present embodiment, hot swapping is adopted. Hot swapping is a scheme in which the movement of one of two liquid containers41and42containing the same kind of liquid is restricted so that this one is not replaceable during liquid-consuming operation when this one is currently used as the liquid supplying source, whereas the movement of the other, which is not currently used, is not restricted so that the other is replaceable during the liquid-consuming operation. Since hot swapping is adopted, the other of the two liquid containers41and42, which is not currently used, is able to be replaced even during liquid-consuming operation. Therefore, even if the above-mentioned one of the two liquid containers41and42, which is currently used, runs out of the liquid, switching the liquid supplying source to the other makes it possible to continue print operation, without any interruption for the purpose of replacement of the liquid container40. As illustrated inFIG.3, to realize hot swapping, the mounting unit31includes a supply mechanism50. The supply mechanism50includes the aforementioned switching unit38and the movement restriction unit39. When the currently-active one, meaning the one that is currently used, of the first liquid container41and the second liquid container42configured to contain the same kind of liquid runs out of the liquid, the switching unit38performs switching so as to use the other as a new currently-active source. That is, the switching unit38performs selective switching between the first liquid container41and the second liquid container42as to whether to allow or not allow the supplying of the liquid. One of the first engagement portion33A and the second engagement portion33B corresponds to the liquid container40that is currently used, and the other corresponds to the liquid container40that is not currently used; the movement restriction unit39locks this one in the engagement state and unlocks the other. As illustrated inFIGS.2and3, the supply mechanism50includes a first driving mechanism51, which constitutes the switching unit38, a second driving mechanism52, which constitutes the movement restriction unit39, and a driving source53configured to output motive power to the first driving mechanism51and the second driving mechanism52. The second driving mechanism52includes a rod39A for transmitting, to the engagement portion33A,33B, motive power for performing lock operation of locking the engagement portion33A,33B in the engagement state and unlock operation of unlocking the lock. The rod39A extends linearly in the depth direction Y1along a side of the housing case32inside each of the slots SL1and SL2. Schematic Configuration of Liquid Ejecting Apparatus Next, with reference toFIG.4, the schematic configuration of the liquid ejecting apparatus11equipped with the liquid supplying apparatus30will now be explained. Note that only a single set (pair) containing the same kind of liquid, among the plural sets (pairs) of liquid containers41and42, is illustrated inFIG.4. In this example, the number of liquid containers containing the same kind of liquid in each set (pair) is two. The first liquid container41and the second liquid container42illustrated inFIG.4contain the same kind of liquid. Although a single pair only is illustrated inFIG.4, plural pairs each made up of the first liquid container41and the second liquid container42containing the same kind of liquid are provided. For example, if the liquid is ink, the first liquid container41and the second liquid container42are provided for each of the colors of the ink such as cyan, magenta, and yellow. That is, the liquid containers include the first liquid container41and the second liquid container42containing cyan liquid, the first liquid container41and the second liquid container42containing magenta liquid, and the first liquid container41and the second liquid container42containing yellow liquid (seeFIGS.2and3). The number of the pairs each made up of the first liquid container41and the second liquid container42is not limited to three. This number may be two, or four or more. A pair made up of the first liquid container41and the second liquid container42containing black liquid may be included. The first liquid container41is inserted into the first slot SL1. The second liquid container42is inserted into the second slot SL2. The liquid supplying apparatus30includes a first sensor SE1configured to detect the presence of the first liquid container41in the first slot SL1and a second sensor SE2configured to detect the presence of the second liquid container42in the second slot SL2. Based on a detection signal inputted from the first sensor SE1, the control unit25determines whether there is the first liquid container41in the first slot SL1or not. Based on a detection signal inputted from the second sensor SE2, the control unit25determines whether there is the second liquid container42in the second slot SL2or not. The control unit25includes a sensor configured to detect that the first engagement portion33A is in the engagement state (not illustrated) and a sensor configured to detect that the second engagement portion33B is in the engagement state (not illustrated). Based on the detection results of these sensors, the control unit25determines individually whether the first engagement portion33A is in the engagement state or not and whether the second engagement portion33B is in the engagement state or not. As illustrated inFIG.4, the liquid supplying apparatus30includes the supply flow passage35, which is in communication with the liquid ejecting head20, a first supply flow passage36for communication between the first liquid container41and the supply flow passage35, and a second supply flow passage37for communication between the second liquid container42and the supply flow passage35. The liquid supplying apparatus30includes the aforementioned switching unit38capable of switching the flow passage that is in communication with the supply flow passage35, between the first supply flow passage36and the second supply flow passage37. The liquid supplying apparatus30includes the aforementioned movement restriction unit39capable of, linked with switching by the switching unit38, restricting the movement of the first liquid container41and the second liquid container42selectively. The mounting unit31includes a first connection portion31A configured to be connected to the first liquid container41inserted in the first slot SL1and a second connection portion31B configured to be connected to the second liquid container42inserted in the second slot SL2. The connection portion31A,31B protrudes like a needle from the rear inner surface inside the slot SL1, SL2. The first liquid container41has a liquid supply outlet (not illustrated) on its end face in the insertion direction ID. When the first liquid container41that is being inserted comes to a position for attachment to the first slot SL1, the needle-like first connection portion31A is inserted into the liquid supply outlet. This needle insertion brings the first liquid container41into communication with the first supply flow passage36. The second liquid container42has a liquid supply outlet (not illustrated) on its end face in the insertion direction ID. When the second liquid container42that is being inserted comes to a position for attachment to the second slot SL2, the needle-like second connection portion31B is inserted into the liquid supply outlet. This needle insertion brings the second liquid container42into communication with the second supply flow passage37. When the switching unit38causes the first supply flow passage36to be in communication with the supply flow passage35, the movement restriction unit39restricts the movement of the first liquid container41. When the switching unit38causes the second supply flow passage37to be in communication with the supply flow passage35, the movement restriction unit39restricts the movement of the second liquid container42. The switching unit38includes a first on-off valve54for opening and closing the first supply flow passage36, a second on-off valve55for opening and closing the second supply flow passage37, and the first driving mechanism51for switching between the opening and closing of the first on-off valve54and the second on-off valve55. The switching unit38switches the flow passage that is in communication with the supply flow passage35, between the first supply flow passage36and the second supply flow passage37. The control unit25stores, into a non-illustrated memory (storage unit), use information for identifying which one of the first liquid container41and the second liquid container42is to be used. Based on the use information, the control unit25opens the one, of the first on-off valve54and the second on-off valve55, identified as the valve that is to be used and closes the other. When the one of the first liquid container41and the second liquid container42that is active for use (currently used) runs out of liquid, on condition that a necessary amount of liquid is contained in the other, for example, if the other is a brand-new liquid container, the liquid container40to be used is switched from the one to the other by putting the other into use. The liquid container41,42includes a non-illustrated storage element configured to store liquid information, including information about the kind of the liquid contained inside and the amount of the liquid left. By reading the liquid information out of each storage element of the liquid container41,42inserted in the slot SL1, SL2, the control unit25obtains the information about the kind of the liquid contained in the liquid container41,42(for example, ink color) and the amount of the liquid left. When the switching unit38causes the first supply flow passage36to be in communication with the supply flow passage35, the first liquid container41is in communication with the liquid ejecting head20via the first supply flow passage36and the supply flow passage35. Therefore, the liquid is supplied from the first liquid container41to the liquid ejecting head20. When the switching unit38causes the second supply flow passage37to be in communication with the supply flow passage35, the second liquid container42is in communication with the liquid ejecting head20via the second supply flow passage37and the supply flow passage35. Therefore, the liquid is supplied from the second liquid container42to the liquid ejecting head20. The control unit25controls the carriage21and the liquid ejecting head20. By controlling the driving of a non-illustrated carriage motor, the control unit25causes the carriage21to reciprocate in the width direction X. The liquid ejecting head20includes a plurality of nozzles20N capable of ejecting the liquid supplied from the one of the first liquid container41and the second liquid container42that is currently used. During print operation, the control unit25causes the liquid ejecting head20to eject the liquid from its nozzles20N toward the medium14(seeFIG.1) while the carriage21moves. In addition, the control unit25controls the maintenance unit22. The maintenance unit22includes a cap22A. The maintenance unit22performs cleaning as one of maintenance operations. The cleaning is operation of discharging liquid from the nozzles20N of the liquid ejecting head20forcibly. The cleaning may be pressure cleaning or suction cleaning. In the suction cleaning, the cap22A is brought into contact with a nozzle surface20A, in which the nozzles20N of the liquid ejecting head20are formed, so as to form a closed space between the nozzle surface20A and the cap22A, and the pressure of the closed space is made negative by driving a non-illustrated suction pump. Due to the negative pressure, the liquid is discharged from the nozzles20N forcibly. In the pressure cleaning, the liquid contained in the one of the first liquid container41and the second liquid container42that is currently used is pressurized using pressure applied by a pressure pump, thereby discharging the liquid from the nozzles20N of the liquid ejecting head20forcibly. The liquid (waste liquid) discharged from the nozzles20N in the process of the cleaning is collected into a non-illustrated waste liquid tank via the cap22A. As illustrated inFIG.4, the movement restriction unit39includes the first engagement portion33A, which is able to be engaged with the first liquid container41, the second engagement portion33B, which is able to be engaged with the second liquid container42, and the second driving mechanism52for selective switching between the restriction state and the non-restriction state of the first engagement portion33A and the second engagement portion33B. The movement restriction unit39restricts the movement of the first liquid container41in a detachment direction from an inserted state by locking the first engagement portion33A at an engagement position where the first engagement portion33A is engaged with the first liquid container41. The movement restriction unit39restricts the movement of the second liquid container42in a detachment direction from an inserted state by locking the second engagement portion33B at an engagement position where the second engagement portion33B is engaged with the second liquid container42. A more detailed explanation is given below. The second driving mechanism52includes the aforementioned first lock mechanism391and the aforementioned second lock mechanism392(seeFIG.3). The first lock mechanism391restricts the removal of the first liquid container41from the first slot SL1by locking the first engagement portion33A engaged with the first liquid container41. The second lock mechanism392restricts the removal of the second liquid container42from the second slot SL2by locking the second engagement portion33B engaged with the second liquid container42. If the amount of the liquid left in the one, of the first liquid container41and the second liquid container42, whose movement is restricted by the movement restriction unit39becomes smaller than a predetermined threshold, the control unit25switches the flow passage that is in communication with the supply flow passage35. In addition to this flow-passage switching, the control unit25cancels the restriction on the movement of the one, of the first liquid container41and the second liquid container42, whose movement has been restricted by the movement restriction unit39, and causes the movement restriction unit39to restrict the movement of the other. Specifically, if the amount of the liquid left in the first liquid container41whose movement is restricted by the movement restriction unit39becomes smaller than a predetermined threshold, the control unit25switches the flow passage that is in communication with the supply flow passage35. In addition to this flow-passage switching, the control unit25cancels the restriction on the movement of the first liquid container41and causes the movement restriction unit39to restrict the movement of the second liquid container42. If the amount of the liquid left in the second liquid container42whose movement is restricted by the movement restriction unit39becomes smaller than a predetermined threshold, the control unit25switches the flow passage that is in communication with the supply flow passage35. In addition to this flow-passage switching, the control unit25cancels the restriction on the movement of the second liquid container42and causes the movement restriction unit39to restrict the movement of the first liquid container41. Premised on that the movement of either one of the first liquid container41and the second liquid container42is not restricted by the movement restriction unit39, if this non-restricted one is replaced with a new liquid container40, the control unit25switches the flow passage that is in communication with the supply flow passage35. In addition to this flow-passage switching, the control unit25cancels the restriction on the movement of the other of the liquid containers40and causes the movement restriction unit39to restrict the movement of this new liquid container40. Specifically, if the first liquid container41whose movement is not restricted by the movement restriction unit39is replaced with a new first liquid container41, the control unit25switches the flow passage that is in communication with the supply flow passage35from the second supply flow passage37to the first supply flow passage36. In addition to this flow-passage switching, the control unit25cancels the restriction on the movement of the second liquid container42and causes the movement restriction unit39to restrict the movement of this new first liquid container41. The switching of the flow passage that is in communication with the supply flow passage35from the second supply flow passage37to the first supply flow passage36and the restricting of the movement of the new first liquid container41may be executed when the amount of the liquid left in the second liquid container42becomes smaller than a predetermined threshold after the replacement with the new first liquid container41. If the second liquid container42whose movement is not restricted by the movement restriction unit39is replaced with a new second liquid container42, the control unit25switches the flow passage that is in communication with the supply flow passage35from the first supply flow passage36to the second supply flow passage37. In addition to this flow-passage switching, the control unit25cancels the restriction on the movement of the first liquid container41and causes the movement restriction unit39to restrict the movement of this new second liquid container42. The switching of the flow passage that is in communication with the supply flow passage35from the first supply flow passage36to the second supply flow passage37and the restricting of the movement of the new second liquid container42may be executed when the amount of the liquid left in the first liquid container41becomes smaller than a predetermined threshold after the replacement with the new second liquid container42. As illustrated inFIG.4, the liquid supplying apparatus30includes the driving source53configured to drive the first driving mechanism51and the second driving mechanism52. By causing the driving source53to perform drive operation, the control unit25controls the driving of the two on-off valves54and55, which constitute the switching unit38, and the two lock mechanisms391and392, which constitute the movement restriction unit39. An example of the driving source53is an electric motor. The driving source53is not limited to an electric motor. For example, the driving source53may be an electric cylinder or a solenoid. As illustrated inFIG.4, the operation panel24is electrically connected to the control unit25. The liquid ejecting apparatus11includes a communication unit26for connection to the host apparatus80communicably. The control unit25is connected to the host apparatus80communicably via the communication unit26. The user is able to give instructions to the liquid ejecting apparatus11by operating the operation panel24. In addition, the user is able to give instructions to the liquid ejecting apparatus11also by operating the input unit of the host apparatus80. These instructions include instructions for liquid-consuming operation, which involves liquid consumption. The instructions for liquid-consuming operation include print instructions and maintenance instructions. The print instructions instruct the liquid ejecting head20to perform printing on the medium14by ejecting liquid such as ink toward the medium14. The maintenance instructions instruct that cleaning, in which liquid is discharged from the nozzles20N forcibly, be performed. More specifically, the maintenance instructions are instructions for cleaning the nozzles20N by discharging liquid with increased viscosity inside the nozzles20N and air bubbles contained in the liquid from the nozzles20N together with the liquid. When print instructions are received via the operation panel24or from the host apparatus80, the control unit25controls the liquid ejecting head20and the transportation unit23to cause them to print an image or a text on the medium14. The control unit25further controls the timing of maintenance execution. The control unit25manages the time that has elapsed from the last maintenance execution and the number of sheets that have been printed since the last maintenance execution. When the elapsed time exceeds a time threshold, the control unit25causes the maintenance unit22to perform maintenance operation. When the number of sheets that have been printed exceeds a number-of-sheets threshold, the control unit25causes the maintenance unit22to perform maintenance operation. When maintenance instructions are received via the operation panel24or from the host apparatus80, the control unit25causes the maintenance unit22to perform maintenance operation. The maintenance operation may be operation other than cleaning. For example, the maintenance operation may be idle discharging (flushing) of liquid from the nozzles20N of the liquid ejecting head20. The control unit25configured to control the operation of the liquid ejecting apparatus11includes, for example, a CPU, a memory, and so forth. By running a program stored in the memory by the CPU, the control unit25controls the components the liquid ejecting apparatus11such as the liquid ejecting head20, the liquid supplying apparatus30, the maintenance unit22, the transportation unit23, and so forth. For example, in the control unit25according to this example, a program illustrated by the flowchart inFIG.12is stored in its memory. Structure of Supply Mechanism50 Next, with reference toFIGS.5to8, the structure of the supply mechanism50will now be explained. As illustrated inFIG.5, the supply mechanism50includes the driving source53, and the first driving mechanism51and the second driving mechanism52, each of which is driven by motive power outputted from the driving source53. More specifically, the supply mechanism50includes the driving source53, a gear train58configured to transmit rotational power outputted from the driving source53, and a plurality of cams61to64configured to rotate based on the rotational power transmitted by the gear train58. The cams61to64are fixed to a common shaft portion65supported rotatably. The cams61to64are fixed with predetermined phase differences therebetween to the shaft portion65. The gear train58includes an input gear56and an output gear57. The input gear56is fixed to the output shaft of the driving source53. The output gear57is located on the downstream end on the power transmission path of the gear train58. The first driving mechanism51includes the first cam61and the second cam62. The first cam61is mounted on the shaft portion65configured to rotate when driven indirectly by and in synchronization with driving by the driving source53. The first cam61is capable of switching the first on-off valve54between an open state and a closed state. The second cam62is mounted on the shaft portion65and is capable of switching the second on-off valve55between an open state and a closed state. The second driving mechanism52includes the third cam63, which is mounted on the shaft portion65and is capable of switching the state of the first engagement portion33A (seeFIGS.3and8), and the fourth cam64, which is mounted on the shaft portion65and is capable of switching the state of the second engagement portion33B (seeFIGS.3and8). The output gear57illustrated inFIG.5is in meshing engagement with a gear portion66, which is provided between the third cam63and the fourth cam64in such a way as to be able to rotate integrally with them. Therefore, the first cam61, the second cam62, the third cam63, and the fourth cam64, which are fixed to the shaft portion65, rotate integrally due to the rotation of the shaft portion65by the transmission of the motive power of the driving source53via the gear train58. As illustrated inFIG.6, the first cam61has a cam face61A formed on its outer periphery, and the second cam62has a cam face62A formed on its outer periphery. The cam face61A is configured to mechanically act on a sliding surface71A of a first lever71corresponding to the first cam61, and the cam face62A is configured to mechanically act on a sliding surface71A of a first lever71corresponding to the second cam62. The first lever71has, for example, a shape like a letter L in a side view and is able to rotate within a predetermined angular range around its fulcrum72. By mechanically acting on the sliding surface71A of the first lever71, the first cam61switches the first on-off valve54between an open state and a closed state through the rotation of the first cam61. By mechanically acting on another first lever71different from the first lever71on which the first cam61is configured to mechanically act, the second cam62switches the second on-off valve55between an open state and a closed state through the rotation of the second cam62. A drive shaft73configured to switch each of the first on-off valve54and the second on-off valve55between an open state and a closed state is each coupled to the other end portion that is the opposite of one end portion where the sliding surface71A of each first lever71is located. Each of the first on-off valve54and the second on-off valve55is switched between an open state and a closed state individually by the driving of the drive shaft73in an axial direction. A relationship between the rotational position of the first cam61, the rotational position of the second cam62, the open/closed state of the first on-off valve54, and the open/closed state of the second on-off valve55will be described later. As illustrated inFIGS.5and6, the third cam63has a cam face63A formed on its outer periphery, and the fourth cam64has a cam face64A formed on its outer periphery. The cam face63A is configured to mechanically act on a sliding surface75A of a second lever75corresponding to the third cam63, and the cam face64A is configured to mechanically act on a sliding surface75A of a second lever75corresponding to the fourth cam64(seeFIG.6). As illustrated inFIG.6, the second lever75has, for example, a shape like a letter L in a side view and is able to rotate within a predetermined angular range around its fulcrum76. By mechanically acting on the sliding surface75A of the second lever75, the third cam63causes a rod39A to change in position in an axial direction through the rotation of the third cam63. By mechanically acting on another second lever75different from the second lever75on which the third cam63is configured to mechanically act, the fourth cam64causes a rod39A to change in position in an axial direction through the rotation of the fourth cam64. The base end portion of the rod39A is each coupled to the other end portion that is the opposite of one end portion where the sliding surface75A of each second lever75is located. The change in position of the rod39A in the axial direction switches the engagement portion33A,33B (seeFIG.8) between a restriction state (lock state) for restricting the movement of the liquid container40and a non-restriction state (unlock state) for not restricting the movement of the liquid container40. A relationship between the rotational position of the third cam63, the rotational position of the fourth cam64, the state of the engagement portion33A, and the state of the engagement portion33B will be described later. As illustrated inFIG.7, the supply mechanism50includes the first supply flow passage36, which is in communication with the first on-off valve54, the second supply flow passage37, which is in communication with the second on-off valve55, and the supply flow passage35as a common passage with which the first supply flow passage36and the second supply flow passage37are in communication. Though not illustrated inFIG.7, also in a portion for supplying other kind of liquid, the first supply flow passage36, which is in communication with the first on-off valve54, the second supply flow passage37, which is in communication with the second on-off valve55, and the supply flow passage35are provided. Different kinds of liquid are supplied to the liquid ejecting head20respectively through non-illustrated tubes or the like (seeFIG.1) of the plurality of supply flow passages35. As illustrated inFIG.7, the movement restriction unit39includes the first lock mechanism391configured to restrict the movement of the first liquid container41inserted in the first slot SL1and the second lock mechanism392configured to restrict the movement of the second liquid container42inserted in the second slot SL2. As illustrated inFIG.8, an urging member39S such as a spring for urging the rod39A is provided on the head end portion of the rod39A. The first lock mechanism391shown on the upper side inFIG.8is in a restriction state. The second lock mechanism392shown on the lower side inFIG.8is in a non-restriction state (restriction-canceled state). Due to the urging force of the urging member39S, the rod39A is positioned to a restriction position, as indicated by the first lock mechanism391shown on the upper side inFIG.8. When the rod39A is located at the restriction position, the head end portion39B of the rod39A is in engagement with a restriction portion33C extending from the engagement portion33. Since the rod39A restricts the movement of the restriction portion33C, operation for moving the engagement portion33from an engagement state into a non-engagement state is restricted. That is, the user is not allowed to move the operation portion34from an engagement state, in which the liquid container40cannot be detached, into a non-engagement state, in which the liquid container40can be detached. Therefore, the user is unable to detach the liquid container40. When the second cam62or the fourth cam64pushes the second lever75, the rod39A is positioned to a restriction-canceled position against the urging force of the urging member39S, as indicated by the second lock mechanism392shown on the lower side inFIG.8. When the rod39A is located at the restriction-canceled position, the head end portion39B of the rod39A is retracted to an extent that it is not in engagement with the restriction portion33C extending from the engagement portion33. Since the rod39A does not restrict the movement of the restriction portion33C, the user is able to move (operate) the engagement portion33from an engagement state into a non-engagement state. That is, the user is able to detach the liquid container40by moving the operation portion34from an engagement state, in which the liquid container40cannot be detached, into a non-engagement state, in which the liquid container40can be detached. States of On-Off Valves and Lock Mechanisms With reference toFIG.9, three possible states based on combinations of switching of the on-off valves54and55and the lock mechanisms391and392will now be explained. As illustrated inFIG.9, the first on-off valve54switches the first supply flow passage36, which is in communication with the first liquid container41inserted in the first slot SL1, between an open state and a closed state. The second on-off valve55switches the second supply flow passage37, which is in communication with the second liquid container42inserted in the second slot SL2, between an open state and a closed state. The first lock mechanism391is switchable between a lock state, in which the movement of the first liquid container41inserted in the first slot SL1is restricted, and an unlock state, in which the movement of the first liquid container41inserted in the first slot SL1is not restricted. The second lock mechanism392is switchable between a lock state, in which the movement of the second liquid container42inserted in the second slot SL2is restricted, and an unlock state, in which the movement of the second liquid container42inserted in the second slot SL2is not restricted. As illustrated inFIG.9, based on combinations of switching of the on-off valves54and55and the lock mechanisms391and392, there are three possible states: “State 1”, “State 2”, and “State 3”. In “State 1”, the first on-off valve54is open, the second on-off valve55is closed, the first lock mechanism391is in a lock state, and the second lock mechanism392is in an unlock state. In “State 2”, the first on-off valve54is closed, the second on-off valve55is closed, the first lock mechanism391is in an unlock state, and the second lock mechanism392is in an unlock state. In “State 3”, the first on-off valve54is closed, the second on-off valve55is open, the first lock mechanism391is in an unlock state, and the second lock mechanism392is in a lock state. FIG.10illustrates the state transition of the on-off valve54and the lock mechanism391for the first slot SL1and the state transition of the on-off valve55and the lock mechanism392for the second slot SL2. The state shifts into one of “State 1”, “State 2”, and “State 3” as a result of controlling the switching of the on-off valves54and55and controlling the switching of the lock mechanisms391and392. InFIG.10, the horizontal axis represents the angle of rotation of the shaft portion65, to which the cams61to64are fixed. The control unit25controls the drive operation of the driving source53, and, as a result of this driving control, the shaft portion65rotates in a reciprocating manner within an angular range of 180° from −90° to 90°. The state is “State 1” when the angle of rotation of the shaft portion65is within a first angular range that includes −90°. The state is “State 2” when the angle of rotation of the shaft portion65is within a second angular range that includes 0°. The state is “State 3” when the angle of rotation of the shaft portion65is within a third angular range that includes 90°. In “State 1”, the first on-off valve54for the first slot SL1is in an open state, the first lock mechanism391for the first slot SL1is in a lock state, the second on-off valve55for the second slot SL2is in a closed state, and the second lock mechanism392for the second slot SL2is in an unlock state. In “State 2”, the first on-off valve54for the first slot SL1is in a closed state, the first lock mechanism391for the first slot SL1is in an unlock state, the second on-off valve55for the second slot SL2is in a closed state, and the second lock mechanism392for the second slot SL2is in an unlock state. In “State 3”, the first on-off valve54for the first slot SL1is in a closed state, the first lock mechanism391for the first slot SL1is in an unlock state, the second on-off valve55for the second slot SL2is in an open state, and the second lock mechanism392for the second slot SL2is in a lock state. In the present embodiment, switching between the states illustrated inFIG.10is performed by controlling the driving source53by the control unit25. More specifically, switching between the states is performed by controlling the angle of rotation of each of the first cam61, the second cam62, the third cam63, and the fourth cam64described above. Next, with reference toFIG.11, a relationship between the angles of rotation of the four cams61to64and the three states will now be explained.FIG.11is a graph that illustrates, for the two slots SL1and SL2, a relationship between the angles of rotation of the four cams61to64and the transition states of the on-off valves54and55and the lock mechanisms391and392. As illustrated inFIG.11, the first cam61is an eccentric cam having the cam face61A formed on its outer periphery. The second cam62is an eccentric cam having the cam face62A formed on its outer periphery. For example, the second cam62has the same size and the same shape as those of the first cam61. The phase of the second cam62is shifted from that of the first cam61by approximately 180°. The third cam63is an eccentric cam having the cam face63A formed on its outer periphery. The fourth cam64is an eccentric cam having the cam face64A formed on its outer periphery. For example, the fourth cam64has the same size and the same shape as those of the third cam63. The phase of the fourth cam64is shifted from that of the third cam63by approximately 90°. With this structure, in State 1, the first on-off valve54is opened because the first cam61pushes the first lever71, and the second on-off valve55is closed because the second cam62does not push the first lever71. Moreover, in “State 1”, the first lock mechanism391is locked because the third cam63does not push the second lever75, and the second lock mechanism392is unlocked because the fourth cam64pushes the second lever75. In State 2, the first on-off valve54is closed because the first cam61does not push the first lever71, and the second on-off valve55is closed because the second cam62does not push the first lever71. Moreover, in “State 2”, the first lock mechanism391is unlocked because the third cam63pushes the second lever75, and the second lock mechanism392is unlocked because the fourth cam64pushes the second lever75. In State 3, the first on-off valve54is closed because the first cam61does not push the first lever71, and the second on-off valve55is opened because the second cam62pushes the first lever71. Moreover, in “State 3”, the first lock mechanism391is unlocked because the third cam63pushes the second lever75, and the second lock mechanism392is locked because the fourth cam64does not push the second lever75. Operational Effects of Embodiment Next, the operational effects of the liquid ejecting apparatus11and the liquid supplying apparatus30will now be explained. With reference toFIGS.1to12, an example of liquid supply control processing performed by the control unit25will now be explained. The control unit25according to the present embodiment performs the liquid supply control processing of controlling the liquid supplying apparatus30. The liquid supply control processing includes controlling print operation of printing an image or a text on the medium14and controlling maintenance operation of discharging liquid from the liquid ejecting head20forcibly. The user gives instructions for print operation by operating the operation panel24or operating the input unit of the host apparatus80. The user gives instructions for maintenance on the liquid ejecting head20by operating the operation panel24or operating the input unit of the host apparatus80. The maintenance operation includes cleaning operation. The control unit25includes a management unit configured to manage the time that has elapsed from the last maintenance execution and the number of sheets that have been printed since the last maintenance execution. If either one of the elapsed time and the number of sheets exceeds the corresponding threshold, the control unit25receives instructions for maintenance operation from the management unit. With reference toFIG.12, the liquid supply control processing performed by the control unit25will now be explained. In a step S11, the control unit25determines whether or not instructions for liquid-consuming operation are received. The liquid-consuming operation is operation involving the consumption of liquid (for example, ink) by the liquid ejecting head20. In this example, the liquid-consuming operation includes print operation and maintenance operation. Accordingly, in this step, the control unit25determines whether or not instructions for print operation or instructions for maintenance operation are received. The process proceeds to a step S12if instructions for liquid-consuming operation are received. If not, the process is in waiting state until the instructions are received. In a step S12, the control unit25opens the one, of the two on-off valves, corresponding to the liquid container that is to be used. The control unit25has acquired use information for every liquid container40and information about the amount of liquid left therein. The use information is information for recognizing whether or not the liquid container40is currently used (active for use). When the currently-active one of the first liquid container41and the second liquid container42runs out of the liquid (for example, “ink end”), the use of the other such as brand-new one is started, and use information indicating that the other, the use-started brand-new one, is currently used is created. The timing of switching the one, of the first liquid container41and the second liquid container42, that is to be used to the other, the brand-new one, can be set at design discretion. The timing of this switching is not limited to the timing of running out of the liquid (for example, “ink end”). This switching may be performed when the liquid left will be empty soon (“near end”) or at any other timing of reaching a predetermined remaining amount. In the step S12, for example, if the first liquid container41is to be used, the control unit25opens the first on-off valve54only, which corresponds to the first liquid container41. The second on-off valve55remains closed when the first on-off valve54is opened. If, for example, the second liquid container42is to be used, the control unit25opens the second on-off valve55only, which corresponds to the second liquid container42. The first on-off valve54remains closed when the second on-off valve55is opened. In a step S13, the control unit25restricts the movement of the liquid container that is active for use. By controlling the movement restriction unit39, the control unit25restricts the movement of the one, of the first liquid container41and the second liquid container42, determined to be active for use. That is, if the liquid container that is active for use is the first liquid container41, the control unit25restricts the movement of the first liquid container41only, by the locking of the first lock mechanism391and the unlocking of the second lock mechanism392. If the liquid container that is active for use is the second liquid container42, the control unit25restricts the movement of the second liquid container42only, by the unlocking of the first lock mechanism391and the locking of the second lock mechanism392. In this way, the movement of the liquid container40that is currently in communication with the supply flow passage35is restricted by the movement restriction unit39. The processing in the step S13corresponds to “restricting the movement of the liquid container40that is currently in communication with the supply flow passage35is restricted by the movement restriction unit39.” In the present embodiment, the control unit25executes the processing in the step S12and the processing in the step S13by controlling the driving source53to put the four cams61to64into “State 1” or “State 3” (seeFIGS.10and11for both). More specifically, the four cams61to64are in “State 1” when the first liquid container41is currently used. In “State 1”, the first on-off valve54is open, and the second on-off valve55is closed. In addition, in “State 1”, the first lock mechanism391is in a lock state, and the second lock mechanism392is in an unlock state. Therefore, the user is unable to operate the first operation portion34A from an engagement state to a non-engagement state while the liquid-consuming operation is performed. For this reason, the first liquid container41, which is currently used, is not detachable during the liquid-consuming operation. On the other hand, the second liquid container42, which is not currently used, is detachable during the liquid-consuming operation. The four cams61to64are in “State 3” when the second liquid container42is currently used. In “State 3”, the first on-off valve54is closed, and the second on-off valve55is open. In addition, in “State 3”, the first lock mechanism391is in an unlock state, and the second lock mechanism392is in a lock state. Therefore, the user is unable to operate the second operation portion34B from an engagement state to a non-engagement state while the liquid-consuming operation is performed. For this reason, the second liquid container42, which is currently used, is not detachable during the liquid-consuming operation. On the other hand, the first liquid container41, which is not currently used, is detachable during the liquid-consuming operation. In a step S14, the control unit25causes the apparatus to perform liquid-consuming operation. The liquid-consuming operation includes print operation and maintenance operation. If the instructions for liquid-consuming operation are print instructions, the control unit25causes the apparatus to perform print operation. If the instructions for liquid-consuming operation are maintenance instructions, the control unit25causes the apparatus to perform maintenance operation. Upon completion of the liquid-consuming operation, the control unit25advances the process to a step S15. The processing in the step S14corresponds to “performing the operation involving liquid consumption”. If the first liquid container41is currently used while the liquid-consuming operation is performed, the user is unable to operate the first operation portion34A, which corresponds to the first liquid container41, into a non-engagement state. If the second liquid container42is currently used while the liquid-consuming operation is performed, the user is unable to operate the second operation portion34B, which corresponds to the second liquid container42, into a non-engagement state. This makes it possible to prevent a print failure or a maintenance failure from occurring due to the removal of the liquid container40that is currently used while the print operation or the maintenance operation is performed. In the step S15, the control unit25closes the first on-off valve54and the second on-off valve55. That is, the control unit25controls the switching unit38to put the apparatus into a state in which neither of the first supply flow passage36and the second supply flow passage37is in communication with the supply flow passage35. More specifically, the control unit25closes both the first on-off valve54and the second on-off valve55by controlling the driving source53to put the first cam61and the second cam62into “State 2” (seeFIGS.10and11). Therefore, when no liquid-consuming operation is performed, the first supply flow passage36configured to be in communication with the first liquid container41is closed, and the second supply flow passage37configured to be in communication with the second liquid container42is closed. Consequently, neither of the first supply flow passage36and the second supply flow passage37is in communication with the supply flow passage35. The processing in the step S15corresponds to “after the operation is performed, performing switching to a state in which neither of the first supply flow passage36and the second supply flow passage37is in communication with the supply flow passage35by the switching unit38.” In a step S16, the control unit25puts the two liquid containers41and42into a non-restricted state. That is, the control unit25controls the movement restriction unit39to perform restriction cancellation such that the movement of the first liquid container41is not restricted and the movement of the second liquid container42is also not restricted. More specifically, the control unit25puts the first lock mechanism391into an unlock state in which the first engagement portion33A is not locked in an engagement state and puts the second lock mechanism392into an unlock state in which the second engagement portion33B is not locked in an engagement state, by controlling the driving source53to put the third cam63and the fourth cam64into “State 2” (seeFIGS.10and11). Therefore, when no liquid-consuming operation is performed, both the first liquid container41and the second liquid container42are detachable by operating the operation portion34by the user. As explained here, during the period of non-execution of liquid-consuming operation, in which a print failure or a maintenance failure could never happen, both the first liquid container41and the second liquid container42are detachable by the user. The processing in the step S16corresponds to “after the operation is performed, performing restriction cancellation such that neither of the movement of the first liquid container41and the movement of the second liquid container42is restricted by the movement restriction unit39.” In the present embodiment, the control unit25executes the processing in the step S15and the processing in the step S16by controlling the driving source53to put the four cams61to64into “State 2” (seeFIGS.10and11). In “State 2”, both the first on-off valve54and the second on-off valve55are closed, and both the first lock mechanism391and the second lock mechanism392are in an unlock state. Therefore, when no liquid-consuming operation is performed, both the first liquid container41and the second liquid container42are detachable by operating the operation portion34by the user. In the first embodiment, a control method that includes the following first, second, and third steps is implemented by performing the liquid supply control processing by the control unit25. First Step When instructions for operation involving liquid consumption (instructions for liquid-consuming operation) are received, the following processing is performed. Either the first supply flow passage36or the second supply flow passage37is brought into communication with the supply flow passage35by the switching unit38. In addition, the movement of the liquid container40that is currently in communication with the supply flow passage35is restricted by the movement restriction unit39. The first step described here corresponds to the processing in the steps S12and S13illustrated inFIG.12. Second Step The operation involving liquid consumption is performed. That is, the liquid-consuming operation, in which the liquid ejecting head20consumes liquid, is performed. The second step described here corresponds to the processing in the step S14illustrated inFIG.12. Third Step After the liquid-consuming operation is performed, switching to a state in which neither of the first supply flow passage36and the second supply flow passage37is in communication with the supply flow passage35is performed by the switching unit38, and restriction cancellation is performed such that neither of the movement of the first liquid container41and the movement of the second liquid container42is restricted by the movement restriction unit39. The third step described here corresponds to the processing in the steps S15and S16illustrated inFIG.12. Therefore, it is possible to prevent printing from being interrupted by the removal of the liquid container40that is currently used by operating the operation portion34by the user during print operation. Therefore, it is possible to prevent wasteful consumption of the medium14caused by a print failure due to the interruption, and prevent wasteful consumption of liquid such as ink due to redoing printing. In addition, it is possible to prevent maintenance from being interrupted by the removal of the liquid container40that is currently used by operating the operation portion34by the user during maintenance operation. Therefore, it is possible to prevent wasteful consumption of liquid such as ink due to redoing the interrupted maintenance. Moreover, in the present embodiment, the removal of the liquid container40that is currently used during print operation or during maintenance operation is prevented by mechanical locking. For example, it is possible to design and provide a configuration in which firmware troubleshoots an error in a case where the error occurs due to the removal of the liquid container40that is currently used during print operation or during maintenance operation. However, if such a configuration is adopted, the firmware needs to be capable of troubleshooting every predictable kind of error. This will make the firmware complex. Moreover, there is a risk of some omissions in error troubleshooting. Since the configuration of the present embodiment mechanically locks the liquid container40that is currently used so that it cannot be removed, it is possible to avoid the firmware from becoming complex and avoid omissions in error troubleshooting, and so forth. Therefore, the firmware will not be complex, and such an error caused by the removal of the liquid container40that is currently used will not occur. As described in detail above, the following effects can be obtained from the present embodiment.(1-1) The liquid supplying apparatus30includes: the supply flow passage35that is in communication with the liquid ejecting head20configured to eject liquid; the first supply flow passage36for communication between the first liquid container41and the supply flow passage35, the first liquid container41containing liquid; and the second supply flow passage37for communication between the second liquid container42and the supply flow passage35, the second liquid container42containing the same kind of liquid as the liquid contained in the first liquid container41. The liquid supplying apparatus30further includes: the switching unit38configured to switch a flow passage that is in communication with the supply flow passage35, between the first supply flow passage36and the second supply flow passage37; and the movement restriction unit39configured to, linked with switching by the switching unit38, restrict movement of the first liquid container41and the second liquid container42selectively. With this configuration, it is possible to restrict the movement of the liquid container40that is in communication with the liquid ejecting head20and not restrict the movement of the liquid container40that is not in communication with the liquid ejecting head20. Therefore, it is possible to prevent the liquid container40that is currently used from being removed by mistake.(1-2) When the switching unit38causes the first supply flow passage36to be in communication with the supply flow passage35, the movement restriction unit39restricts the movement of the first liquid container41. When the switching unit38causes the second supply flow passage37to be in communication with the supply flow passage35, the movement restriction unit39restricts the movement of the second liquid container42. With this configuration, it is possible to prevent the liquid container40that is currently used from being removed by mistake.(1-3) The switching unit38includes the first on-off valve54for opening and closing the first supply flow passage36, the second on-off valve55for opening and closing the second supply flow passage37, and the first driving mechanism51for switching between opening and closing of the first on-off valve54and the second on-off valve55. The movement restriction unit39includes the first engagement portion33A configured to be engaged with the first liquid container41, the second engagement portion33B configured to be engaged with the second liquid container42, and the second driving mechanism52configured to perform selective switching for each of the first engagement portion33A and the second engagement portion33B between a restriction state, in which the movement is restricted, and a non-restriction state, in which the movement is not restricted. The liquid supplying apparatus30includes the driving source53configured to drive the first driving mechanism51and the second driving mechanism52. This configuration makes it possible to, just with a single driving source53, switch the opening/closing of the on-off valve54,55and switch the engagement portion33A,33B between the restriction state and the non-restriction state. Therefore, it is possible to simplify the configuration of the liquid supplying apparatus30.(1-4) The first engagement portion33A includes the first operation portion34A operable by a user for disengagement from a state of engagement with the first liquid container41. The second engagement portion33B includes the second operation portion34B operable by the user for disengagement from a state of engagement with the second liquid container42. The second driving mechanism52is configured to perform selective switching for each of the first operation portion34A and the second operation portion34B between a restriction state, in which the disengagement from the state of engagement is restricted, and a non-restriction state, in which the disengagement from the state of engagement is not restricted. In this configuration, operation of the first operation portion34A is restricted when the first liquid container41is currently used, and operation of the second operation portion34B is restricted when the second liquid container42is currently used. On condition that operation of the operation portion34is not restricted, the user is able to disengage the liquid container40by operating the operation portion34when the user wants to.(1-5) The switching unit38includes the first on-off valve54for opening and closing the first supply flow passage36, the second on-off valve55for opening and closing the second supply flow passage37, and the first driving mechanism51for switching between opening and closing of the first on-off valve54and the second on-off valve55. The movement restriction unit39includes the first engagement portion33A configured to be engaged with the first liquid container41, the second engagement portion33B configured to be engaged with the second liquid container42, and the second driving mechanism52configured to perform selective switching for each of the first engagement portion33A and the second engagement portion33B between an engagement state and a non-engagement state. The liquid supplying apparatus30includes the driving source53configured to drive the first driving mechanism51and the second driving mechanism52. This configuration makes it possible to, just with a single driving source53, switch the opening/closing of the first on-off valve54and the second on-off valve55and switch the engagement of the first engagement portion33A and the second engagement portion33B with the liquid container40between the engagement state and the non-engagement state. Therefore, it is possible to simplify the configuration of the liquid supplying apparatus30.(1-6) The first driving mechanism51includes the first cam61mounted on the shaft portion65and configured to switch the first on-off valve54between an open state and a closed state, the shaft portion65being configured to rotate when driven indirectly by and in synchronization with driving by the driving source53, and further includes the second cam62mounted on the shaft portion65and configured to switch the second on-off valve55between an open state and a closed state. The second driving mechanism52includes the third cam63mounted on the shaft portion65and configured to switch the state of the first engagement portion33A, and further includes the fourth cam64mounted on the shaft portion65and configured to switch the state of the second engagement portion33B. This configuration realizes the switching of all of the first on-off valve54, the second on-off valve55, the first engagement portion33A, and the second engagement portion33B just by rotating the shaft portion65serving as a common shaft on which the first cam61, the second cam62, the third cam63, and the fourth cam64are mounted. Therefore, it is possible to simplify the configuration of the liquid supplying apparatus30.(1-7) The liquid ejecting apparatus11includes: the liquid ejecting head20configured to eject liquid; the liquid supplying apparatus30; and the control unit25that controls the switching unit38and the movement restriction unit39. The liquid ejecting apparatus11having this configuration produces the same effects as those of the liquid supplying apparatus.(1-8) When an amount of the liquid left in movement-restricted one of the liquid containers40, the movement-restricted one being the one whose movement is restricted by the movement restriction unit39, becomes smaller than a predetermined threshold, the control unit25switches the flow passage that is in communication with the supply flow passage35, and cancels restriction on the movement-restricted one of the liquid containers40and causes the movement restriction unit39to restrict the movement of an other of the liquid containers40. With this configuration, if the amount of the liquid left in the liquid container40that is currently used becomes smaller than the predetermined threshold, the liquid container40that is in communication with the liquid ejecting head20is automatically switched from the one, namely, the liquid container40that has currently been used, to the other of the liquid containers40. Such automatic switching makes it possible to suppress the use of the liquid container40having a low remaining-liquid level. Moreover, it is possible to continue liquid-consuming operation without interruption even when the amount of the liquid left in the liquid container40that is currently used has become small.(1-9) When non-restricted one of the liquid containers40, the non-restricted one being the one whose movement is not restricted by the movement restriction unit39, is replaced with a new liquid container40, the control unit25switches the flow passage that is in communication with the supply flow passage35. In addition to switching the flow passage that is in communication with the supply flow passage35, the control unit25cancels the restriction on the movement of the other of the liquid containers40and causes the movement restriction unit39to restrict the movement of the new liquid container40. With this configuration, the liquid contained in of the new liquid container40is always used first. Therefore, it is possible to continue liquid-consuming operation without interruption.(1-10) Another disclosed aspect is a method for controlling the liquid ejecting apparatus11that includes the liquid ejecting head20, the supply flow passage35, the first supply flow passage36, the second supply flow passage37, the switching unit38, and the movement restriction unit39. The control method includes the following first, second, and third steps. In the first step, when instructions for operation involving liquid consumption are received, either the first supply flow passage36or the second supply flow passage37is brought into communication with the supply flow passage35by the switching unit38, and, in addition, the movement of the liquid container40that is currently in communication with the supply flow passage35is restricted by the movement restriction unit39(steps S12and S13). In the second step, the operation involving liquid consumption is performed (step S14). In the third step, after this operation is performed, switching to a state in which neither of the first supply flow passage36and the second supply flow passage37is in communication with the supply flow passage35is performed by the switching unit38, and restriction cancellation is performed such that neither of the movement of the first liquid container41and the movement of the second liquid container42is restricted by the movement restriction unit39(steps S15and S16). With this control method, it is possible to prevent the liquid container40from being removed by mistake while the operation involving liquid consumption is performed. Second Embodiment In the first embodiment described above, the movement of the currently-active one of the first liquid container41and the second liquid container42is restricted while liquid-consuming operation is performed. In a second embodiment, this movement is restricted while the power of the liquid ejecting apparatus11is ON. The user turns the power of the liquid ejecting apparatus11ON by operating a power operation portion (not illustrated) of the operation panel24. When the liquid ejecting apparatus11is powered ON, the control unit25is activated. Upon activation, the control unit25runs a program illustrated by the flowchart inFIG.13. With reference toFIG.13, the liquid supply control processing performed by the control unit25will now be explained. First, in a step S21, the control unit25determines whether the power is turned ON or not. If the power is turned ON, the process proceeds to a step S22. In steps S22and S23, the control unit25performs the same processing as the processing performed in the steps S12and S13of the first embodiment. In the step S22, the control unit25opens the one, of the two on-off valves, corresponding to the liquid container that is to be used. The control unit25identifies the liquid container40that is to be used (currently used) by acquiring, for every liquid container40, use information and information about the amount of liquid left therein. Then, the control unit25opens the one, of the two on-off valves, corresponding to the one, of the first liquid container41and the second liquid container42, identified as the liquid container that is to be used. For example, if the first liquid container41is to be used, the control unit25opens the first on-off valve54only. The second on-off valve55remains closed when the first on-off valve54is opened. If the second liquid container42is to be used, the control unit25opens the second on-off valve55only. The first on-off valve54remains closed when the second on-off valve55is opened. In the step S23, the control unit25restricts the movement of the liquid container that is active for use. By controlling the movement restriction unit39, the control unit25restricts the movement of the one, of the first liquid container41and the second liquid container42, determined to be active for use. That is, if the liquid container that is active for use is the first liquid container41, the control unit25restricts the movement of the first liquid container41only, by the locking of the first lock mechanism391and the unlocking of the second lock mechanism392. If the liquid container that is active for use is the second liquid container42, the control unit25restricts the movement of the second liquid container42only, by the unlocking of the first lock mechanism391and the locking of the second lock mechanism392. In the present embodiment, the control unit25executes the processing in the step S22and the processing in the step S23by controlling the driving source53to put the four cams61to64into “State 1” or “State 3” (seeFIGS.10and11for both). The processing in the steps S22and S23corresponds to “when the liquid ejecting apparatus is powered on, bringing either the first supply flow passage36or the second supply flow passage37into communication with the supply flow passage35by the switching unit38, and restricting the movement of the liquid container that is currently in communication with the supply flow passage35by the movement restriction unit39.” Next, in a step S24, the control unit25determines whether or not instructions for turning the power OFF are received. If the instructions for turning the power OFF are received, the process proceeds to a step S25. In steps S25and S26, the control unit25performs the same processing as the processing performed in the steps S15and S16of the first embodiment. In the step S25, the control unit25closes the first on-off valve54and the second on-off valve55. That is, the control unit25controls the switching unit38to put the apparatus into a state in which neither of the first supply flow passage36and the second supply flow passage37is in communication with the supply flow passage35. More specifically, the control unit25closes both the first on-off valve54and the second on-off valve55by controlling the driving source53to put the first cam61and the second cam62into “State 2” (seeFIGS.10and11). Therefore, in a power-OFF state, the first supply flow passage36configured to be in communication with the first liquid container41is closed, and the second supply flow passage37configured to be in communication with the second liquid container42is closed. Consequently, neither of the first supply flow passage36and the second supply flow passage37is in communication with the supply flow passage35. In the step S26, the control unit25puts the two liquid containers41and42into a non-restricted state. That is, the control unit25controls the movement restriction unit39to perform restriction cancellation such that the movement of the first liquid container41is not restricted and the movement of the second liquid container42is also not restricted. More specifically, the control unit25puts the first lock mechanism391into an unlock state in which the first engagement portion33A is not locked in an engagement state and puts the second lock mechanism392into an unlock state in which the second engagement portion33B is not locked in an engagement state, by controlling the driving source53to put the third cam63and the fourth cam64into “State 2” (seeFIGS.10and11). Therefore, in a power-OFF state, both the first liquid container41and the second liquid container42are detachable by operating the operation portion34by the user. As explained here, in a power-OFF state, in which a print failure or a maintenance failure could never happen, both the first liquid container41and the second liquid container42are detachable by the user. The processing in the steps S25and S26corresponds to “when instructions for turning the power off are received, performing switching to a state in which neither of the first supply flow passage36and the second supply flow passage37is in communication with the supply flow passage35by the switching unit38, and performing restriction cancellation such that neither of the movement of the first liquid container41and the movement of the second liquid container42is restricted by the movement restriction unit39.” In the second embodiment, a control method that includes the following fourth and fifth steps is implemented by performing the liquid supply control processing by the control unit25. Fourth Step When the liquid ejecting apparatus is powered on, either the first supply flow passage36or the second supply flow passage37is brought into communication with the supply flow passage35by the switching unit38, and the movement of the liquid container40that is currently in communication with the supply flow passage35is restricted by the movement restriction unit39. The fourth step described here corresponds to the processing in the steps S22and S23illustrated inFIG.13. Fifth Step When instructions for turning the power off are received, switching to a state in which neither of the first supply flow passage36and the second supply flow passage37is in communication with the supply flow passage35is performed by the switching unit38, and restriction cancellation is performed such that neither of the movement of the first liquid container41and the movement of the second liquid container42is restricted by the movement restriction unit39. The fifth step described here corresponds to the processing in the steps S25and S26illustrated inFIG.13. In addition to the same effects as the effects (1-1) to (1-9) of the first embodiment, the following effect can be obtained from the second embodiment.(2-1) Still another disclosed aspect is a method for controlling the liquid ejecting apparatus11that includes the liquid ejecting head20, the supply flow passage35, the first supply flow passage36, the second supply flow passage37, the switching unit38, and the movement restriction unit39. The control method includes the following fourth and fifth steps. In the fourth step, when the liquid ejecting apparatus is powered on, either the first supply flow passage36or the second supply flow passage37is brought into communication with the supply flow passage35by the switching unit38, and, in addition, the movement of the liquid container40that is currently in communication with the supply flow passage35is restricted by the movement restriction unit39(steps S22and S23). In the fifth step, when instructions for turning the power off are received, switching to a state in which neither of the first supply flow passage36and the second supply flow passage37is in communication with the supply flow passage35is performed by the switching unit38, and restriction cancellation is performed such that neither of the movement of the first liquid container41and the movement of the second liquid container42is restricted by the movement restriction unit39(steps S25and S26). With this control method, it is possible to prevent the liquid container40that is currently used from being removed by mistake while the power is ON. Moreover, it is possible to detach the liquid container40for replacement while the power is OFF. Third Embodiment In the first embodiment described earlier, the movement restriction unit39restricts the movement of the liquid container40that is currently used by locking the engagement portion33having the operation portion34and by, by the locking, not allowing the user to perform disengaging operation of the operation portion34. By contrast, the engagement portion33according to a third embodiment does not have the operation portion34. That is, the engagement portion33according to the present embodiment is not configured to be operated by the user. The movement restriction unit39according to the present embodiment causes the driving source53to perform driving to put the engagement portion33into an engagement state, in which the engagement portion33is in engagement with the liquid container40, or a non-engagement state, in which the engagement portion33is not in engagement therewith. The movement of the liquid container40that is currently used is restricted (locked) by moving the engagement portion33to a position corresponding to the engagement state (engagement position) by the driving source53. The movement of the liquid container40that is not currently used is not restricted (not locked) because the driving source53moves the engagement portion33to a position corresponding to the non-engagement state (non-engagement position). Accordingly, of the first liquid container41inserted in the first slot SL1of the mounting unit31and the second liquid container42inserted in the second slot SL2thereof, the one that is active for use is restricted, and the other, which is not active for use, is not restricted. The third embodiment described here has a configuration obtained by eliminating the operation portion34fromFIG.4. The other basic configuration of the third embodiment is the same as the configuration of the first and second embodiments. Therefore, with reference toFIG.4, etc., an explanation will be given below with a focus on the difference. Another point of difference from the first and second embodiments is that the engagement portion33is able to move between the engagement state and the non-engagement state due to driving via the rod39A by the driving source53. As illustrated inFIG.4, the switching unit38includes the first on-off valve54for opening and closing the first supply flow passage36, the second on-off valve55for opening and closing the second supply flow passage37, and the first driving mechanism51for switching between opening and closing of the first on-off valve54and the second on-off valve55. The movement restriction unit39includes the first engagement portion33A and the second engagement portion33B. The first engagement portion33A is configured to be engaged with the first liquid container41. The second engagement portion33B is configured to be engaged with the second liquid container42. The movement restriction unit39further includes the second driving mechanism52for selective switching between the engagement state and the non-engagement state of the first engagement portion33A and the second engagement portion33B. The liquid supplying apparatus30includes the driving source53configured to drive the first driving mechanism51and the second driving mechanism52. For example, the engagement portion33is urged in a direction of going from the engagement state toward the non-engagement state (restriction-canceling direction). More specifically, the engagement portion33is urged in the restriction-canceling direction by an urging member such as a spring. Driven by the motive power of the driving source53via the second driving mechanism52, the engagement portion33is positioned from the non-engagement state into the engagement state against the urging force of the urging member, thereby coming into engagement with the liquid container40. The positioning of the engagement portion33into the engagement state restricts the movement of the liquid container40. That is, the liquid container40is locked such that it cannot be detached from the mounting unit31. Similarly to the first and second embodiments, also in the third embodiment, linked with switching by the switching unit38, the movement restriction unit39restricts the movement of the first liquid container41and the second liquid container42selectively. When the switching unit38causes the first supply flow passage36to be in communication with the supply flow passage35, the movement restriction unit39restricts the movement of the first liquid container41. When the switching unit38causes the second supply flow passage37to be in communication with the supply flow passage35, the movement restriction unit39restricts the movement of the second liquid container42. More specifically, when the switching unit38causes the first supply flow passage36to be in communication with the supply flow passage35, the third cam63and the fourth cam64driven by the driving source53are in “State 1” (seeFIG.11). In “State 1”, since the rod39A pushes the first engagement portion33A into the engagement position, the first engagement portion33A is in engagement with the first liquid container41. Consequently, the movement of the first liquid container41inserted in the first slot SL1is restricted. Therefore, the user is unable to detach the first liquid container41. When the switching unit38causes the second supply flow passage37to be in communication with the supply flow passage35, the third cam63and the fourth cam64driven by the driving source53are in “State 3” (seeFIG.11). In “State 3”, since the rod39A pulls the engagement portion33back into the non-engagement position, the second engagement portion33B is not in engagement with the second liquid container42. Consequently, the movement of the second liquid container42inserted in the second slot SL2is restricted. Therefore, the user is unable to detach the second liquid container42. To realize the operation of the engagement portion33A,33B described above, the structure in the present embodiment is different from the structure in the first and second embodiments illustrated inFIG.8. Specifically, the restriction portion33C has a sloped surface (not illustrated) with which the head end portion39B of the rod39A is able to come into contact in the process of advancement of the rod39A due to the urging force of the urging member39S as illustrated in the upper part ofFIG.8. The head end portion39B of the rod39A pushes the engagement portion33from the non-engagement position into the engagement position via the sloped surface in the process of advancement of the rod39A due to the urging force of the urging member39S, and, as a result of this pushing, the engagement portion33comes into engagement with the liquid container40. On the other hand, since the head end portion39B of the rod39A loses the force of pushing the engagement portion33via the sloped surface in the process of retraction of the rod39A against the urging force of the urging member39S, the engagement portion33is pulled back from the engagement position into the non-engagement position due to the urging force of an urging member such as a spring that is not illustrated. This puts the engagement portion33into the state of not being in engagement with the liquid container40. The same effects as the effects (1-1) to (1-9) of the first embodiment and the effect (2-1) to (1-9) of the second embodiment can be obtained from the third embodiment. The exemplary embodiments described above may be modified as described in modification examples below. Any of the exemplary embodiments described above may be combined with any of the modification examples described below to produce another modification example. Any two or more of the modification examples described below may be combined together to produce another modification example. The four cams61to64may be fixed to different shafts65configured to rotate by receiving the motive power of the driving source53. When modified so, two of the four cams61to64may be fixed to a common shaft65, and the remaining two of them may be fixed to another common shaft65. Alternatively, the four cams61to64may be fixed to respective different shafts65. The liquid supplying apparatus30may include a plurality of driving sources53for driving the four cams61to64. When modified so, two of the four cams61to64may be driven by a common driving source53, and the remaining two of them may be driven by another common driving source53. Alternatively, the four cams61to64may be driven individually by respective different driving sources53. The four cams61to64are not limited to eccentric cams, which are rotational-type plane cams. The four cams61to64may be plane cams or three-dimensional cams. When the four cams61to64are plane cams, they may be other rotational-type cams or translation-type cams. The four cams61to64may be mutually different types of cams. The four cams61to64may be a mixture of plane cams and three-dimensional cams. Examples of other rotational-type cam are: plate cam, face grooved cam, and face rib cam. Examples of translation-type cam are: translating cam, translating grooved cam, and translating rib cam. Examples of three-dimensional cam are: cylindrical cam, conical cam, convex globoidal cam, and concave globoidal cam. The number of the cams is not limited to four. The two on-off valves54and55and the two lock mechanisms391and392may be switched by two cams. For example, two first levers71for switching the two on-off valves54and55respectively may be driven via one common cam. For example, two second levers75for switching the two lock mechanisms391and392respectively may be driven via another one common cam. Although it has been described that the movement of one of two liquid containers40containing the same kind of liquid is restricted, the movement of one of three liquid containers40containing the same kind of liquid may be restricted. The bottom line is, it is sufficient as long as the movement of the currently-active one of a plurality of liquid containers40including the first liquid container41and the second liquid container42containing the same kind of liquid is restricted. The mounting unit31may be equipped with, for each of its slots individually, a cover by which the liquid container40inserted in the slot is covered. The movement of the currently-active one of the liquid containers40may be restricted by locking, by the movement restriction unit39, the cover by which the currently-active one of the two liquid containers41and42containing the same kind of liquid is covered. For example, when the driving source53is driven, the one of the engagement portions33corresponding to the currently-active one of the liquid containers40is put into a state of being in engagement with the cover by which the currently-active one of the liquid containers40is covered. In addition, the other of the engagement portions33corresponding to the currently-inactive one of the liquid containers40is put into a state of being not in engagement with the cover by which the currently-inactive one of the liquid containers40is covered. The engagement portion33may be a snap-fit that is able to be engaged with the liquid container40. More specifically, the first engagement portion33A may be a first snap-fit that is able to be engaged with the first liquid container41, and the second engagement portion33B may be a second snap-fit that is able to be engaged with the second liquid container42. When the first liquid container41is inserted into the first slot SL1, the first snap-fit comes into engagement with the first liquid container41, thereby restricting the movement of the first liquid container41. When the second liquid container42is inserted into the second slot SL2, the second snap-fit comes into engagement with the second liquid container42, thereby restricting the movement of the second liquid container42. The engagement with the snap-fit restricts the movement of the currently-active one of the first liquid container41and the second liquid container42while the liquid-consuming operation is performed. The other, namely, the currently-inactive one, is not in engagement with the snap-fit. Disengagement from the snap-fit is performed by moving the engagement pin of the snap-fit in a direction of disengagement from the liquid container40by utilizing motive power exerted when the control unit25causes the driving source53to perform driving. The switching of the switching unit38and the movement restriction unit39may be performed between State 1 and State 3 only, without including State 2. If a transportation scheme of transporting a cut-sheet medium14or the like is used, the transportation unit23may include a medium-containing portion such as a cassette in which sheets of the medium14are to be contained, a feeding unit configured to feed the medium14from the medium-containing portion, and transportation rollers configured to transport the medium14fed therefrom. The transportation unit23may include a tray on which the medium14is to be placed, a feeding unit configured to feed the medium14placed on the tray, and transportation rollers configured to transport, toward a recording position, the medium14fed therefrom. The liquid is not limited to ink. For example, the liquid may be cleaning/washing liquid, pre-treatment liquid, or post-treatment liquid. The medium14is not limited to paper such as roll paper or cut-sheet paper. For example, the medium14may be a plastic sheet/film, a metal sheet/film, a laminate sheet/film, or a ceramic sheet/film. | 109,506 |
11858279 | DESCRIPTION OF EXEMPLARY EMBODIMENTS 1. First Embodiment First, a configuration of a recording device1is described. The recording device1of this example is, for example, an ink-jet printer. In each drawing, the direction along the X axis is the depth direction of the recording device1, the direction along the Y axis is the width direction of the recording device1, and the direction along the Z axis is the height direction of the recording device1. In this embodiment, the −X direction side of the recording device1is the device front side, and the +X direction side is the device back side. As illustrated inFIG.1, the recording device1of this embodiment is configured as a multifunctional device including a device main body2and a scanner unit3. The device main body2includes a plurality of medium housing cassettes4that house a medium P. Each medium housing cassette4is detachably attached from the device front side of the device main body2. The medium P is, for example, a sheet such as plain paper, thick paper, and a photograph sheet. In the device height direction in the device main body2, a sheet ejection unit7that ejects the medium P on which recording has been performed by a line head9(FIG.2) serving as a recording unit that performs recording by discharging ink, which is an example of liquid, and a medium placing part5where the medium P ejected from the sheet ejection unit7is placed are provided between the scanner unit3and the medium housing cassette4. In addition, an operation unit6is provided on the device front side of the device main body2. The operation unit6is provided with a display member such as a liquid crystal panel. Instructions of a recording operation and an image reading operation can be input to the recording device1by operating the operation unit6. Next, a conveyance path11of the medium P in the recording device1is described. As illustrated inFIG.2, the recording device1includes the conveyance path11of the medium P. The conveyance path11includes a feed path14that sends the medium P picked up from the medium housing cassette4, a straight path12coupled to the feed path14and including a recording region A of the line head9(seeFIG.3A), and a face-down ejection path13that sends the medium P from the straight path12to the sheet ejection unit7. The medium P is conveyed along the conveyance path11by a medium conveyance unit10(a feed roller17, a separation roller pair18, a registration roller19, a belt conveyance unit20, and a conveyance roller pair42). Conveyance of the medium P from the medium housing cassette4to the sheet ejection unit7is described below. Note that the recording device1includes a switchback path15branched off from the straight path12on the downstream side of the line head9, and an inversion path16coupled to the switchback path15. The inversion path16inverts the first surface (front surface) and the second surface (rear surface) of the medium P and then returns the medium P to the straight path12. The recording device1is configured to enable so-called double-sided recording in which after recording on the first surface of the medium P is performed, recording is performed on the second surface. The description of the inversion of the medium P at the switchback path15and the inversion path16is omitted. At the feed path14, the feed roller17and the separation roller pair18that separates a plurality of mediums P into single sheet are provided in this order along the conveyance direction of the medium P. The feed roller17is configured to be driven into rotation by a driving source not illustrated in the drawing. In addition, the separation roller pair18is also called retard roller, and includes a driving roller18athat sends the medium P toward the straight path12, and a driven roller18bthat separates the medium P by nipping the medium P together with the driving roller18a. Of the plurality of mediums P housed in the medium housing cassette4, the topmost medium P is picked up by the feed roller17and conveyed downstream in the conveyance direction. At this time, the next and subsequent media P may also be conveyed together with the topmost medium P in some situation, but the topmost medium P and the next and subsequent media P are separated by the separation roller pair18such that only the topmost medium P is sent to the feed path14. The registration roller19is provided downstream of the separation roller pair18in the conveyance direction. The feed path14and the straight path12are coupled at the position of the registration roller19. The straight path12is configured as a linearly extending path, and the registration roller19, the belt conveyance unit20, a static eliminator unit25, and the line head9are provided at the straight path12. The straight path12is a path extending through the recording region A of the line head9(FIG.3A) to the upstream side and downstream side of the line head9. In this embodiment, the belt conveyance unit20is disposed in a region facing the head surface of the line head9, and supports the side opposite to the recording surface of the medium P. When the medium P is conveyed at a position facing the line head9on the belt conveyance unit20, the line head9, disposed facing the conveyance belt21, performs recording by discharging ink as droplets to the recording surface of the medium P. The line head9is a recording head in which the nozzle that discharges ink is provided to cover the entire width of the medium P, and is capable of performing recording over the entire width direction of the medium P with no movement in the width direction of the medium P. Note that while the recording device1of this embodiment includes the line head9, it is also possible to adopt a serial recording head mounted in a carriage and configured to perform recording by discharging liquid to the medium P while moving back and forth in a direction intersecting the medium conveyance direction. The medium P conveyed through the straight path12is then sent to the face-down ejection path13. The face-down ejection path13is the conveyance path11with a curvature coupled to the straight path12, and sends the medium P recorded by the line head9such that the medium P is ejected from the sheet ejection unit7with the recording surface side down. The medium P having entered the face-down ejection path13is conveyed by a plurality of the conveyance roller pairs42, ejected from the sheet ejection unit7, and placed on the medium placing part5with the recording surface side down. As illustrated inFIG.3A, the belt conveyance unit20according to this embodiment includes an endless conveyance belt21that suctions the medium P to a belt outer surface21a, an upstream driving roller22that is at least two rollers around which the conveyance belt21is provided, and a downstream driven roller23located downstream of the upstream driving roller22in the medium conveyance direction (the +Y-axis direction inFIG.3A). The conveyance belt21is disposed facing the head surface of the line head9. The belt conveyance unit20conveys the medium P downstream in the medium conveyance direction when the upstream driving roller22is driven into rotation by a driving source such as a motor and the conveyance belt21is driven. At this time, the downstream driven roller23is driven and rotated by the conveyance belt21that is driven by the rotational driving of the upstream driving roller22. The upstream driving roller22is driven into rotation around a drive shaft22a. The driving source of the belt conveyance unit20is configured to enable forward and reverse rotation so as to circumferentially move the conveyance belt21in the forward direction, which is the conveyance direction in which the medium P is conveyed (the +C direction of the two-headed arrow illustrated inFIG.3A), and in the reverse direction (the −C direction of the two-headed arrow illustrated inFIG.3A), which is the opposite direction. The belt conveyance unit20is configured to be switchable, by a state switching unit not illustrated in the drawing, between a first state where at least a part of the belt outer surface21ais located at a recording position B (facing position) of the line head9, and a second state where the belt outer surface21ais farther from the line head9than the recording position B (the dashed line inFIG.2). The first state is a state where the recording on the medium P is performed by the line head9. On the other hand, the second state is a state where the recording on the medium P by the line head9is not performed. At this time, to maintain the recording performance of the line head9, the line head9in the non-recording state is covered from the −Z direction side with a cap not illustrated in the drawing, for example. The recording device1includes a cleaning unit70that cleans the conveyance belt21. The cleaning unit70includes a scrape unit71that scrapes residuals (such as paper dust and ink) adhered to the belt outer surface21aof the conveyance belt21. In this manner, the residuals are removed from the belt outer surface21a. Note that the specific configuration of the cleaning unit70is described later. The scrape unit71is provided upstream of a charging roller24in the movement direction of the conveyance belt21. In this embodiment, the conveyance belt21is a belt that conveys the medium P by electrostatically attracting it on the belt outer surface21a, and the belt conveyance unit20includes the charging roller24as an example of a charging unit that charges the conveyance belt21, and the static eliminator unit25that eliminates the electric charge of the surface of the medium P conveyed by the conveyance belt21. The charging roller24is provided upstream of the static eliminator unit25in the movement direction of the conveyance belt21, at a position facing the upstream driving roller22below the conveyance path11, and the charging roller24makes contact with the belt outer surface21a. When the upstream driving roller22and the downstream driven roller23are rotated and the conveyance belt21is driven, the charged belt outer surface21aafter the contact with the charging roller24becomes a path formation surface that forms the conveyance path11. Thus, suctioning of the medium P at the conveyance belt21that forms the conveyance path11can be increased, and the medium P can be more effectively suctioned to the conveyance belt21. The static eliminator unit25includes an endless static eliminator belt26that is provided over the width direction (the direction along the X axis) of the medium P and rotates in the width direction. The static eliminator belt26is provided with a brush26aprotruding on the outside, and a portion facing the medium P on the conveyance belt21moves in the direction along the X axis, which is the medium width direction. The brush26aof the static eliminator belt26is pressed against the medium P, and thus the electric charge is removed from the surface of the medium P. The suctioning of the medium P to the conveyance belt21can be improved by eliminating the electric charge of the surface of the medium P. In addition, the belt conveyance unit20includes a first backup plate28aand a second backup plate28bthat support the conveyance belt21from the inner surface side between the upstream driving roller22and the downstream driven roller23. The first backup plate28ais disposed facing the static eliminator unit25with the conveyance belt21therebetween, and the second backup plate28bis disposed facing the cleaning unit70(the scrape unit71) with the conveyance belt21therebetween. The recording device1includes the control unit100that controls various operations executed at the recording device1. The control unit100includes a CPU, a memory, a control circuit, and an I/F (interface). The CPU is a computation processing device. The memory is a storage device that secures a region that stores the program of the CPU, a work area and the like, and includes a memory element such as a RAM and an EEPROM. When recording data or the like is acquired from an external device such as an information processing terminal through the I/F, the CPU transmits a control signal to each driving unit through the control circuit. In this manner, the medium conveyance unit10, the line head9, and the like are controlled. Here, when a plate-shaped blade is used to scrape the residual (such as calcium carbonate included in paper dust) adhered to the belt outer surface21aof the conveyance belt21, for example, the residual is scraped out by the blade and the residual is removed from the conveyance belt21. However, if the time passes in the state where the residual adhered to the end portion of the blade is accumulated, a part of the residual solidifies. Then, when the solidified residual makes contact with the belt outer surface21aof the conveyance belt21, the conveyance belt21is locally damaged. The conveyance belt21of this embodiment is a belt that conveys the medium P by electrostatically attracting the medium P, and therefore, if the belt outer surface21aof the conveyance belt21is damaged by the solidified residual, the insulation layer and the adhesive layer formed on the belt outer surface21aare damaged, the charging function is degraded, and conveyance failure of the medium P occurs. That is, the lifetime of the conveyance belt21is reduced. Note that to suppress the solidification of the residual adhered to the plate-shaped blade, it is conceivable to adopt a configuration including a cleaning mechanism that removes the residual adhered to the end portion of the blade, a mechanism that performs contact and separation of the blade to and from the conveyance belt21and the like, but there are concerns that the structure will become more complex and the recording device1will become larger. In view of this, the cleaning unit70of the recording device1of this embodiment is configured to suppress the occurrence of the above-mentioned failure. A configuration of the cleaning unit70of this embodiment is described below. The cleaning unit70includes the scrape unit71that makes contact with the conveyance belt21and scrapes out the residual adhered to the belt outer surface21aof the conveyance belt21. The scrape unit71includes a sponge member72. The sponge member72has a block-like cuboid shape and extends in the direction along the X axis. In the first state, the sponge member72is disposed below the conveyance belt21. The end portion of the sponge member72in the +Z direction includes a contact part72athat makes contact with the belt outer surface21a. The contact part72ais composed of a flat surface, and makes surface contact with the conveyance belt21. The size of the sponge member72in the direction along the X axis is equal to the size of the conveyance belt21in the direction along the X axis. In this manner, the residual can be scraped out over the entire width direction of the belt outer surface21aof the conveyance belt21. The cleaning unit70includes a supporting part73that supports the lower end portion of the sponge member72, a pressing part75that pushes the supporting part73upward, and a fixing member77that supports the pressing part75. The fixing member77is fixed at a certain distance from the second backup plate28b. The pressing part75is, for example, a coil spring. One end of the pressing part75is coupled to the supporting part73, and the other end is coupled to the fixing member77. The sponge member72supported by the supporting part73is biased in the +Z direction by the pressing part75, and is pressed against the conveyance belt21with a substantially constant pressure over the entire longitudinal direction of the sponge member72. In this manner, the contact part72aof the sponge member72scrapes off the residual adhered to the belt outer surface21a. The sponge member72is brought into contact with the conveyance belt21at all times by the pressing part75, and thus the cleaning performance can be improved. In addition, in the first state, the supporting part73includes a recess73arecessed downward, and the lower end portion of the sponge member72is fit to the recess73a. In addition to the lower end surface of the sponge member72, the surface of the sponge member72on the +Y direction side and the surface of the sponge member72on the −Y direction are supported by the supporting part73. Thus, the sponge member72is not detached from the supporting part73even when the sponge member72makes contact with the conveyance belt21that is in circumferential movement, and the sponge member72can be brought into contact with the conveyance belt21in a stable state. The sponge member72is a member whose contact part72ais worn when making contact with the circumferentially moving conveyance belt21. That is, the sponge member72is a member that scrapes off the residual on the conveyance belt21while the contact part72athat makes contact with the conveyance belt21will be worn. The sponge member72of this embodiment is a foaming melamine sponge made of melamine resin. Melamine sponge is composed of multiple fine mesh structures. Melamine sponge is favorable in scraping of residuals and wearing of the contact part72amaking contact with the conveyance belt21. The size of the sponge member72can be appropriately set. It is set in accordance with the periodical replacement period of the conveyance belt21, for example. In this manner, the maintenance frequency of the sponge member72can be reduced. In addition, the position of the cleaning unit70relative to the belt conveyance unit20is fixed, and the cleaning unit70moves along with the state switching of the belt conveyance unit20. That is, as illustrated inFIG.3B, when the conveyance belt21is switched from the first state to the second state, the cleaning unit70moves together with the conveyance belt21. In this manner, the interference with the cleaning unit70can be prevented at the time of switching of the state of the conveyance belt21. In this manner, the interference with the cleaning unit70can be prevented at the time of switching of the state of the conveyance belt21. In addition, since the sponge member72makes contact with the conveyance belt21, the contact part72aof the sponge member72is worn due to the friction with the conveyance belt21. That is, the sponge member72scrapes off the residual adhered to the conveyance belt21, while being worn and dropped from the scrape unit71together with the scraped residual. In this manner, the residual scraped off from the conveyance belt21is not accumulated on the contact part72aof the sponge member72. That is, the residual adheres to the contact part72aof the sponge member72, and the residual does not solidify. Accordingly, for example, in comparison with a case where the residual on the conveyance belt21is removed with the blade, the damage of the conveyance belt due to the solidified residual is suppressed, and thus the lifetime of the conveyance belt21can be increased. In addition, in comparison with a configuration including a cleaning mechanism that removes the residual adhered to the end portion of the blade and/or a mechanism that performs contact and separation of the blade to and from the conveyance belt21in the configuration of removing the residual on the conveyance belt21using the blade, the structure of the recording device1is simplified and the upsizing of the recording device1can be suppressed. 2. Second Embodiment Next, a second embodiment is described. Note that the same configurations as those of the first embodiment are denoted with the same reference numerals, and the overlapping description is omitted. As illustrated inFIG.4, a recording device1A of this embodiment includes a cleaning unit80. The cleaning unit80includes a scrape unit81that scrapes off the residual at the conveyance belt21. The scrape unit81includes a roller84with a rotation shaft84a, and a sponge member82is disposed around the peripheral surface of the roller84. The sponge member82is disposed at the peripheral surface of the roller84, with equal thickness. The sponge member82and the roller84are fixed, and the sponge member82rotates along with the rotation of the roller84. The sponge member82is a melamine sponge. The cleaning unit80includes a pressing part85(such as a coil spring) and a fixing member87that supports the pressing part85, and the roller84is pushed by the pressing part85toward the conveyance belt21. The roller84is driven into rotation along with the circumferential movement of the conveyance belt21. Thus, the entirety in the circumferential direction of the sponge member82disposed on the roller84can serve as a contact part82a. In this manner, the residual at the conveyance belt21can be scraped off while rotating the roller84along with the circumferential movement of the conveyance belt21. In addition, since the sponge member82is equally worn by the rotation of the roller84, the durability (lifetime) of the sponge member82can be improved in comparison with the configuration in which the sponge member82is brought into contact with the conveyance belt21in a fixed manner. Further, in the recording device1A of this embodiment, a speed difference is set between the circumferential speed of the conveyance belt21and the circumferential speed of the roller84. In this manner, the speed difference between the conveyance belt21and the roller84can make it easier to scrape off the residual at the conveyance belt21. More specifically, a torque limiter86is coupled to the rotation shaft84a. The torque limiter86exerts a load on the rotation of the rotation shaft84a, and it is thus possible to easily generate a speed difference between the conveyance belt21and the roller84. As described above, according to this embodiment, when the conveyance belt21is circumferentially moved in the +C direction, the roller84is driven into rotation clockwise, and thus the conveyance belt21and the roller84rotate together. Then, when the torque limiter86acts on roller84, a load is exerted on the rotation shaft84a, and the circumferential speed of the roller84is reduced relative to the circumferential speed of the conveyance belt21(a speed difference is caused). In this manner, the friction between the conveyance belt21and the contact part82aof the sponge member82increases, and thus the cleaning performance can be improved. In addition, since the sponge member82makes contact with the conveyance belt21while being rotated, the durability (lifetime) of the sponge member82can be improved. Note that the residual scraped by the sponge member82is ejected in the −Y direction from the contact part82awith the rotation of the roller84, and dropped from the scrape unit81. 3. Third Embodiment Next, a third embodiment is described. Note that the same configurations as those of the first embodiment are denoted with the same reference numerals, and the overlapping description is omitted. As illustrated inFIG.5AandFIG.5B, a recording device1B of this embodiment includes a cleaning unit90. The cleaning unit90includes a scrape unit91that scrapes off the residual at the conveyance belt21. The scrape unit91includes a roller94with a rotation shaft94a, and a sponge member92is disposed around the peripheral surface of the roller94. The sponge member92is disposed around the peripheral surface of the roller94, with equal thickness. The sponge member92and the roller94are fixed. The sponge member92is a melamine sponge. The cleaning unit90includes a pressing part95(such as a coil spring) and a fixing member97that supports the pressing part95, and the pressing part95pushes the roller94toward the conveyance belt21. Further, in the recording device1B of this embodiment, a speed difference is set between the circumferential speed of conveyance belt21and the circumferential speed of the roller94. More specifically, a one-way clutch96is coupled to the rotation shaft94a. The one-way clutch96includes a mechanism that does not rotate the roller94in one direction around the rotation shaft94a, but rotates the roller94in the other direction around the rotation shaft94a. Then, in this embodiment, the roller94does not rotate when the conveyance belt21rotates in the conveyance direction of the medium P (circumferentially moves in the +C direction) as illustrated inFIG.5A. On the other hand, the roller94is rotated following the conveyance belt21when the conveyance belt21rotates in the direction opposite to the conveyance direction of the medium P (circumferentially moves the −C direction) as illustrated inFIG.5B. As described above, according to this embodiment, when the conveyance belt21rotates counterclockwise, the roller94does not rotate due to the one-way clutch96, and a speed difference is caused between the circumferential speed of the conveyance belt21and the circumferential speed of the roller94. Thus, since the sponge member92is fixed and the friction is increased at a contact part92a, the cleaning performance on the conveyance belt21can be improved. On the other hand, when the conveyance belt21rotates clockwise, the roller94rotates following that rotation (rotates counterclockwise). Along with the rotation of the roller94, the residual adhered to the contact part92aof the sponge member92can be dropped from the sponge member92. InFIG.5B, the residual is ejected from the contact part92ain the +Y direction, and dropped from the scrape unit91. Thereafter, when the conveyance belt21rotates counterclockwise again, the roller94does not rotate. At this time, a new surface in the sponge member92can serve as the contact part92a, and thus the durability (lifetime) of the sponge member92can be improved in comparison with the sponge member92is brought into contact with the conveyance belt21in a fixed manner. | 25,741 |
11858280 | DESCRIPTION OF THE EMBODIMENTS Hereinafter, with reference to the accompanying drawings, detailed explanations are given of examples of an embodiment of a printing apparatus, an ordering system, and a control method. Note that it is not intended that the following embodiments limit the present invention, and every combination of the characteristics explained in the present embodiments is not necessarily essential to the solution in the present invention. In addition, relative positions, shapes, etc., of the constituent elements described in the embodiments are merely examples and are not intended to limit the present invention to the range of the examples. First Embodiment FIG.1is an internal configuration diagram of an inkjet printing apparatus1(hereinafter referred to as a printing apparatus1) used in the present embodiment. In the drawings, x-direction is the horizontal direction, y-direction (the direction perpendicular to the paper plane) is the direction in which an array of ejection ports is arranged in the later-described print head8; and z-direction is the vertical direction. The printing apparatus1is a multifunctional peripheral including a print part2and a scanner part3. The printing apparatus1is capable of executing various processes related to a printing operation and a reading operation with the print part2and the scanner part3moving separately or moving together. The scanner part3includes an automatic document feeder (ADF) and a flatbed scanner (FBS). The scanner part3is capable of reading a document automatically fed by the ADF and reading (scanning) a document placed on a platen glass of the FBS by the user. Note that, although the present embodiment is directed to the multifunctional peripheral including both the print part2and the scanner part3, a form in which the scanner part3is not included is possible as well.FIG.1is a diagram illustrating the printing apparatus1being in a standby state, in which neither a printing operation nor a reading operation is performed. In the print part2, the first cassette5A and the second cassette5B for accommodating a print medium (cut sheet) S are detachably installed at the bottom of the casing4in the vertical direction. A relatively small print medium of up to A4 size is stacked and accommodated in the first cassette5A and a relatively large print medium of up to A3 size is stacked and accommodated in the second cassette5B. Near the first cassette5A, the first feeding unit6A for separately feeding each of the accommodated print media is installed. Similarly, near the second cassette5B, the second feeding unit6B is installed. In a case where a printing operation is performed, a print medium S is selectively fed from either one of the cassettes. Conveyance rollers7, discharging rollers12, pinch rollers7a, spurs7b, a guide18, an inner guide19, and a flapper11are conveyance mechanisms for guiding a print medium S in a predetermined direction. The conveyance rollers7are drive rollers disposed on the upstream side and on the downstream side relative to the print head8(platen9) and driven by a conveyance motor, which is not herein illustrated. The pinch rollers7aare follower rollers that rotate while nipping a print medium S together with the conveyance rollers7. The discharging rollers12are drive rollers disposed on the downstream side relative to the conveyance rollers7and driven by a discharging motor, which is not herein illustrated. The spurs7bpinch and convey a print medium S together with the discharging rollers12and the conveyance rollers7disposed on the downstream side relative to the print head8(platen9). The guide18is disposed in the conveyance path of a print medium S so as to guide a print medium S in a predetermined direction. The inner guide19is a member extending in the y-direction, and has a curved side surface so as to guide a print medium S along the side surface. The flapper11is a member for changing directions in which a print medium S is conveyed in a double-sided printing operation. The discharging tray13is a tray for stacking/retaining a print medium S discharged by the discharging rollers12after a printing operation is completed. The print head8of the present embodiment is a full-line type color inkjet print head, and multiple arrays of ejection ports for ejecting ink according to print data are arranged along the y-direction ofFIG.1so as to correspond to widths of print media S. In a case where the print head8is in a standby position, the ejection port surface8aof the print head8is capped with the cap unit10as illustrated inFIG.1. In a case where a printing operation is performed, the orientation of the print head8is changed by the later-described print controller202such that the ejection port surface8afaces the platen9. The platen9is configured with a flat plate extending in the y-direction, so as to support a print medium S, to which a printing operation is performed by the print head8, from the back side thereof. The ink tank unit14is configured with an ink tank224(seeFIG.2) detachably installed for storing each of four colors of ink to be supplied to the print head8. Note that the ink tank224includes a non-volatile type memory225(seeFIG.2) in which ink tank information (described later) and additional information (described later) are stored as information related to a consumable. Note that the non-volatile type memory is also referred to as a non-volatile memory in the present specification. The ink supply unit is disposed in the midstream of a flow path connecting each ink tank224mounted on the ink tank unit14and the print head8, so as to adjust the pressure and the flow rate of ink inside the print head8within a suitable range. The present embodiment adopts a circulation type ink supply system, in which the ink supply unit15adjusts the pressure of ink supplied to the print head8and the flow rate of ink collected from the print head8within a suitable range. The maintenance unit16includes the cap unit10and the wiping unit17, and the maintenance unit16operates the cap unit10and the wiping unit17at predetermined timings, so as to perform a maintenance operation for the print head8. FIG.2is a block configuration diagram of an ordering system mainly illustrating a control configuration of the printing apparatus. The control configuration mainly includes a print engine unit200that exercises control over the print part2, a scanner engine unit300that exercises control over the scanner part3, and a controller unit100that exercises control over the entire printing apparatus1. The print controller202controls various mechanisms of the print engine unit200in accordance with instructions from the main controller101of the controller unit100. Various mechanisms of the scanner engine unit300are controlled by the main controller101of the controller unit100. The control configuration will be explained below in detail. In the controller unit100, the main controller101, which is configured with a CPU, controls the entire printing apparatus1by using the RAM106as a work area in accordance with various parameters and a program stored in the ROM107. For example, in a case where a print job is input from the host apparatus400via the host I/F102or the wireless I/F103, the image processing unit108performs predetermined image processing for received image data in accordance with instructions from the main controller101. Then, the main controller101sends the image data, for which the image processing has been performed, to the print engine unit200via the print engine I/F105. Note that the printing apparatus1may obtain image data from the host apparatus400via a wireless communication or a wired communication or may obtain image data from an external storage (such as a USB memory) connected to the printing apparatus1. There is no limitation on the communication method utilized for the wireless communication or the wired communication. For example, Wi-Fi (Wireless Fidelity; registered trademark), Bluetooth (registered trademark), or the like, is applicable for the communication method utilized for the wireless communication. Further, a USB (Universal Serial Bus) or the like is applicable for the communication method utilized for the wired communication. Moreover, for example, in a case where a scan command is input by the host apparatus400, the main controller101sends this command to the scanner part3via the scanner engine I/F109. The operation panel104is a mechanism for the user to provide an input or output operation for the printing apparatus1. Via the operation panel104, the user can provide an instruction for an operation such as copying or scanning, set a print mode, recognize information about the printing apparatus1, etc. In addition, the controller unit100includes the server I/F110that is connected via a network to each of the ordering server111that accepts an order of a consumable and the contract management server112that manages contract information for the printing apparatus1. Note that the ordering server111accepts an order request for an ink tank224, which is output from the printing apparatus1, and places an order for the ink tank224, based on the order request. The contract management server112manages contract information, which is information related to a contract for the printing apparatus1, etc. That is, in the present embodiment, the ordering server111functions as an ordering apparatus that places an order of a consumable, and the contract management server112functions as a management apparatus that manages a contract for the printing apparatus1. Further, in the present embodiment, the ordering server111and the contract management server112are servers independent from each other, and, for example, contract information managed by the contract management server112is configured not to be sent from the contract management server112to the ordering server111. In the present embodiment, it is assumed that the contract information managed by the contract management server112is, for example, a one-off contract, a flat-rate contract, or the like. The one-off contract is a contract in which an ink tank224is delivered to the user based on an order and the cost related to the order of the ink tank224is charged. Further, the flat-rate contract is a contract in which, by continuing to pay a fixed cost periodically, an ink tank224is delivered based on an order and the cost related to the order of the ink tank224is not charged. Note that, in the present embodiment, an ordering system500that is capable of automatically ordering an ink tank224is configured with the printing apparatus1, the ordering server111, and the contract management server112. In the print engine unit200, the print controller202, which is configured with a CPU, controls various mechanisms provided in the print part2while using the RAM204as a work area in accordance with various parameters and a program stored in the ROM203. Once various commands and image data are received via the controller I/F201, the print controller202temporarily saves the various commands and image data in the RAM204. The print controller202causes the image processing controller205to convert the saved image data into print data, so that the print head8can utilize the print data for a printing operation. After the print data is generated, the print controller202causes the print head8via the head I/F206to execute a printing operation based on the print data. Here, the print controller202drives the feeding unit6A and6B, the conveyance rollers7, the discharging rollers12, and the flapper11illustrated inFIG.1via the conveyance control unit207, so as to convey a print medium S. The printing operation by the print head8is executed in synchronization with the conveyance operation of the print medium S in accordance with an instruction from the print controller202, so that the print processing is performed. The head carriage control unit208changes orientations and positions of the print head8in accordance with operating status of the printing apparatus1such as a maintenance state and a printing state. The ink supply control unit209controls the ink supply unit15such that the pressure of ink supplied to the print head8is controlled within a suitable range. Note that the ink supply unit15outputs the remaining amount of ink stored in an ink tank224in response to a request from the print controller202. That is, the ink supply unit15outputs information related to the ink remaining amount, which is detected by the ink remaining amount sensor226, to the print controller202in response to the request. Note that the ink remaining amount sensor226is a sensor that is capable of detecting the ink remaining amount of each ink tank224. As for the ink remaining amount sensor226, it is possible to use various publicly-known technologies for directly or indirectly detecting the ink remaining amount of an ink tank224, and thus detailed explanations thereof will be omitted. The maintenance control unit210controls operations of the cap unit10and the wiping unit17in the maintenance unit16in a case of performing a maintenance operation for the print head8. Further, the print engine unit200includes the non-volatile memory222that stores information of a predetermined amount and the like, which is used for determining whether or not to send an order request (described later), for example. Specifically, the predetermined amount is the lower limit value of the ink remaining amount of an ink tank224. This predetermined amount may be input in advance or may be input via the operation panel104. Further, the predetermined amount may be set so as to be different or the same for the respective ink colors. Moreover, the non-volatile memory222also stores contract information for the printing apparatus1. In the scanner engine unit300, the main controller101controls hardware resources of the scanner controller302while using the RAM106as a work area in accordance with various parameters and a program stored in the ROM107. Accordingly, various mechanisms provided in the scanner part3are controlled. For example, the main controller101controls hardware resources in the scanner controller302via the controller I/F301, so that a document placed on the ADF by the user is conveyed via the conveyance control unit304and read by the sensor305. Then, the scanner controller302saves the read image data in the RAM303. Note that the print controller202is capable of converting such image data obtained as described above into print data to enable the print head8to execute a printing operation based on the image data read by the scanner controller302. Note that a program for implementing one or more functions of the printing apparatus1(controller unit, print engine unit, scanner engine unit) or the host apparatus400is supplied to a system or an apparatus via a network or various storage media. A computer (CPU, MPU, etc.) of the system or the apparatus reads the program and executes the functions. Alternatively, it is also possible to cause various mechanisms to execute the functions. Further, this program may be implemented by one computer or may be implemented by multiple computers moving together. Moreover, it is not necessary to implement all of the above-described processes by software, and a part or all of the processes may be implemented by hardware such as an ASIC. Furthermore, the form is not limited to the one in which all processes are performed by one CPU, and there may be such a form in which multiple CPUs appropriately move together so as to perform the processes. Further, there may be such a form in which one CPU executes any of the processes and multiple CPUs moves together so as to perform the other processes. The main controller101according to the present embodiment automatically outputs an order request for ordering an ink tank224to the ordering server111according to the ink remaining amount of an ink tank224. That is, in the present embodiment, the main controller101functions as a sending part that sends an order request for an ink tank224, which is a consumable. The main controller101periodically obtains contract information for the printing apparatus1from the contract management server112via the server I/F110and stores the contract information in the non-volatile memory222. That is, for example, the main controller101requests the contract management server112for contract information for the printing apparatus1at a predetermined timing and obtains the contract information for the printing apparatus1, which is output from the contract management server112based on the request. Then, the obtained contract information is stored in the non-volatile memory222via the print engine I/F105and the controller I/F201. The predetermined timing is, for example, the timing at which the printing apparatus1is activated, etc. In a case where the condition (predetermined condition) under which an order request for an ink tank224can be sent is satisfied, the main controller101sends an order request to the ordering server111via the server I/F110. Here, the main controller101adds additional information to the order request. The additional information is stored in the non-volatile memory225provided for the ink tank224. The additional information is, for example, information related to an ink color or a serial number for identifying the ink tank224. The condition under which an order request can be sent will be described later. In the present embodiment, four ink tanks224storing inks of different colors, respectively, are mounted in the ink tank unit14. Specifically, an ink tank storing cyan ink, an ink tank storing magenta ink, an ink tank storing yellow ink, and an ink tank storing black ink are mounted in the ink tank unit14. The print controller202periodically performs polling via the ink supply control unit209, so as to obtain the ink remaining amount of each ink tank224by use of the ink remaining amount sensor226. In the above-described configuration, the printing apparatus1periodically executes a determination process for determining whether or not to order an ink tank224.FIG.3is a flowchart illustrating details of processing of the determination process performed by the printing apparatus according to the first embodiment. The series of processes illustrated in the flowchart ofFIG.3is performed by the print controller202retrieving a program code stored in the ROM203into the RAM204and executing the program code. Alternatively, a part or all of the functions in the steps ofFIG.3may be executed by hardware such as an ASIC or an electronic circuit. Note that the symbol “S” in the explanation of each process means that it is a step in the flowchart (the same applies hereinafter in the present specification). This determination process is executed by the print controller202, based on an instruction from the main controller101. In the present embodiment, the main controller101periodically instructs the print controller202to execute the determination process. In a case where the determination process is started based on the instruction from the main controller101, the print controller202firstly obtains the ink remaining amount, ink tank information, and additional information of each ink tank224(S302). That is, in the present embodiment, the print controller202functions as a first obtaining part that obtains information related to a consumable, such as ink tank information and additional information, as well as the degree of consumption or use of a consumable, such as the ink remaining amount. Note that the ink tank information is information indicating the type of ink tank corresponding to contract information. Details are described later. Specifically, in S302, the print controller202obtains the ink remaining amount of each ink tank224by using the ink remaining amount sensor226via the ink supply control unit209. Further, the print controller202obtains the ink tank information and the additional information, which are stored in the non-volatile memory225, via the ink supply control unit209. The ink remaining amount of an ink tank224is associated with the ink tank information and the additional information obtained from the non-volatile memory225provided in the ink tank224. Next, the print controller202compares the obtained ink remaining amount with the predetermined amount stored in the non-volatile memory222and determines whether or not the ink remaining amount is equal to or less than the predetermined amount (S304). That is, in S304, the ink remaining amounts of the four ink tanks224are compared with the corresponding predetermined amounts, so that whether or not the ink remaining amount of each ink tank224is equal to or less than the predetermined amount is determined. In S304, in a case where it is determined that the ink remaining amount is not equal to or less than the predetermined amount, that is, that the ink remaining amounts of all the ink tanks224are not equal to or less than the predetermined amounts, this determination process ends. Further, in a case where it is determined in S304that the ink remaining amount is equal to or less than the predetermined amount, that is, that the ink remaining amount of at least one ink tank224is equal to or less than the predetermined amount, the print controller202obtains the contract information stored in the non-volatile memory222(S306). In the present embodiment, the print controller202functions as a second obtaining part that obtains information related to a contract for the printing apparatus1. Note that it is also possible that the non-volatile memory222is included as the second obtaining unit. Thereafter, for the ink tank224of which the ink remaining amount is determined to be equal to or less than the predetermined amount, the print controller202determines whether or not to send an order request to the ordering server111, based on the obtained contract information and the ink tank information (S308). That is, in S308, based on the contract information and the ink tank information associated with the ink remaining amount that is equal to or less than the predetermined amount, whether or not to send an order request is determined by use of a table stored in a recording area of the non-volatile memory222, the ROM203, or the like, for example.FIG.4is a table used for determining whether or not to send an order request. In the table ofFIG.4, “SEND AN ORDER REQUEST” or “DO NOT SEND AN ORDER REQUEST” is associated with each of the combinations of contract information for the printing apparatus1and ink tank information. Here, as described above, ink tank information indicates the types of ink tanks corresponding to contract information. In the present embodiment, there are four types of ink tank information: a setup ink tank and a one-off ink tank, which correspond to a one-off contract, a flat-rate ink tank, which corresponds to a flat-rate contract, and other ink tanks. That is, since the setup ink tank and the one-off ink tank correspond to the one-off contract, a cost is incurred at the timing of ordering. On the other hand, since a predetermined cost is paid periodically for the flat-rate ink tank, no cost is incurred at the timing of ordering. In addition, inFIG.4, the contract information indicates contract information for the printing apparatus1, which is obtained from the contract management server112. In the present embodiment, the contract information includes a one-off contract, a flat-rate contract, and other contracts that are not the one-off contract or the flat-rate contract. Specifically, according toFIG.4, an order request is sent in a case where the contract information is “ONE-OFF CONTRACT” and the ink tank information is “SETUP INK TANK” or “ONE-OFF INK TANK”. Further, in a case where the contract information is “FLAT-RATE CONTRACT” and the ink tank information is “FLAT-RATE INK TANK”, an order request is sent. Furthermore, in a case where the combination of the contract information and the ink tank information is a combination other than the above-described combinations, an order request is not sent. Therefore, in the determination as to whether or not to send an order request, it is determined that an order request for a setup ink tank is sent, for example, in a case where the contract information is “ONE-OFF CONTRACT” and the ink tank information is “SETUP INK TANK”, based on the table ofFIG.4. Further, for example, in a case where the contract information is “FLAT-RATE CONTRACT” and the ink tank information is “ONE-OFF INK TANK”, it is determined that an order request is not sent, based on the table ofFIG.4. As described above, in the present embodiment, in a case where the ink tank of which the ink remaining amount is equal to or less than a predetermined amount corresponds to the contract information stored in the non-volatile memory222, it is determined that the condition under which an order request can be sent is satisfied, and a process of sending an order request is performed. In other words, in a case where the ink remaining amount of an ink tank that is suitable for contract information is equal to or less than a predetermined amount, it is determined that the condition under which an order request can be sent is satisfied, and the process of sending an order request is performed. Further, in a case where the ink remaining amount of an ink tank that is not suitable for contract information is equal to or less than a predetermined amount, it is determined that the condition under which an order request can be sent is not satisfied, so that an order request is not sent. Accordingly, ordering of an ink tank can be appropriately performed according to contract information. In S308, in a case where it is determined that an order request will not be sent, this determination process ends. On the other hand, in S308, in a case where it is determined that an order request will be sent, the print controller202instructs the main controller101for sending an order request (S310), and this determination process ends. That is, in S310, an order request is output from the print controller202to the main controller101together with the ink tank information of the ink tank224of which the ink remaining amount is equal to or less than the predetermined amount. Further, to this order request, additional information that is associated with the ink tank information, which is sent together, is added. Note that, in a case where it is determined in S308that an order request will be sent for multiple ink tanks224, an order request for the multiple ink tanks224is to be output to the main controller101in S310. Further, without an instruction for sending an order request, the main controller101does not send an order request to the ordering server111. On the other hand, with an instruction for sending an order request, the main controller101sends an order request to the ordering server111via the server I/F110together with the ink tank information and the additional information. Upon receiving this order request, the ordering server111determines the detailed order contents and places an order based on the determined order contents. That is, the type of ink tank224to be ordered and presence or absence of a cost charge are determined based on the ink tank information and the additional information. Note that the request sent to the ordering server111only needs to be a predetermined request including ink tank information and additional information, and it is not necessary that an order is explicitly requested. Furthermore, in a case where the ordering server111receives a predetermined request including ink tank information and additional information from the printing apparatus1, the ordering server111may interpret the predetermined request as an order request and perform processing. FIG.5is a table for determining the type of ink tank224to be ordered and presence or absence of a cost charge. In the table ofFIG.5, the type of ink tank224and presence or absence of a cost charge are associated with each of the combinations of color information of ink, which is additional information, and ink tank information. Specifically, inFIG.5, the cost is charged in a case where the ink tank information is “SETUP INK TANK” or “ONE-OFF INK TANK”, and the cost is not charged in a case where the ink tank information is “FLAT-RATE INK TANK”. Further, based on the color information, determination of an ink tank224storing cyan ink, magenta ink, yellow ink, or black ink is made. Therefore, for example, in a case where the color information, which is additional information, is “CYAN” and the ink tank information is “ONE-OFF INK TANK”, the order contents are determined so that a one-off ink tank storing cyan ink is delivered and the cost is charged. Further, in a case where the color information is “BLACK” and the ink tank information is “FLAT-RATE INK TANK”, the order contents are determined so that a flat-rate ink tank storing black ink is delivered and the cost is not charged. Note that, although an ink remaining amount, ink tank information, and additional information are obtained in S302of the determination process inFIG.3, the determination process is not limited as such. That is, it is also possible that only an ink remaining amount is obtained in S302, then ink tank information is obtained immediately before the process of S308, and then additional information is obtained immediately before the process of S310. As explained above, for the printing apparatus1, the ordering system500capable of automatically ordering an ink tank224is configured with the contract management server112that manages contract information and the ordering server111that places an order of an ink tank224. In a case where the ink remaining amount of an ink tank224becomes equal to or less than a predetermined amount, the printing apparatus1determines whether or not to send an order request for the ink tank224to the ordering server111. This determination is made based on contract information obtained from the contract management server112and ink tank information of the mounted ink tank224. Accordingly, even though the ordering system500includes the ordering server111that cannot obtain contract information, it is possible for the ordering system500to order a consumable according to the contract information without incurring a high cost. The present embodiment is particularly effective in such a form where various types of consumables can be mounted on the printing apparatus1in accordance with contract information and the types of consumables mounted on the printing apparatus1cannot be immediately specified based on information of the apparatus type of the printing apparatus1only. Second Embodiment Next, with reference toFIG.6, an explanation is given of the printing apparatus according to the second embodiment. Note that, in the following explanation, the same or corresponding configurations as those of the printing apparatus according to the first embodiment described above are assigned with the same signs as those used in the first embodiment, so as to omit detailed explanations thereof. This second embodiment is different from the printing apparatus according to the first embodiment described above in terms of the determination based on an ink remaining amount as well as a remaining contract period, which is performed before whether or not to send an order request is determined. Specifically, in the present embodiment, the contract management server112manages contract information for the printing apparatus1as well as the contract expiration date of the contract information. Further, the main controller101periodically obtains contract information for the printing apparatus1and the contract expiration date corresponding to the contract information from the contract management server112via the server I/F110and stores the obtained contract information and contract expiration date in the non-volatile memory222. Then, in the determination process, the contract expiration date corresponding to the contract information is obtained from the contract management server112together with the contract information, and, after determination based on the obtained contract expiration date is performed, determination as to whether or not to send an order request is performed. FIG.6is a flowchart illustrating details of processing of the determination process performed by the printing apparatus according to the second embodiment. The series of processes illustrated in the flowchart ofFIG.6is performed by the print controller202retrieving a program code stored in the ROM203into the RAM204and executing the program code. Alternatively, a part or all of the functions in the steps ofFIG.6may be executed by hardware such as an ASIC or an electronic circuit. This determination process is executed by the print controller202, based on an instruction from the main controller101. In the present embodiment, the main controller101periodically instructs the print controller202to execute the determination process. In a case where the determination process is started based on the instruction from the main controller101, the print controller202firstly obtains the ink remaining amount, ink tank information, and additional information of each ink tank224(S602). Next, the print controller202compares the obtained ink remaining amount with the predetermined amount stored in the non-volatile memory222and determines whether or not the ink remaining amount is equal to or less than the predetermined amount (S604). Note that, since the specific details of processing of S602and S604are the same as those of S302and S304described above, respectively, the detailed explanations thereof are omitted. Then, in a case where it is determined in S604that the ink remaining amount is equal to or less than the predetermined amount, the print controller202obtains the contract information for the printing apparatus1and the contract expiration date corresponding to the contract information, which are stored in the non-volatile memory222(S606). Thereafter, the print controller202determines whether or not the remaining contract period is equal to or more than a predetermined number of days (S608). That is, in S608, the date on which this determination process is performed is obtained, so as to determine whether or not the difference between the date and the contract expiration date obtained in S606is equal to or more than the predetermined number of days. Note that the printing apparatus1is provided with a counter (not illustrated in the drawings) for counting dates, so that the print controller202obtains the date counted by this counter as the current date. In addition, the setting of the predetermined number of days can be appropriately changed. For example, the predetermined number of days is set according to the number of days taken for delivering the consumable. In a case where it is determined in S608that the remaining contract period is not equal to or more than the predetermined number of days, that is, that the remaining contract period is less than the predetermined number of days, this determination process ends. On the other hand, in a case where it is determined in S608that the remaining contract period is equal to or more than the predetermined number of days, the print controller202determines whether or not to send an order request to the ordering server111, based on the contract information obtained in S606and the ink tank information obtained in S602(S610). In a case where it is determined in S610that an order request will not be sent, this determination process ends. On the other hand, in a case where it is determined in S610that an order request will be sent, the print controller202instructs the main controller101for sending an order request (S612), and this determination process ends. Note that, since the specific details of processing of S610and S612are the same as those of S308and S310described above, respectively, the detailed explanations thereof are omitted. As described above, in the present embodiment, it is determined that the condition under which an order request can be sent is satisfied in a case where the ink tank of which the ink remaining amount is equal to or less than a predetermined amount corresponds to the contract information stored in the non-volatile memory222and the remaining contract period is equal to or more than a predetermined number of days. Then, the process of sending an order request is performed. Note that, in cases other than the above, it is determined that the condition under which an order request can be sent is not satisfied, so that an order request will not be sent. Further, without an instruction for sending an order request, the main controller101does not send an order request to the ordering server111. On the other hand, with an instruction for sending an order request, an order request is sent to the ordering server111via the server I/F110together with the ink tank information and the additional information. Upon receiving the order request, the ordering server111determines a detailed order request by use of the table ofFIG.5, etc., and places an order based on the determined contents. As explained above, in the printing apparatus1according to the second embodiment, after the determination based on an ink remaining amount, in a case where the remaining contract period is equal to or more than a predetermined number of days, whether or not to send an order request is determined. Accordingly, in the ordering system500including the printing apparatus1, it is possible to appropriately manage the contents of a contract, in addition to the effect of the first embodiment. Other Embodiments Note that the above-described embodiments may be modified as shown in the following (1) through (4). (1) Although the cases in which an ink tank224storing ink is ordered as a consumable are explained in the above-described embodiments, the consumable to be ordered in the ordering system500is not limited to ink. That is, the consumable to be ordered may be, for example, a conveyance roller7having a durable life. In this case, the position information of the conveyance roller7, etc., are information related to the consumable. Further, in the determination process, the degree of consumption or use of the consumable is detected, and, in a case where it is determined that this degree exceeds a predetermined degree, contract information, etc., are obtained. Further, the present embodiments are not limited to the ordering system500that automatically orders a consumable in the printing apparatus1. That is, it is also possible to apply the present embodiments as an ordering system for a consumable in various kinds of processing apparatuses that perform predetermined processing with consumption of consumables. (2) Although the determination process ends in a case where it is determined that the remaining contract period is not equal to or more than the predetermined number of days in the above-described second embodiment, the second embodiment is not limited as such. That is, the contract management server112also manages next contract information, which corresponds to the contract after the current contract ends, in addition to the current contract information and the contract expiration date corresponding to the current contract information. Further, the current contract information for the printing apparatus1, contract expiration date corresponding to the current contract information, and next contract information, which are managed by the contract management server112, are stored in the non-volatile memory222by the main controller101. Then, in the determination process, in a case where it is determined in S608that the remaining contract period is less than the predetermined number of days, whether or not new contract information (next contract information) after the contract expiration date is present is determined, and, in a case where it is determined that new contract information is not present in this determination, the determination process ends. Further, in a case where it is determined that new contract information is present in the above-described determination, whether or not to send an order request is determined based on the new contract information, that is, the next contract information. Here, there may be a case in which the new contract information is different from the current contract information. In this case, the ink tank information, etc., which are the information related to the consumable obtained in S602, do not correspond to the new contract information. Therefore, in a case where it is determined that new contract information is present in the above-described determination, whether or not to send an order request is determined based on the new contract information only. Accordingly, it is possible for the ordering system500to appropriately place an order according to the contract contents for the printing apparatus1. For example, in a case where the remaining contract period, which is calculated based on the date on which the determination process is performed and the contract expiration date, is shorter than the number of days in which the consumable can be delivered and the current contract information is different from the next contract information, the next contract information is reflected for ordering a consumable for the user. (3) Although there are two types of contract information, that is, the one-off contract and the flat-rate contract in the above-described embodiments, it is also possible that there are three or more types. Further, although the explanations are given of the cases in which the printing apparatus1performs printing by use of four types of ink in the above-described embodiments, the types of ink that can be used may also be one to three types or five or more types. Furthermore, although the printing apparatus1includes the ink remaining amount sensor226for obtaining the ink remaining amount in the above-described embodiments, the present embodiments are not limited as such. That is, it is also possible that the printing apparatus1is configured to detect and obtain the ink remaining amount by use of a sensor that is provided separately from the printing apparatus1, for example, as long as it is possible to obtain the ink remaining amount. Moreover, although the ink remaining amount is obtained in order to determine the degree of consumption of the consumable in the above-described embodiments, the present embodiments are not limited as such, and any types of information, such as the consumption of ink, can be obtained as long as it is information related to the consumed amount of ink. For example, in a configuration where the consumption of ink is obtained, whether or not the consumption of ink exceeds a predetermined consumption amount is determined in the determination process, and, in a case where it is determined that the consumption of ink exceeds the predetermined consumption amount, the contract information, etc., are obtained. (4) Embodiment(s) of the present invention can also be realized by a computer of a system or apparatus that reads out and executes computer executable instructions (e.g., one or more programs) recorded on a storage medium (which may also be referred to more fully as a ‘non-transitory computer-readable storage medium’) to perform the functions of one or more of the above-described embodiment(s) and/or that includes one or more circuits (e.g., application specific integrated circuit (ASIC)) for performing the functions of one or more of the above-described embodiment(s), and by a method performed by the computer of the system or apparatus by, for example, reading out and executing the computer executable instructions from the storage medium to perform the functions of one or more of the above-described embodiment(s) and/or controlling the one or more circuits to perform the functions of one or more of the above-described embodiment(s). The computer may comprise one or more processors (e.g., central processing unit (CPU), micro processing unit (MPU)) and may include a network of separate computers or separate processors to read out and execute the computer executable instructions. The computer executable instructions may be provided to the computer, for example, from a network or the storage medium. The storage medium may include, for example, one or more of a hard disk, a random-access memory (RAM), a read only memory (ROM), a storage of distributed computing systems, an optical disk (such as a compact disc (CD), digital versatile disc (DVD), or Blu-ray Disc (BD)™), a flash memory device, a memory card, and the like. (5) The above-described embodiments and various forms shown in (1) through (4) may be combined as appropriate. While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions. This application claims the benefit of Japanese Patent Application No. 2020-014808, filed Jan. 31, 2020, which is hereby incorporated by reference herein in its entirety. | 45,556 |
11858281 | DETAILED DESCRIPTION The following is a description of systems and methods for improving the durability of color material applied to non-printed machined characters on plastic cards. A material that is curable by radiation, such as UV radiation, is applied to the non-printed machined characters. The radiation curable material can be applied over the color material or mixed into the color material. Thereafter, the radiation curable material is cured by applying radiation, such as UV radiation. Non-printed machined characters (or just machined characters) refers to characters that are formed in a substrate material (the card body or card substrate) of the plastic card by permanently deforming the substrate material in some manner. Examples of non-printed machined characters include, but are not limited to, characters formed by embossing or indenting, characters formed by removing the substrate material with a laser (e.g. laser etching) or chemically, or characters formed by causing the substrate material to bubble or raise up using a laser or chemical reaction. Embossing, indenting, etching and bubbling a plastic card are known in the art of plastic card processing. The machined characters can be alphabetic characters, numerals, symbols, and combinations thereof. The machined characters can also have a design form including, but not limited to, emblems, seals, logos, and others. Embossed characters described herein are characters that are indented from one side of the plastic card and raised above the surface at the opposite side of the card. Embossed characters and bubbled characters may be collectively referred to as raised characters since they are raised above the surrounding card surface. Indented characters and etched characters may be collectively referred to as recessed characters since they are recessed below the surrounding card surface in one card surface and are not raised above the opposite card surface. Embossed characters and indented characters may also be collectively referred to as stamped characters since in embossing and indenting, a die stamp that is brought into engagement with the substrate material and pressure, optionally together with heat, is used to deform the substrate material to create the embossed or indented characters. A non-printed machined character excludes printed characters formed by printing processes such as thermal transfer printing, drop-on-demand printing, or the like. The plastic card can be any type of plastic card that is issued to a card holder and that includes machined characters. Examples of plastic cards include, but are not limited to, financial (e.g., credit, debit, or the like) cards, access cards, driver's licenses, national identification cards, business identification cards, gift cards, and other plastic cards. The term “plastic cards” as used throughout the specification and claims, unless indicated otherwise, refers to cards of this type where the card substrate can be formed entirely of plastic, formed of a combination of plastic and non-plastic material, or formed mostly or completely of non-plastic materials. In one embodiment, the cards can be sized to comply with ISO/IEC 7810 with dimensions of about 85.60 by about 53.98 millimeters (about 3⅜ in×about 2⅛ in) and rounded corners with a radius of about 2.88-3.48 mm (about ⅛ in). The plastic card may include personal data that is personal to the intended card holder, including a personal account number, the card holder's name, a photograph of the intended card holder, an address, an expiration date, and other personal data known in the art. The plastic card may also include non-personal data such as a name and/or logo of the card issuer and graphical elements. The machined characters described herein can form some or all of a personal account number, a card verification value (CVV) number, the card holder's name, an address, an expiration date, and other personal data. The machined characters may also form some or all of non-personal data. FIG.1illustrates an example of a plastic card10. In this example, the card10is shown to include a front surface12, a rear or back surface14(best seen inFIG.5A) opposite the front surface12, and a perimeter edge16. The card10includes personal data18, an optional integrated circuit chip20, and an optional magnetic stripe22. With continued reference toFIG.1, the personal data18in this example can be a photograph of the intended card holder, a personal account number, a CVV number, and the name of the cardholder. Some of the personal data18, such as portions of or the entirety of the personal account number, CVV number, and/or the cardholder name, can be formed by machined characters24that are formed on the card10. Some of the personal data18may be printed onto the card10using known printing techniques, for example direct to card thermal printing, drop-on-demand printing, retransfer printing, laser marking, and other printing techniques known in the art of plastic card processing. For sake of convenience, the machined characters24will be described and illustrated inFIG.1as forming the personal account number of the intended card holder. The machined characters24can be formed to be visible from the front surface12as depicted inFIG.1. Alternatively, the machined characters24can be formed to be visible from the rear surface14. Referring toFIG.2, a method30of personalizing a plastic card as described herein is illustrated. The method30includes forming the machined characters on the plastic card in step32. Thereafter, in step34, radiation curable material, such as UV curable colored ink and/or a UV curable varnish applied over a previously applied color material or applied together with a layer of color material, is applied to at least one of the machined characters. Thereafter, in step36, the radiation curable material is cured, for example in a curing mechanism. Additional optional steps that can occur prior to forming the machined characters can include a step38of inputting the card from a card input and in one or more steps40performing additional processing on the card. Additional optional steps that can occur after curing the radiation curable material can include in one or more steps42performing additional processing on the card, followed by a step44of outputting the card into a card output. Referring toFIG.3, the formation of the machined characters is preferably achieved using a first mechanism50. The application of the radiation curable material to the machined characters is preferably achieved using a second mechanism52. The curing of the radiation curable material is achieved using a curing mechanism54. The mechanisms50,52,54are preferably incorporated together into a plastic card personalization system56. The system56can be configured as a desktop card system that is typically designed for relatively smaller scale, individual card personalization in relatively small volumes, for example measured in tens or low hundreds of cards per hour, often times with a single card being processed at any one time. These card personalization machines are often termed desktop personalization machines because they have a relatively small footprint intended to permit the machine to reside on a desktop. Many examples of desktop personalization machines are known, such as the SD or CD family of desktop card printers available from Entrust Corporation of Shakopee, Minnesota Other examples of desktop personalization machines are disclosed in U.S. Pat. Nos. 7,434,728 and 7,398,972, each of which is incorporated herein by reference in its entirety. The system56can also be configured as a large volume batch production card personalization system (or central issuance personalization system) that processes cards in high volumes, for example on the order of high hundreds or thousands of cards per hour, and that employs multiple processing stations or modules to process multiple cards at the same time to reduce the overall per card processing time. Examples of such large volume card personalization machines include the MX and MPR family of central issuance personalization machines available from Entrust Corporation of Shakopee, Minnesota Other examples of central issuance personalization machines are disclosed in U.S. Pat. Nos. 4,825,054, 5,266,781, 6,783,067, and 6,902,107, all of which are incorporated herein by reference in their entirety. The first mechanism50can be any mechanism that is suitable for forming machined characters described herein. For example, the first mechanism50can be an embossing mechanism, an indenting mechanism, or a laser mechanism each of which are well known in the art of plastic card processing. Embossing mechanisms, indenting mechanisms, and laser mechanisms are available from Entrust Corporation of Shakopee, Minnesota. The second mechanism52is positioned relative to the first mechanism50to receive the plastic card from the first mechanism50after the machined characters are formed. The second mechanism52(which may also be referred to an as application mechanism) is configured to apply the radiation curable material to the machined characters. The radiation curable material can be applied over or incorporated into a color material that is applied to the machined characters. The color material and the radiation curable material (and an optional adhesive) can be applied from a topping foil in a single transfer step using heat and pressure or applied using one or more drop-on-demand print heads. In one embodiment, the color material and the radiation curable material (and the optional adhesive) can be separate layers. In another embodiment, the color material and the radiation curable material (and the optional adhesive) that is applied to the machined characters can be blended together or blended in other combinations (for example, color ink with adhesive with a separate radiation curable layer) and applied as a composition to the machined characters, for example using drop-on-demand printing. When the radiation curable material is in liquid or gel form, radiation curable material can be applied to the machined characters by a number of methods including, but not limited to, spraying, drop on demand printing, a pad, a roller, cylinders, anilox, and others. FIG.4Aillustrates an example of one of the machined characters24described herein in the form of a raised character raised on the surface12,14of the card10. In one embodiment, the raised character24can be an embossed character. In the example illustrated inFIG.4A, each machined character24can include a tip60. The tip60can be flat, upwardly or convexly rounded or curved, or have other shapes. In the example illustrated inFIG.4A, a colored material layer62and a radiation-cured transparent or translucent layer64are disposed on the tip60of each machined character24. The colored material layer62is disposed between the layer64and the surface of the tip60. In some embodiments, an adhesive layer66can be disposed between the colored material layer62and the surface of the tip60. FIG.4Billustrates another example of one of the machined characters24described herein in the form of a recessed character, for example an indented character, that is recessed into the surface12,14of the card10. In the example illustrated inFIG.4B, each machined character24can include a bottom surface68and upwardly extending side walls70. The cross-section of the recessed character is depicted as being generally rectangular. However, the recessed character can have other cross-sectional shapes such as U-shaped, V-shaped, and other shapes. In the example illustrated inFIG.4B, a colored material layer72is disposed in the recess and a radiation-cured transparent or translucent layer74is disposed over the layer72. In some embodiments, an adhesive layer (not shown) similar to the adhesive layer66inFIG.4A, can be disposed between the colored material layer72and the bottom surface68. The colored material layer72can cover a portion of the bottom surface68or the entire bottom surface68. In addition, the colored material layer72and the translucent layer74may fill only a portion of the depth of the recessed character, in which case the recessed character may be tactile, or the colored material layer72and the translucent layer74may fill the entire depth of the recessed character. Instead of separate layers62,64,66,72,74inFIGS.4A and4B, the layers62,64,66,72,74may be blended or mixed together in any combinations. For example, the colored material and the radiation curable material may be mixed together and simultaneously applied; the colored material and the adhesive may be mixed together and simultaneously applied, followed by application of the radiation curable material. Other combinations are possible. The colored material can be formed by any material that provides the desired color to the machined characters24. Examples of the colored material include, but are not limited to, a colored ink or a colored metal. Examples of colors include, but are not limited to, black, white, metallic silver, metallic gold, and the like, each of which is known in the art. When the colored ink is formed by a metallic ink such as metallic silver or metallic gold, the adhesive layer66inFIG.4Amay be useful to help adhere the metallic ink to the card material. The radiation curable material, such as the layer64inFIG.4Aor the layer74inFIG.4B, is a layer of transparent or translucent material that is initially applied to the machined characters24in an uncured form and then cured after being applied via radiation applied to the uncured material. Examples of the radiation curable material that can be used include, but are not limited to, UV curable varnish, UV curable topcoat such as CardGard™, UV curable acrylates, UV curable urethanes, and UV curable clear overlay, each of which is available from Entrust Corporation of Shakopee, Minnesota. In one embodiment described further below, the colored ink layer and the uncured radiation curable material (and the adhesive layer if used), are applied together in a single transfer step from a topping foil in a hot stamping process. Once cured, the radiation-cured layer protects the underlying ink layer thereby enhancing the durability of the ink layer. In another embodiment, the colored ink and the radiation curable material can be blended together into a mixture, with the mixture then applied to the machined characters24, and the radiation curable material is then cured. Examples of colored ink that can be used to color the machined characters herein are the color inks in ink jet cartridges, and the Cyan, Magenta, Yellow, Black and White drop-on-demand ink cartridges available from Entrust Corporation of Shakopee, Minnesota. In addition, an example of a clear varnish that can be used as the radiation curable material is the clear varnish drop-on-demand cartridge available from Entrust Corporation of Shakopee, Minnesota. Returning toFIG.1, the integrated circuit chip20is known in the art and can include data storage for storing data thereon. The data stored on the chip20can include personal data of the intended card holder such as the cardholder's name, personal account number, the CVV number, biometric data of the cardholder, and other data. The chip20can be a contactless chip that is powered by a contactless chip reader through radio frequency induction via an antenna of the chip reader. The chip20may also be a contact chip that is intended for direct contact with a contact chip reader which provides power to the chip20. The chip20may be completely embedded within the thickness of the card so that no portion of the chip20is exposed, or portions of the chip20may be exposed. The construction and operation of both contactless chips and contact chips on cards is well known in the art. The magnetic stripe22has a construction and operation that is well known in the art. In the example illustrated inFIG.1, the magnetic stripe22is depicted as being located on the rear surface14of the card10. However, the magnetic stripe22(if present) can be located on the front surface12. The magnetic stripe22can store various data thereon including, but not limited to, data of the intended card holder such as the cardholder's name, the CVV number, personal account number, biometric data of the cardholder, and other data. Referring toFIG.5A, an embodiment of a plastic card personalization system80that incorporates the mechanisms50,52,54is illustrated. The system80includes the first mechanism50which in this embodiment is illustrated as creating a machined character24in the form of a raised character on the plastic card10. However, in other embodiments, the first mechanism50can be configured to form indented or other recessed characters. A card transport direction of the card10through the system80is illustrated by the arrow D. The system80can optionally include additional card processing mechanisms. The50,52,54can be separate mechanisms or modules, or the functions of the mechanisms50,52,54can be integrated together into a single mechanism. InFIG.5A, the second mechanism52is configured as a topping mechanism that is configured to apply radiation curable material as well as colorant material to the tips of the machined characters24. The first mechanism50is configured to receive the card10and create one or more of the machined characters24on the card10. The construction and operation of mechanisms, such as embossers and lasers, for creating raised, machined characters on cards is well known in the art. An example of an embosser that can be used is the embossing mechanism described in US 2007/0187870 the entire contents of which are incorporated herein by reference. Additional examples of embossers that can be used are the embossing mechanisms used in the MX and MPR family of central issuance processing machines available from Entrust Corporation of Shakopee, Minnesota. The second mechanism52receives the card10after the card10is formed with the machined characters in the first mechanism50, and the second mechanism52is configured to apply the colored material layer to color the tips of the machined characters and also apply the radiation curable material layer. In this example, the second mechanism52includes a foil82, a supply spool84that supplies the foil82, and a take-up spool86that takes-up used foil82. The foil82is directed past a transfer station that includes a heated stamp or die88that is actuatable toward and away from the card10to press the foil82into engagement with the tips of the machined characters to transfer the colorant, for example a colored ink or colored metal, and the radiation curable material to the tips, and a fixed platen90disposed opposite the stamp88to support the card during hot stamping by the stamp88. The foil82is configured to transfer the colored material layer and the radiation-curable layer (and optionally the adhesive layer) to the tips of the machined characters (or into the recessed machined characters) in a single transfer step at the transfer station.FIG.6illustrates a first embodiment of the foil82. In this embodiment, the foil82includes a carrier layer92, a layer94of radiation curable material disposed on the carrier layer92, and a layer96of colored ink disposed over the layer94. In operation, a portion of the ink from the layer96and a portion of the radiation curable material from the layer94are simultaneously transferrable from the carrier layer92to the tips of the machined characters (or into the recessed machined characters) in the transfer station to form the colored material layer and the uncured radiation curable layer. In another embodiment, the material of the layers94,96are combined together into a mixture so that the foil82has a single layer on the carrier layer92which combines both coloring material and radiation curable material to form a radiation curable colored ink, with material from the single layer then being transferred from the foil to the machined characters and thereafter the material is cured. In one non-limiting embodiment, the first mechanism50is configured to form embossed characters, the second mechanism is configured to apply color material and/or radiation curable material to the tips of the embossed characters from the foil82, followed thereafter by curing the radiation curable material in the curing mechanism54. FIG.7illustrates a second embodiment of the foil82. In this embodiment, the foil82includes the carrier layer92, the layer94of radiation curable material disposed on the carrier layer60, the layer96of colored material disposed over the layer94, and a layer98of adhesive material that helps to adhere the colored material to the machined characters. In operation of this embodiment, a portion of the adhesive from the layer98, a portion of the colored material from the layer96, and a portion of the radiation curable material from the layer94are simultaneously transferrable from the carrier layer92to the machined characters in the transfer station. In another embodiment, the material of the layers94.96are combined together into a mixture so that the foil82has a layer on the carrier layer92which combines both coloring material and radiation curable material to form a radiation curable colored ink together with the adhesive layer98. In still another embodiment, the material of the layers94,96,98are combined together into a mixture so that the foil82has a single layer on the carrier layer92which combines both coloring material, radiation curable material and adhesive to form a radiation curable colored ink. Returning toFIG.5A, after the material is applied to the machined characters, the card10is transported to the curing mechanism54to cure the radiation curable material. The curing mechanism54is configured to generate and apply radiation, such as UV radiation, to the radiation curable material to cure the radiation curable material. An example of a mechanism that can generate and apply curing radiation in a card personalization system is the radiation applicator used in the DATACARD® MX8100™ Card Issuance System available from Entrust Corporation of Shakopee, Minnesota. Referring toFIG.5B, another embodiment of a plastic card personalization system180is illustrated. In the system180, elements that are the same as or similar to the elements inFIG.5Aare referenced using the same reference numerals. The system180is depicted as being configured to create indented characters on the card10and at the same time apply coloring material and radiation curable material (and optionally adhesive) to the indented characters at the same time the indented characters are formed. So in the system180the first mechanism50and the second mechanism52are combined into a common mechanism. InFIG.5B, the combined mechanism50,52is configured as an indenting mechanism that creates machined characters in the form of indented characters and that uses one of the ribbons82inFIGS.6and7. The construction and operation of indenting mechanisms, for creating indented, machined characters on cards is well known in the art. An example of an indenter that can be used is the indenting mechanism described in U.S. Pat. No. 10,625,464 the entire contents of which are incorporated herein by reference. Additional examples of indenters that can be used are available from Entrust Corporation of Shakopee, Minnesota. In this example, the combined mechanism50,52includes the foil82, the supply spool84that supplies the foil82, and the take-up spool86that takes-up used foil82. The foil82is directed past a transfer station that includes a heated stamp or die88that is actuatable toward and away from the card10. The die88includes one or more projecting, heated characters89press into the card10to create the indented character. At the same time, the foil82is pressed into the indented character that is being formed to simultaneously transfer the colorant, for example a colored ink or colored metal, and the radiation curable material (or the mixture thereof) into the indented character created by the character(s)89. The fixed platen90is disposed opposite the stamp88to support the card during creation of the indented character(s) by the character(s)89. The card10is then transported to the curing mechanism54to cure the radiation curable material. With reference toFIG.8, in another embodiment, the application of the colored material and/or the application of the UV curable material to the machined characters in the second mechanism52can be performed using drop-on-demand printing technology. InFIG.8, elements that are or can be the same as inFIGS.1-7are referenced using the same reference numerals. InFIG.8, a plastic card personalization system100includes the first mechanism50, the second mechanism52which in this embodiment functions by drop-on-demand printing using one or more drop-on-demand print heads102a-f, and the curing mechanism54. The card transport direction of the card10through the system100is illustrated by the arrow D. The system100can also optionally include a vision module104, and a surface treatment mechanism106. The vision module104and the surface treatment mechanism106may be considered part of the second mechanism52or separate from the second mechanism52. The first mechanism50, the vision module104, the surface treatment mechanism106, the second mechanism52and the curing mechanism54can be separate mechanisms or modules, or the functions thereof can be integrated together into a single mechanism. In operation of the system inFIG.8, the machined characters24are formed on the card10in the first mechanism50. Thereafter, the card10can be transported to the vision module104(if present) to capture an image of the machined characters24on the card10to ascertain details of the machined characters and where the machined characters are located on the card. Thereafter, the card can be transported to the second mechanism52which performs drop-on-demand printing using one or more of the drop-on-demand print heads102a-fto apply colored ink or other colored material, radiation curable material (such as radiation curable colored ink or other radiation curable colored material) or radiation curable varnish (which is clear or translucent or semi-clear), and/or a mixture of colored ink and radiation curable material or radiation curable varnish on the machined characters24. In some embodiments, for example if radiation curable varnish is applied over a previously applied radiation curable colored ink or other radiation curable colored material, an additional curing mechanism, sometimes called a pinning lamp, can be provided, for example immediately after the individual print head102a-fthat applies the radiation curable colored ink or other colored material, to partially cure the colored ink/colored material before applying the radiation curable varnish. In this case, the radiation curable colored ink/colored material can be applied in a first drop-on-demand print head, which is followed by the additional curing mechanism, which in turn is followed by a second drop-on-demand print head that applies the radiation curable varnish. The print heads102a-fcan also perform other drop-on-demand printing on portions of the card surface other than the machined characters as well. As illustrated inFIG.8, separate print heads102a-fcan be provided to print different colors and/or different materials on the machined characters. However, in some embodiments, the second mechanism52can include a single drop-on-demand print head, or any other number of drop-on-demand print heads. Thereafter, the card is transported to the curing mechanism54to cure the radiation curable material. In some embodiments, the surface treatment mechanism106can be provided to apply surface treatments, such as plasma or corona treatment, to the machined characters (as well as to other portions of the card surface) before printing with radiation curable inks. The use of drop-on-demand printing techniques permits application of any color on the machined characters24. In addition, radiation cured inks are inherently more durable than uncured inks. Additionally, a clear varnish can be applied over the radiation curable ink for a further increase in the durability. In some embodiments, material can be applied to the machined characters using a combination of application techniques described herein. For example, colored material (optionally together with an adhesive) such as colored ink can be applied to one or more of the machined characters using the foil50, while a radiation curable material, such as radiation curable varnish, can be applied over the colored material using one of the drop-on-demand print heads102a-f FIG.9is a schematic depiction of a plastic card processing system110that includes the first mechanism50, the second mechanism52and the curing mechanism54. In this example, the mechanisms50,52,54are illustrated as being in-line and in sequential order with one another so that the mechanisms50,52,54effectively form a single combined mechanism. However, the mechanisms50,52,54can be spaced apart from one another with or without one or more additional mechanisms disposed between the mechanisms50,52,54. In this example, the system110can be configured to perform only the formation of the machined characters, the application of the radiation curable material to the machined characters, and the curing of the radiation curable material on the card. FIG.10is a schematic depiction of another embodiment of a plastic card processing system120that includes the first mechanism52, the second mechanism52and the curing mechanism54. In this example, the mechanisms50,52,54are illustrated as being in-line and in sequential order with one another. Each mechanism50,52,54is a separate module or mechanism from the other, facilitating replacement and/or maintenance on the mechanisms50,52,54and/or inclusion of other mechanisms between the mechanisms50,52,54. The system120can also include additional card processing mechanisms in addition to the mechanisms50,52,54to perform additional processing on the card. For example, the system120can include a card input122(also referred to as a card input hopper) which can be located, for example upstream of the first mechanism50, to feed cards one by one into the system120. The card input122is configured to hold a plurality of plastic cards to be processed as described herein. One or more additional card processing mechanisms124can be provided between the card input122and the first mechanism50. The card processing mechanism(s)124can be one or more of an integrated circuit chip programming mechanism, a magnetic stripe read/write mechanism, a printing mechanism for performing printing on the cards, and other card processing mechanisms know in the art. Similarly, one or more additional card processing mechanisms126can be provided downstream of the curing mechanism54. The card processing mechanism(s)126can be one or more of an integrated circuit chip programming mechanism, a magnetic stripe read/write mechanism, a printing mechanism for performing printing on the cards, a quality assurance mechanism for checking the quality of the processing on the cards, and other card processing mechanisms know in the art. A card output128(also referred to as a card output hopper) can be located downstream from the curing mechanism54at the end of the system120. The card output128is configured to hold a plurality of the plastic cards after being processed. The card is transported in the systems described herein using one or more suitable mechanical card transport mechanisms (not shown). Mechanical card transport mechanism(s) for transporting cards in card processing equipment of the type described herein are well known in the art. Examples of mechanical card transport mechanisms that could be used are known in the art and include, but are not limited to, transport rollers, transport belts (with tabs and/or without tabs), vacuum transport mechanisms, transport carriages, and the like and combinations thereof. Card transport mechanisms are well known in the art including those disclosed in U.S. Pat. Nos. 6,902,107, 5,837,991, 6,131,817, and 4,995,501 and U.S. Published Application No. 2007/0187870, each of which is incorporated herein by reference in its entirety. A person of ordinary skill in the art would readily understand the type(s) of card transport mechanisms that could be used, as well as the construction and operation of such card transport mechanisms. The following additional implementations of the invention are also possible. A plastic card personalization system can include a first mechanism that is configured to form non-printed machined characters on a plastic card by deforming a substrate material of the plastic card, a second mechanism that is positioned relative to the first mechanism to receive the plastic card with the non-printed machined characters, where the second mechanism is configured to apply radiation curable material to the non-printed machined characters, and a curing mechanism is positioned relative to the second mechanism to receive the plastic card with the radiation curable material applied to the non-printed machined characters, where the curing mechanism is configured to generate and apply radiation to the non-printed machined characters to cure the radiation curable material. The second mechanism can be configured to apply an ink to the indented characters. In addition, a card input can be provided that is configured to hold a plurality of the plastic cards and feed the plastic card for processing by the first mechanism, as well as include a card output that is configured to hold the plastic card after the radiation curable material is cured in the curing mechanism. The second mechanism can include one or a plurality of drop-on-demand print heads. The radiation curable material can be applied from a plurality of drop-on-demand print heads. A method of personalizing a plastic card can include forming non-printed machined characters on the plastic card in a first mechanism by deforming a substrate material of the plastic card. Thereafter, the plastic card can be transported to a second mechanism and radiation curable material is applied to the non-printed machined characters in the second mechanism. Thereafter the plastic card can be transported to a curing mechanism and the radiation curable material that is applied to the non-printed machined characters is cured in the curing mechanism. The second mechanism may be used to apply an ink to the indented characters. In addition, prior to forming the non-printed machined characters on the plastic card, the plastic card can be fed from a card input that is configured to hold a plurality of the plastic cards, and after curing the radiation curable material the plastic card can be output into a card output that is configured to hold the plastic card. In addition, a plastic card personalization system can include an embossing mechanism configured to form embossed characters on a plastic card; an application mechanism positioned to receive the plastic card after the plastic card is embossed in the embossing mechanism, where the application mechanism is configured to apply radiation curable material to tips of the embossed characters, and a curing mechanism that is positioned to receive the plastic card after the application mechanism applies the radiation curable material, where the curing mechanism is configured to generate and apply radiation to the embossed characters to cure the radiation curable material. The application mechanism may be configured to apply the radiation curable material and an ink to the tips of the embossed characters. In addition, the application mechanism may be configured to apply the radiation curable material using a topping foil or using drop-on-demand printing. In addition, the system ca include a card input that is configured to hold a plurality of the plastic cards, and a card output that is configured to hold the plastic card after the radiation curable material is cured. In addition, the application mechanism can include a topping foil that includes a carrier layer, a layer of the radiation curable material, and a layer of ink, wherein the layer of the radiation curable material is disposed between the carrier layer and the layer of ink. In addition, the topping foil can further include a layer of adhesive, wherein the layer of the radiation curable material and the layer of ink are disposed between the carrier layer and the layer of adhesive. In addition, the application mechanism can include at least one drop-on-demand print head that applies the radiation curable material. In addition, the application mechanism can include a plurality of drop-on-demand print heads that apply the radiation curable material. In another implementation, a plastic card personalization system can include an indenting mechanism configured to form indented characters on a plastic card, an application mechanism positioned to receive the plastic card after the indented characters are formed in the indenting mechanism, wherein the application mechanism is configured to apply radiation curable material to the indented characters, and a curing mechanism positioned to receive the plastic card after the application mechanism applies the radiation curable material, where the curing mechanism is configured to generate and apply radiation to the indented characters to cure the radiation curable material. The application mechanism may be configured to apply the radiation curable material and an ink to the indented characters. In addition, the application mechanism may be configured to apply the radiation curable material using a topping foil or using drop-on-demand printing. In addition, the system can include a card input that is configured to hold a plurality of the plastic cards, and a card output that is configured to hold the plastic card after the radiation curable material is cured. In addition, the application mechanism can include a topping foil that includes a carrier layer, a layer of the radiation curable material, and a layer of ink, wherein the layer of the radiation curable material is disposed between the carrier layer and the layer of ink. In addition, the topping foil can further include a layer of adhesive, wherein the layer of the radiation curable material and the layer of ink are disposed between the carrier layer and the layer of adhesive. In addition, the application mechanism can include at least one drop-on-demand print head that applies the radiation curable material. In addition, the application mechanism can include a plurality of drop-on-demand print heads that apply the radiation curable material. The examples disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. | 39,244 |
11858282 | DETAILED DESCRIPTION Reference will now be made in detail to the various non-limiting exemplary embodiments of the disclosed subject matter, non-limiting exemplary embodiments of which are illustrated in the accompanying drawings. The structure and corresponding method of operation of the disclosed subject matter will be described in conjunction with the detailed description of the system. The presently disclosed subject matter relates generally to systems, methods, and devices for marking tablet-shaped articles. The presently disclosed subject matter is particularly suited for post-production marking and/or printing on tablet-shaped articles, such as candies. The terms used in this specification generally have their ordinary meanings in the art, within the context of the present disclosure and in the specific context where each term is used. Certain terms are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner in describing the systems and methods of the present disclosure and how to make and use them. Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises,” mean “including but not limited to,” and do not exclude other components, integers or steps. Moreover, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. As used herein, the use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification can mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” Still further, the terms “having,” “including,” “containing” and “comprising” are interchangeable and one of skill in the art is cognizant that these terms are open ended terms. The term “about” or “approximately” means within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, i.e., the limitations of the measurement system. For example, “about” can mean within 3 or more than 3 standard deviations, per the practice in the art. Alternatively, “about” can mean a range of up to 20%, up to 10%, up to 5%, or up to 1% of a given value. Alternatively, particularly with respect to biological systems or processes, the term can mean within an order of magnitude, within 5-fold, or within 2-fold, of a value. Preferred features of each aspect of the presently disclosed subject matter can be as described in connection with any of the other aspects. Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, can be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, certain example embodiments. Subject matter can, however, be embodied in a variety of different forms and, therefore, covered or claimed subject matter is intended to be construed as not being limited to any example embodiments set forth herein; example embodiments are provided merely to be illustrative. Likewise, a reasonably broad scope for claimed or covered subject matter is intended. Among other things, for example, subject matter can be embodied as methods, devices, components, or systems. The following detailed description is, therefore, not intended to be taken in a limiting sense. The disclosed subject matter is directed to printing on tablet-shaped articles, such as for purposes of example drugs and candies. Tablet-shaped articles suitable for the present printer include medicinal tablets or pills, such as Advil® ibuprofen tablets and Tylenol® acetaminophen tablets, candies, such as M&M's chocolate candies, Skittles® fruity candies and Reese's™ Pieces candies, and tablet gums, such as Orbit® gum tablets. A tablet-shaped article as used herein can have two opposing surfaces joined by a continuous transitional surface that connects the two opposing surfaces. The two opposing surfaces can be flat surfaces or have a convex or concave contour. The shape of the opposing surfaces can be any geometric shape, including a circle, oval, square or rectangle, and the transitional surface can be flat or curved. The diameter or width of each opposing surface can be larger than the width of the transitional surface such that the thickness of the tablet-shaped article is smaller than the diameter or width of the opposing surfaces. Tablet-shaped articles suitable for use with the disclosed subject matter can be relatively small such that one or more of the articles can be easily handled. Examples of tablet-shaped articles in accordance with the disclosed subject matter include medicament tablets and candies, as noted above. Systems in accordance with the disclosed subject matter include a hopper and a conveyor. The conveyor has opposing first and second side portions, and at least one pocket is defined in the conveyor between the opposing first and second side portions. The conveyor is configured to receive from the hopper a tablet-shaped article in the at least one pocket. A first window is defined in the first side portion of the conveyor. The first window defines an opening between the pocket and an external environment. The system further includes a first printing head adjacent the first side portion of the conveyor. The first printing head is configured to mark the tablet-shaped article through the first window. Printing systems in accordance with the disclosed subject matter can have fewer moving parts such that the printer can be operated reliably with less maintenance downtime of operation, such as for cleaning and replacing parts. In addition, printers and systems in accordance with the disclosed subject matter can have a compact profile and can be suitable as a mobile printer. Hereinafter, the terms printing and marking are used to indicate printing and marking by applying inks, etching a thin layer from the surface, or causing a change in color on the surface of a tablet-shaped article. A non-limiting exemplary embodiment of a system in accordance with the disclosed subject matter for marking and/or printing marks or information on tablet-shaped articles is illustrated with reference toFIG.1. The system10includes a hopper12and a conveyor14. The hopper12can hold a multitude of tablet-shaped articles and can dispense the tablet-shaped articles onto the conveyor14. As embodied herein, the bottom of the hopper can include an article aligner disposed proximate an exit path of the hopper12. The article aligner can align the tablet-shaped articles in a row for dispensing the tablet-shaped articles onto the conveyor14in a desired orientation. For example, the article aligner can align tablet-shaped articles in a vertical orientation, with the tablet-shaped articles standing on their respective transitional surfaces. A non-limiting exemplary article aligner30is illustrated inFIG.2. As embodied herein, the article aligner can define a channel31having a longitudinal dimension. As embodied herein channel31can be defined between two vertical panels32and34, and a bottom panel36, and from an open end to a closed end. As embodied herein, the three panels can form a U-shaped channel or slot with an upper opening33. The bottom panel36can have a bottom panel width that is slightly larger than the thickness of the tablet-shaped articles to be dispensed, but smaller than the width or diameter of the opposing surfaces of the tablet-shaped articles to be dispensed. The upper opening33can have an opening width substantially similar to the bottom panel width. The channel31can have a width dimension greater than a thickness dimension of articles to be dispensed from the hopper and less than a width dimension of articles to be dispensed from the hopper. The upper opening33of the article aligner30can allow tablet-shaped articles in the hopper to drop into the channel or slot31, thereby the tablet-shaped articles can form a line of consecutively placed tablet-shaped articles in a linear row in a vertically oriented position. For example, the tablet-shaped articles can be oriented with the two opposing surfaces of the tablet-shaped articles facing the two vertical panels30and32and the tablet-shaped articles standing on their respective transitional surfaces in the channel31. As embodied herein, one end of the bottom horizontal panel36can include a bottom opening38, which is slightly larger than the table-shaped articles to be dispensed, such that the tablet-shaped articles positioned above the bottom opening38can pass through the bottom opening38, one at a time. For example, the end of the article aligner30opposite the bottom opening38can be elevated such that tablet-shaped articles placed in the article aligner30move down towards the bottom opening38by gravity and fall therethrough. Alternatively or additionally, there can be a mechanical advancing mechanism to move the tablet-shaped articles through the article aligner30. For purpose of example, the advancing mechanism can include a vibrational mechanism or rotary advancing mechanism. Additionally or alternatively, the hopper12can include a mechanism that vibrates the hopper12. Vibrating the hopper can cause the tablet-shaped articles disposed in the hopper12to move towards the article aligner30and the bottom opening38. In accordance with another aspect of the disclosed subject matter, the hopper12can include an opening at the bottom of the hopper12. The opening can have a shape and dimensions substantially similar to a shape and dimensions of a vertically standing tablet-shaped article to be dispensed, such that the tablet-shaped articles fall through the bottom opening of the hopper, one at a time and properly aligned. As embodied herein, the hopper12can be mounted to a table24. The table24can provide a sturdy surface for mounting components of the system. The table24can be moveable, such as on wheels, which can facilitate movement of the system10to the desired location. Systems in accordance with the disclosed subject matter further include a conveyor14. As embodied herein, the conveyor can be a rotary wheel conveyor. The rotary wheel conveyor can rotationally transfer the at least one tablet-shaped article from the hopper. With reference to the non-limiting exemplary system10depicted inFIG.1, the rotary wheel conveyor14can be placed under the bottom opening38of the article aligner30disposed proximate the exit path of the hopper12to receive tablet-shaped articles coming out of the hopper12.FIG.3illustrates an example of a rotary wheel conveyor14in accordance with an aspect of the disclosed subject matter. The rotary wheel conveyor14can be fabricated from a rigid material, such as aluminum, steel, iron or copper, and fabricated to be a one-piece wheel or have different sections. The rotary wheel conveyor14can be driven by a motor to rotate it along the center of the rotary wheel conveyor. As embodied herein, the rotary wheel conveyor14can be driven directly by a gear motor. Using direct drive can control movement of the conveyor using fewer components. For example, systems in accordance with the disclosed subject matter using direct drive do not require a chain threaded around sprockets, or other features such as pulleys and belts to drive the conveyor. As described further herein, systems utilizing pulleys and belts, for example, to control motion of a conveyor can require additional maintenance and downtime. Rotary wheel conveyors can also assist with drying of printed ink on tablet-shaped articles after printing. For example, the tablet-shaped articles can continue drying in the conveyor as they are rotationally advanced. As embodied herein, the rotary wheel conveyor14has an inner wheel portion42, and a plurality of outer wheel portions44coupled to the inner wheel portion42. The plurality of the outer wheel portions44can together define an outer circumference of the rotary wheel conveyor14. As embodied herein, the plurality of outer wheel portions44can also define an inner surface that securely couples with the inner wheel portion42to form the rotary wheel conveyor14. As embodied herein, each of the plurality of outer wheel portions44can be removable from the rotary wheel conveyor14and configured to be replaced by another outer wheel portion. As described further herein, the at least one pocket46can be defined in at least one of the plurality of outer wheel portions44. One advantage of using the multi-portion outer wheel design is that each outer wheel portion44can be individually replaced. As such, if one outer wheel portion is damaged, it can be quickly and easily replaced while the remaining outer portions remain affixed to the inner wheel portion. Furthermore, each outer wheel portion can be the same to receive the same sized tablets therein or can be different to accommodate different shapes and sizes of the tablet-shaped articles. In accordance with the disclosed subject matter, the conveyor includes opposing first and second side portions41,43and at least one pocket46defined in the conveyor between the opposing first and second side portions41,43. With reference toFIG.3, the at least one pocket46can be defined along the outer circumference of the rotary wheel conveyor14. For example, and as embodied herein, the at least one pocket46can be defined in at least one of the plurality of outer wheel portions44. The at least one pocket46is configured to receive a tablet-shaped article from the hopper12. As embodied herein, each pocket46can be configured to receive and reversibly hold one of the tablet-shaped articles. There can be a plurality of pockets46defined in the conveyor14. For example but not for limitation, at least three pockets46can be defined in each of the outer wheel portions44, as depicted inFIG.4. The at least one pocket46can have different shapes, including the lower holding section of the pocket as further described below. The non-limiting exemplary system in accordance with the disclosed subject matter is described with reference to a circular tablet-shaped article, for illustration purposes.FIGS.4and5illustrate pockets46that are adapted to handle (i.e., hold and carry) one or more circular tablet-shaped articles. As embodied herein, the pocket46can have a U-shape in front view such that the circular tablet-shaped article can be snuggly placed in the pocket46. The U-shape can be characterized as an upper longitudinal section45and a lower holding section47. The depth of the pocket46, including the upper longitudinal section45and the lower holding section47, can be configured at least as deep as the diameter or width of the tablet-shaped article to be conveyed. As such, the tablet-shaped article can be disposed completely within the at least one pocket46. As embodied herein, the at least one pocket46can have a pocket thickness48measured between the opposing first and second side portions41,43. The pocket thickness48can be larger than a thickness of the tablet-shaped article to be conveyed such that the at least one pocket46can hold the tablet-shaped article in a vertically standing position. The dimensions of the pocket46are such that the tablet-shaped article is completely held within the pocket46of the rotary wheel conveyor, except for the windows50that are fabricated to expose one or both of the two opposing surfaces of the tablet-shaped article, as described further below. As embodied herein, the shape of the lower holding section47of the at least one pocket46resembles or substantially resembles at least the lower half of the vertically standing tablet-shaped article to be conveyed. The dimensions of the at least one pocket46can be selected such that the tablet-shaped article snugly fits into the pocket and can rest on the lower holding section47of the pocket46when the at least one pocket46is in an upright orientation, with the upper longitudinal section45above the lower holding section47. As embodied herein, the dimensions of the pocket46can be slightly larger than the dimensions of the tablet-shaped article to be conveyed for tolerances and the like, such that the tablet-shaped article can move in and out of the pocket46under gravitational forces without requiring additional mechanical force and without substantial friction. For example, and as embodied herein, tablet-shaped articles to be conveyed can be received in the at least one pocket46with the pocket in an upright orientation with the upper longitudinal section45above the lower holding section47. As the conveyor14turns, the at least one pocket46can transition to a downward facing orientation, with the upper longitudinal section45below the lower holding section47. Conveyed tablet-shaped articles can be dispensed from the conveyor with the pocket in a downward facing configuration. As embodied herein, the tablet-shaped articles can be dispensed into a collection basket22. The dimensions of the pocket can be selected such when the tablet-shaped article is received in the at least one pocket46and sits in the lower holding section47, the tablet-shaped article does not tilt from side to side or move around within the pocket46. For example, the pocket thickness and the pocket width of the lower holding section47of the pocket can be less than 2 mm, desirably less than 1 mm, larger than the thickness and width, respectively, of the tablet-shaped article to be conveyed. As embodied herein, the at least one pocket46has an upper opening52with opening dimensions larger than the dimensions of the tablet-shaped article to be conveyed. For example, the upper opening52can have opening thickness and opening width dimensions larger than the pocket thickness and the pocket width of the lower holding section47of the pocket46so that the tablet-shaped articles can freely (i.e., without any frictional or other dimensional restrictions) move in and out of the pocket46through the upper opening52. For example, the opening thickness and the opening width of the upper opening52of the pocket46can be less than 4 mm, desirably less than 3 mm, larger than the thickness and width, respectively, of the tablet-shaped article to be conveyed. The dimensions of the at least one pocket46can gradually transition from the upper opening52to the lower holding section47of the pocket46through the upper longitudinal section45, which can ensure uninterrupted, smooth passage between the two sections. As embodied herein, and with reference toFIG.5, the conveyor can include at least one pressure port52in communication with the at least one pocket46. The pressure port52can apply vacuum to hold the tablet-shaped article in the pocket46. As embodied herein, the pressure port52can be placed at the lowest point of the lower holding section47. As further described herein, the pressure port52can additionally or alternatively apply a positive pressure to eject the at least one tablet-shaped article from the conveyor. For example, a positive pressure can be applied to eject the tablet-shaped article after the article has been marked. Additionally or alternatively, the system may include one or more clean out brushes, and the one or more clean out brushes can be used to help extract tablet-shaped articles from the at least one pocket46in the conveyor after the tablet-shaped article has been printed or marked. In accordance with the disclosed subject matter, the first side portion41of the conveyor14defines a first window50. The first window50comprises an opening between the pocket and an external environment. As embodied herein, the first window50can expose a surface of the tablet-shaped article when the tablet-shaped article is placed in the pocket46, and the exposed surface of the tablet-shaped article can be printed through the first window50. The dimensions of the first window50can be smaller than the width of the tablet-shaped article to be marked to prevent the tablet-shaped article from slipping out of the pocket46through the first window50. As embodied herein, the first window50can expose a center area of one of the opposing surfaces of the tablet-shaped article. The first window50can be an opening defined in the lower holding section47of the at least one pocket46. Alternatively, and as embodied herein, the first window can be an elongated opening extending from the upper opening52to the lower holding section47of the at least one pocket46. With reference toFIG.1, systems in accordance with the disclosed subject matter include a first printing head18adjacent the first side portion41of the conveyor14. As embodied herein, the first printing head18can be provided, such as mounted to the table24. As further described herein, the first printing head18is configured to mark or print the tablet-shaped article through the first window50as the tablet-shaped article is passed by the first printing head18by the conveyor14. Printers in accordance with the disclosed subject matter can include non-contact marking printers, such as inkjet printers, laser printers, and laser etching-printers. Suitable printers and inks are known and for example disclosed in U.S. Pat. No. 7,597,752, which is hereby incorporated by reference in its entirety. Particularly suitable printers and edible inks can produce edible products. In accordance with an aspect of the disclosed subject matter, and with reference toFIG.4, the second side portion43of the conveyor14can define a second window51. The second window51can have any of the features described above with respect to the first window50. As embodied herein, the first and second windows50,51can have matching configurations. Alternatively, the first and second windows50,51, can have different configurations. The first window50, second window51and space therebetween can be fluidly coupled with each other, as shown inFIG.4. As embodied herein, and with reference toFIG.1, systems in accordance with the disclosed subject matter can include a second printing head20adjacent the second side portion43of the conveyor14. The second printing head20can be configured to mark the tablet-shaped articles through the second window. For example, the system10can be configured with the first printing head18and the second printing head20configured to mark tablet-shaped articles on each opposing surface of the tablet-shaped article through the first and second window of the conveyor, respectively. As embodied herein, and with reference toFIG.1, systems in accordance with the disclosed subject matter can include an inspection station16. The inspection station can inspect and detect potential issues in the system for at least two aspects. First, the inspection station can inspect and detect, for example through the first window50and/or the second window51, that there is a tablet-shaped article in the at least one pocket46. Second, when a tablet-shaped article is present in the pocket46, the inspection station can inspect and determine whether there is any marking or printing on the surface of the tablet-shaped article exposed through the first window50. Additionally or alternatively, the inspection station can inspect the opposing surface of the tablet-shaped article, for example through the second window51, to determine if there is any marking or printing on the opposing surface of the tablet-shaped article. The inspection information of whether there is a (previously applied or otherwise) printing on one or both of the opposing surfaces of the tablet-shaped article can be communicated by signal or the like to a central processing unit (CPU) and stored for further system optimization. In accordance with one aspect of the disclosed subject matter, if tablet-shaped articles that have pre-applied printing on one of their opposing surfaces are supplied to the hopper12, a new marking or printing can be applied on the unmarked opposing surface of the tablet-shaped articles. Algorithms suitable for such inspection stations are known in the art. In accordance with an aspect of the disclosed subject matter, the system10can include an article rotator configured to rotate the tablet-shaped article and orient a first surface of the tablet-shaped article towards the first side portion41of the conveyor14. The rotating mechanism can be a robotic manipulating device, for example. An article rotator can be used, for example, in systems configured with only a first printer head18. For example, the tablet-shaped article rotator can be disposed between the inspection station and the printing head. Based on the result of the inspection, if an unmarked surface of the tablet-shaped article is not oriented towards the first printing head18, the article rotator can remove the tablet-shaped article from the pocket46, rotate the tablet-shaped article, and insert the tablet-shaped article back into the pocket46with the unmarked side oriented towards the printing head18. The disclosed subject matter also includes methods for marking tablet-shaped articles. Methods in accordance with the disclosed subject matter include providing a system for marking tablet-shaped articles having any combination of the features described above. Methods in accordance with the disclosed subject matter further include disposing at least one tablet-shaped article in the system's hopper and dispensing the at least one tablet-shaped article from the hopper into the at least one pocket defined in the conveyor. Methods in accordance with the disclosed subject matter further include conveying the at least one tablet-shaped article from the hopper to the first printing head and marking the at least one tablet-shaped article with the first printing head. In accordance with the disclosed subject matter, the first printing head marks the at least one tablet-shaped article through the first window. With reference to the non-limiting exemplary system10depicted inFIG.1, the hopper12can include an opening at the bottom of the hopper12, and tablet-shaped articles can be dispensed out the hopper12through the opening one at a time into a pocket46of the rotary wheel conveyor14when the opening at the bottom of the hopper12and the pocket46are aligned as the rotary wheel conveyor14rotationally advances under the opening. In accordance with an aspect of the disclosed subject matter, the system can include an article aligner, as described above, and dispensing the at least one tablet-shaped article can include passing the tablet-shaped article through the article aligner. Methods in accordance with the disclosed subject matter further include conveying the at least one tablet-shaped article from the hopper to the first print head18. As embodied herein, the rotary wheel conveyor14can rotationally advance the pocket46with the tablet-shaped article therein from the hopper12to an inspection station16, and the inspection station can inspect the tablet-shaped article as described above. For example, the inspection station16can detect the presence of a marking on the tablet-shaped article and instruct the first printer18to mark the tablet-shaped article when no marking is detected. After the inspection station16, the conveyor can convey the tablet-shaped article to the first printing station18. In accordance with an aspect of the disclosed subject matter, the system can include an article rotator as described above, and if the inspection16detects that the surface of the tablet-shaped article oriented towards the first printing head18has previously been marked, the article rotator can rotate the at least one tablet-shaped article to orient an unmarked surface of the tablet-shaped article towards the first side portion of the conveyor and the first printing head18. Methods in accordance with the disclosed subject matter further include marking the at least one tablet-shaped article, wherein the first printing head18marks the at least one tablet-shaped article through the first window50. In accordance with an aspect of the disclosed subject matter, the system can include a second window defined in the second side portion of the conveyor, as described further above. With reference toFIG.1, the non-limiting exemplary system10includes a first printing head18and a second printing head20. As embodied herein, the first printing head18can be adjacent the first side portion41of the rotary wheel conveyor14and the second printing head20can be adjacent the second side portion43of the rotary wheel conveyor14. For purpose of example, and as embodied herein, the first printing head18and the second printing head20can be mounted adjacent the respective side portions of the conveyor14using brackets attached to the table24. As embodied herein, the first printing head18and the second printing head20can be mounted in series, such that the conveyor can convey the tablet-shaped articles past the first print head18, followed by the second printing head20. Alternatively, the first printing head18and the second print head20can be mounted opposite one another, such that the conveyor conveys the tablet-shaped article past the first printing head18and the second print head20at the same time. Methods in accordance with the disclosed subject matter can include marking the at least one tablet-shaped article through the second window51with the second printing head20. For example, based on the inspection information obtained from the inspection station16and stored in the CPU, one or both of the printing heads can be instructed to mark or print on one surface or both opposing surfaces of the tablet-shaped article. One aspect of the disclosed subject matter is directed to printing tablet-shaped articles that have pre-printed information on one of the opposing surfaces of the tablet-shape article. For example, a new printing can be applied on the unmarked opposing surface of the tablet-shaped article, and the pre-printed information can remain on the pre-printed opposing surface without further marking. For example, the CPU can instruct one of the first printing head18or the second printing head20that is aligned with the unmarked surface of the tablet-shaped article to apply printing. The new information applied on the unmarked surface can be any information, for example, tracking information, identification mark, bar code, or a legible message. In accordance with another aspect of the disclosed subject matter, the system can be programmed to print on the pre-printed surface of the tablet-shaped article, thereby adding or supplementing additional information. After the tablet-shaped articles are printed, the tablet-shaped articles can be discharged from the rotary wheel conveyor14. The tablet-shaped articles can be gravitationally discharged as the rotary wheel conveyor rotationally advances to position the upper opening52and the pocket46to allow the tablet-shaped article to gravitationally roll or slide out through the upper opening52. Alternatively, the tablet-shaped article can be pneumatically discharged by applying positive air pressure, for example, through the pressure port52. The discharged tablet-shaped articles can then be collected and advanced for further processing, such as packaging or an additional inspection for printing quality. Systems and methods in accordance with the disclosed subject matter can include additional features, for example, to integrate the systems and methods into existing manufacturing operations. For example, and with reference to the non-limiting exemplary system depicted inFIG.6, systems in accordance with the disclosed subject matter can include an input hopper210for receiving tablet-shaped articles and a sizing roller assembly212to remove tablet-shaped articles having sizes or shapes different from the tablet-shaped articles desired for marking or printing. Systems in accordance with the disclosed subject matter can further include a feed conveyor214to convey tablet-shaped articles of the desired size, shape, or characteristics, from the sizing roller212to the hopper120for printing. Additionally or alternatively, systems can include an exit conveyor216to convey tablet-shaped articles that have been printed from the conveyor140to another area for further processing, or to a collection location. As described above, systems and methods in accordance with the disclosed subject matter can have improved performance characteristics. For example, systems in accordance with the disclosed subject matter can have fewer moving parts compared to prior art printers and can be operated reliably with less maintenance downtime of operation. For example, the outer wheel portions of the rotary wheel conveyor can be easily removed from the conveyor for cleaning, whereas prior art printing systems often use conveyor belts with additional components, such as backing plates and chain assemblies that may require additional maintenance and downtime. In addition, systems in accordance with the disclosed subject matter can have a compact profile that can be particularly suitable for mobile applications. Additionally, systems and methods in accordance with the disclosed subject matter can print more accurately than prior art printers. For example, rotary wheel conveyors, with a rigid wheel directly driven by a gear motor can provide better position tolerance for positioning tablet-shaped articles relative to the printing heads. | 34,078 |
11858283 | DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a preferred embodiment of the present invention will be described with reference to the accompanying drawings. First Embodiment Printing System FIG.1is a diagram showing an example of a system configuration of a printing system of the present embodiment. As shown in this diagram, the printing system according to the present embodiment is a system that comprises a printer10and a smartphone100that can wirelessly communicate with each other, and is configured such that print data is transmitted from the smartphone100to the printer10and printing is performed in the printer10. The smartphone100is an example of a terminal. The printer10is a portable mobile printer. The printer10is an instant printer that prints an image on an instant film12. A sheet film type (also referred to as a mono sheet type) is used as the instant film12. The printer10and the smartphone100are wirelessly connected. For example, the communication between the printer10and the smartphone100is performed by short range wireless communication such as Bluetooth (registered trademark) or Wireless Fidelity (WiFi). Appearance Configuration of Printer FIG.2is a front perspective view showing an example of an appearance configuration of the printer.FIG.3is a rear perspective view of the printer shown inFIG.2. As described above, the printer10is an instant printer (printer that prints on an instant film). The instant film12is loaded into the printer10in a state of a film pack (seeFIG.5) in which a plurality of instant films is accommodated in a case. A printer main body14constituting a body of the printer10has a rounded flat rectangular box shape and is configured to be portable by being held with one hand. The printer main body14is configured to be vertically placed (stand upright on a flat place) and horizontally placed (laid on a flat place).FIGS.1and2show a case where the printer10is vertically placed. On a front side of the printer main body14, a push-type power button16is provided at a substantially central position. The power of the printer10is turned on and off by a long push of the power button16(an operation of continuously pushing the power button for a predetermined time or more). The power button16also serves as a light emitting unit, and emits light by causing a light source unit provided therein to emit light. The power button16is an example of an operation member provided in the printer main body14. A discharge port18is provided at an upper portion of the printer main body14(upper portion when the printer is vertically placed). The printed instant film12is discharged from the discharge port18. A film pack lid20for opening and closing a film pack loading chamber (seeFIG.4) is provided on a rear side of the printer main body14. An unlock lever22that unlocks the film pack lid20is provided. In a case where the unlock lever22releases the lock and the film pack lid20is opened, the film pack loading chamber is opened. When the film pack lid20is closed after the instant film pack is loaded, the film pack lid20is locked by a lock mechanism (not shown), and the film pack is sealed in a light-shielded state. A USB cable connection portion cover24that opens and closes a Universal Serial Bus (USB) cable connection portion (not shown) is provided on one side of the printer main body14. The printer10is charged with a built-in battery through the USB cable connection portion exposed by opening the USB cable connection portion cover24. Configuration of Printing Unit of Printer FIG.4is a cross-sectional view showing a schematic configuration of a printing unit of the printer. This diagram shows a state in which the printer is horizontally placed. As shown in this diagram, the printer10comprises a film pack loading chamber30, a film delivery mechanism32that delivers the instant film12from the film pack loaded in the film pack loading chamber30, a film transport mechanism34that transports the instant film12delivered from the film pack, and a print head36that records an image on the instant film12therein. The film delivery mechanism32, the film transport mechanism34, and the print head36constitute a printing unit of the printer10. The film pack loading chamber30includes a recess into which a film pack40is fitted, and is opened and closed by the film pack lid20. FIG.5is a perspective view of the film pack.FIG.6is a front view of the instant film, andFIG.7is a rear view of the instant film. InFIGS.5to7, a direction indicated by an arrow F is a delivery direction of the instant film12. The instant film12is delivered in the direction indicated by the arrow F, and is discharged from the case42. The instant film12has a rectangular card shape. The instant film12is configured such that one surface is an exposure surface (surface on which an image is recorded through exposing)12aand the other surface is an observation surface (surface on which the recorded image is observed)12b. As shown inFIG.7, an exposure region12c, a pod portion12d, and a trap portion12fare provided on the exposure surface12aof the instant film12. The exposure region12cis a region in which the image is recorded through exposing. The exposure region12cis a region in which the instant film12can be printed. The pod portion12dand the trap portion12fare arranged in front and back in the delivery direction F with the exposure region12cinterposed therebetween. The pod portion12dis disposed in front in the delivery direction F with respect to the exposure region12c. A developing solution pod12ethat contains a developing solution is provided within the pod portion12d. The trap portion12fis disposed in the back in the delivery direction F with respect to the exposure region12c. An absorbent12gis provided within the trap portion12f. As shown inFIG.6, an observation region12his formed on the observation surface12bof the instant film12. The observation region12his a region in which the image is displayed. The image is displayed on the observation region12hby developing the exposure region12c. The observation region12his disposed so as to correspond to the exposure region12c. A frame12iis provided near the observation region12h. Accordingly, the image is displayed within the frame. The observation region12his set so as to be slightly narrower (set so as to be one size smaller) than the exposure region12c. Accordingly, in a case where the image is recorded in the entire region of the exposure region12c, the image of which the surrounding is trimmed is printed. The instant film12is viewed in an orientation in which the trap portion12fis at the top and the pod portion12dis at the bottom. Accordingly, the image is printed in an orientation in which the trap portion12fis at the top and the pod portion12dis at the bottom. The instant film12is developed by spreading the developing solution of the pod portion12dto the exposure region12cafter exposing. The developing solution of the pod portion12dis squeezed out of the pod portion12d, and is spread to the exposure region12cby causing the instant film12to pass between a spreading roller pair34B. The developing solution remaining at the time of spreading is captured in the trap portion12f. The case42has a rectangular box shape. The case42has a rectangular exposure opening42aformed in a front portion. The case42has a slit-like film discharge port42bon the top surface portion. The instant films12are accommodated so as to be stacked such that the exposure surface12afaces a front surface (exposure opening42a) of the case42and the pod portion12dfaces a top surface (film discharge port42b) of the case42. The case42has a slit-like claw opening portion42cformed in a bottom portion. A claw32aenters through the claw opening portion42c, and thus, the instant films12accommodated in the case42are delivered toward the film discharge port42bone by one and are discharged through the film discharge port42b. A plurality (for example, ten) of instant films12is accommodated so as to be stacked in one film pack40. The film delivery mechanism32delivers the instant films12one by one from the film pack40loaded in the film pack loading chamber30. The film delivery mechanism32comprises the claw32athat moves back and forth along the delivery direction of the instant film12. The film delivery mechanism32scrapes the instant films12within the case one by one by the claw32a, and delivers the instant film12from the film pack40. The film transport mechanism34transports the instant film12delivered from the film pack40by the film delivery mechanism32at a constant speed. The film transport mechanism34comprises a transport roller pair34A and the spreading roller pair34B. The transport roller pair34A is rotated by being driven by a motor (not shown), and transports the instant film12while holding both sides of the instant film. The spreading roller pair34B is rotated by being driven by a motor (not shown), and transports the instant film12while holding the entire instant film. The pod portion12dis crushed while the instant film is transported by the spreading roller pair34B, and the instant film12is developed. The print head36records the image on the instant film12delivered from the film pack40. The print head36is a line-type exposure head. The print head36irradiates the exposure surface12aof the instant film12transported by the film transport mechanism34with print light line by line, and records the image on the instant film12in a single pass. Electrical Configuration of Printer FIG.8is a block diagram showing an electrical configuration of the printer. As shown in this diagram, the printer10comprises an operation detection unit50that detects an operation of the power button16, a light source unit52that emits light from the power button16, a wireless communication unit56that wirelessly communicates with the smartphone100via an antenna56A, a power supply unit58that supplies a power to the units of the printer10, a printer storage unit62that stores image data, a movement detection unit66that detects the movement of the printer10, a film delivery mechanism drive unit68that drives the film delivery mechanism32, a film transport mechanism drive unit70that drives the film transport mechanism34, a print head controller72that drives the print head36, and a printer microcomputer80. The operation detection unit50detects the operation of the power button16. The power button16is a push button, and the printer10is turned on and off by long push. While the printer is turned on, a function for inputting a reprint instruction is assigned to the power button16. The reprinting is a function for reprinting the last printed image. The operation detection unit50detects a short push (operation of pushing and then releasing immediately) of the power button16while the printer10is turned on, and outputs a detection signal to the printer microcomputer80(a first processor). The light source unit52includes a light source and a control circuit thereof. A light source configured to switch light emission colors is used as the light source. In the printer10of the present embodiment, a three-color LED (also referred to as a full-color LED) comprising three color elements of red (R), green (G), and blue (B) is used as the light source. The light emission colors of the three-color LED are switched by selecting a mixing ratio of three colors of R, G, and B. An electroluminescent (EL) source such as an organic light emitting diode (OLED) may be employed as the light source. The light source unit52is disposed inside the power button16(seeFIG.4). The power button16is transparent or translucent in whole or in part. In a case where the light source unit52emits light, light is transmitted through the transparent portion or translucent part of the power button16, and is emitted. The wireless communication unit56wirelessly communicates with an external device (for example, the smartphone100) through the antenna56A under the control using the printer microcomputer80. The power supply unit58includes a battery as a power supply and a control circuit thereof. The power supply unit58supplies a power to the units of the printer10under the control of the printer microcomputer80. The battery is a rechargeable secondary battery, and is charged by receiving a power from the outside. The power supply unit58has a function of detecting a state of charge of the battery (a function of a battery state-of-charge detection unit). The printer storage unit62includes a memory and a control circuit thereof. The printer storage unit62stores image data of the printed image and setting data of the printer10. The memory is, for example, a nonvolatile memory such as an electrically erasable programmable read-only memory (EEPROM). The printer storage unit62is an example of a print image storage unit. The image data of the printed image is stored by a preset number of sheets. In a case where the number of images capable of being stored reaches an upper limit, the oldest image is deleted. The minimum number of images capable of being stored is one. That is, at least the image data of the last printed image is stored. In this case, the data is rewritten whenever printing is performed. The movement detection unit66detects the movement of the printer main body14. The movement detection unit66is, for example, a motion sensor. Since the motion sensor itself is well-known, the detailed description is omitted. In general, the motion sensor is configured by combining an acceleration sensor and a gyro sensor. The movement detection unit66detects a posture of the printer main body14(vertical placement, horizontal placement, or tilt) and movement (lifting, placing down, or turning over). The film delivery mechanism drive unit68includes a motor that drives the claw32aof the film delivery mechanism32and a drive circuit thereof, and drives the film delivery mechanism32according to a command from the printer microcomputer80. The film transport mechanism drive unit70includes a motor that drives the transport roller pair34A of the film transport mechanism34and a drive circuit thereof, and a motor that drives the spreading roller pair34B and a drive circuit thereof, and drives the film transport mechanism34according to a command from the printer microcomputer80. The print head controller72includes a control circuit of the print head36, and operates the print head36according to a command from the printer microcomputer80. The printer microcomputer80(a first processor) is a controller that performs overall control of the operation of the printer10. The printer microcomputer80is a microcomputer that comprises a central processing unit (CPU), a read only memory (ROM), and a random access memory (RAM), and realizes various functions by executing predetermined control programs. FIG.9is a block diagram of main functions realized by the printer microcomputer. The printer microcomputer80mainly functions as an image acquisition unit80A, a print data generation unit80B, a print controller80C, a representative color detection unit80D, a light emission controller80E, a power controller80F, a control signal transmission unit80G, and a status information acquisition unit80H, and a status information transmission unit80I. The image acquisition unit80A wirelessly communicates with the smartphone100via the wireless communication unit56, and acquires image data of an image to be printed from the smartphone100. In the case of reprinting, the image data of the last printed image is read out from the printer storage unit62and is acquired. The print data generation unit80B converts the image data acquired by the image acquisition unit80A into a data format printable by the printing unit (data format printable on the instant film12by the print head36), and generates data for printing (print data). The print controller80C controls the delivery of the instant film12by the film delivery mechanism32via the film delivery mechanism drive unit68. The transport of the instant film12by the film transport mechanism34is controlled via the film transport mechanism drive unit70. The driving of the print head36is controlled via the print head controller72. The driving of the print head36is controlled in synchronization with the transport of the instant film12based on the print data generated by the print data generation unit80B. The print controller80C has a function (a function of a printable sheet number detection unit) of detecting the number of printable sheets (the number of remaining films). The number of printable sheets is detected by counting the total number of printed sheets after the film pack is loaded. Since a predetermined number of (for example, 10) instant films12are accommodated in the film pack, the number of printable sheets can be detected by counting the total number of printed sheets after the film pack is loaded. That is, a value obtained by subtracting the number of printed sheets from the total number of instant films12loaded in the film pack before the use of the film pack is started is the number of printable sheets (the number of remaining films). The representative color detection unit80D detects the representative color of the image to be printed. The representative color of the image to be printed is a color used centrally in the image to be printed. For example, the representative color detection unit80D obtains a color distribution of the entire image to be printed, and detects the color occupying the widest area as the representative color. For example, orange is detected as the representative color for a sunset image in which the entire screen is dyed in orange. For example, green is detected as the representative color for a grassland image. The representative color detection unit80D detects the representative color within a color gamut range reproducible in the light source unit52. The representative color may be obtained from a part of the image to be printed, or may be obtained by dividing the image to be printed into a plurality of regions. For example, in a case where the representative color is obtained from a partial region, a detection region is set at a center of the image, and the representative color is detected from the detection region. For example, in a case where the representative color is obtained by dividing the image into the plurality of regions, the image to be printed is equally divided into a plurality of regions in an up-down direction (for example, divided into three equal regions), and the representative color is detected from each region. The light emission controller80E controls the light emission of the light source unit52, and causes the power button16which is the light emitting unit to emit light in a predetermined color and pattern. The light emission controller80E causes the power button16to emit light at a predetermined timing. For example, the power button16emits light in a case where data of the image to be printed is received from the smartphone100and the image is printed. In a case where the image to be printed is received from the smartphone100, a plurality of predetermined colors is emitted while being switched in order at regular time intervals. For example, seven colors (so-called rainbow colors) of red, orange, yellow, green, light blue, blue, and purple are emitted while being switched in order at regular time intervals. The light emission is continuously performed while the image is received. Meanwhile, in a case where the image is printed, the representative color detected by the representative color detection unit80D is emitted. The light emission is continuously performed while the image is printed. In a case where the representative color is obtained by dividing the image into the plurality of regions, the obtained representative colors are emitted while being switched in order. For example, in a case where the image to be printed is divided into three equal regions in the up-down direction and the representative colors are detected from the respective regions, the representative colors detected in the respective regions are emitted at regular time intervals in order from the top. In a case where an achromatic color such as black or gray is detected as the representative color, a specific color is instead emitted. Alternatively, for example, the representative colors are emitted in a specific emission pattern (for example, seven colors (so-called rainbow colors) of red, orange, yellow, green, light blue, blue, and purple are emitted while being switched in order at regular time intervals. Alternatively, a specific color is turned on and off (for example, white is turned on and off)). Alternatively, the light emission is stopped. The power controller80F controls the power supply unit58to control the supply of a power to each unit and the charging of the battery. The turned-on and turned-off of the printer10are controlled by the power controller80F. The power controller80F turns on and off the printer10based on an output from the operation detection unit50. The control signal transmission unit80G wirelessly transmits a predetermined control signal to the smartphone100based on the detection result of the movement detection unit66. That is, in a case where a predetermined movement is detected by the movement detection unit66, the control signal transmission unit generates a control signal corresponding to this movement, and wirelessly transmits the generated control signal to the smartphone100via the wireless communication unit56. The smartphone100performs a predetermined operation by receiving this control signal. Specifically, in a case where the movement detection unit66detects a movement (first movement) in which the printer main body14is horizontally placed, the control signal transmission unit transmits a first control signal to the smartphone100. In a case where the movement detection unit66detects a movement (second movement) in which the printer main body14is vertically placed, the control signal transmission unit transmits a second control signal to the smartphone100. In a case where the first control signal is received, the smartphone100displays, as a top screen, a first top screen (first operation screen) having a predetermined screen configuration on the touch panel120. Meanwhile, in a case where the second control signal is received, the smartphone displays, as the top screen, a second top screen (second operation screen) having a predetermined screen configuration on the touch panel120. The aforementioned top screen will be described in detail below. The top screen (also referred to as a home screen) is a screen that is displayed first in a case where an application program is activated. Buttons of executable functions are displayed on the top screen. The status information acquisition unit80H acquires status information of the printer10. The status information of the printer10includes information of the number of printable sheets and information of the state of charge of the battery. The status information acquisition unit80H acquires the information of the state of charge of the battery from the power supply unit58. The information of the number of printable sheets is acquired from the print controller80C. The status information transmission unit80I transmits the status information acquired by the status information acquisition unit80H to the smartphone100based on the detection result of the movement detection unit66. That is, in a case where a predetermined movement is detected by the movement detection unit66, the status information acquired by the status information acquisition unit80H is transmitted to the smartphone100. Specifically, in a case where the movement detection unit66detects a movement (third movement) of lifting the printer main body14, the status information is transmitted to the smartphone100. The aforementioned top screen will be described in detail below. Smartphone FIG.10is a block diagram showing an example of a hardware configuration of the smartphone. As shown in this diagram, the smartphone100comprises a CPU101that controls the entire operation, a ROM102that stores a basic input and output program, a RAM103that is used as a work area of the CPU101, a built-in memory104, a display105, a touch pad106that detects a touch operation (position input) for a display screen, a Global Positioning Systems (GPS) reception unit107that receives a GPS signal including positional information (latitude, longitude, and altitude) of the smartphone100by a GPS satellite or an Indoor MEssaging System (IMES) as an indoor GPS, an in-camera unit108A (a camera unit provided on a screen side of the touch panel120) and an out-camera unit108B (a camera unit provided on a surface (rear surface) opposite to the screen of the touch panel120) that includes an imaging lens and an image sensor and electronically images an image, a microphone unit109that includes a microphone and inputs voice, a speaker unit110that includes a speaker and outputs voice, a wireless communication unit111that wirelessly communicates with a nearest base station by using an antenna111A, a short range wireless communication unit112that communicates with another external device (for example, the printer10) by using an antenna112A through short range wireless, a sensor unit113that includes various sensors such as a geomagnetic sensor, a gyrocompass, and an acceleration sensor, and a media drive114that reads and writes data in and from a memory card115. The built-in memory104is a nonvolatile memory such as an EEPROM. The built-in memory104stores various data such as image data of an image captured by the in-camera unit108A and an out-camera unit108B and image data acquired from other devices in addition to various programs (for example, display control program) including an operating system. The display105and the touch pad106constitute the touch panel120. The screen of the touch panel120has a rectangular shape. The smartphone100has a normal utilization pattern in which the screen of the touch panel120is vertically oriented (a longitudinal direction of the screen is along a vertical direction). In the smartphone100of the present embodiment, the longitudinal direction of the screen of the touch panel120is a vertical direction (Y direction in the diagram), and a direction (X direction in the diagram) orthogonal to the vertical direction, that is, a direction of a short side of the screen is a width direction. The smartphone100has a function of causing the printer10to print the image captured by the in-camera unit108A or the out-camera unit108B, a function of causing the printer10to print the image recorded in the built-in memory104, and a function of confirming a state (for example, the state of charge of the battery and the number of printable sheets) of the printer10in the relationship with the printer10. As a function related to the printing of the image, the smartphone has a function of processing and editing the image to be printed. FIG.11is a block diagram of main functions of the smartphone related to the printing of the image. As shown in this diagram, the smartphone100has functions of a display controller100A that controls display on the touch panel120, an input controller100B that controls an input to the touch panel120, and an imaging controller100C that controls the imaging of the image to be printed, a reproduction controller100D that controls reproduction of the image to be printed, an image processing unit100E that processes and edits the image to be printed, and a communication controller100F that controls communication with the printer10which are related to the printing of the image. These functions are realized by the CPU101(a second processor) executing a predetermined program. The display controller100A controls the display of the screen on the touch panel120to display an operation screen at the time of printing the image on the touch panel120. The display controller100A controls the display on the screen of the touch panel120by controlling the display on the display105which is a display unit. The display of the operation screen to be described below is controlled by the display controller100A. The input controller100B controls an operation input at the time of printing the image by controlling an operation input to the touch panel120. The input controller100B controls the input of the touch pad106, which is the position input unit of the touch panel120, and controls the operation input to the touch panel120. The imaging controller100C controls the in-camera unit108A and the out-camera unit108B based on an operation input to the touch panel120, and controls the imaging of the image to be printed. The reproduction controller100D controls access to the built-in memory104based on an operation input to the touch panel120, and controls the reproduction of the image to be printed. The image processing unit100E processes and edits the image to be printed based on an operation input to the touch panel120. For example, the image to be printed is processed and edited by performing image processing such as enlargement (trimming) of the image, rotation of the image, filter processing, template combination, and collage. The filter processing refers to a function of changing a color tone of the image or deforming the image. For example, color tone correction, noise removal, mosaic processing, and embossing. The template combination is a process of generating a combination image by combining a template image with an image. The collage mentioned herein is processing for generating a single combination image by applying images to regions of a frame (divided frame) having a plurality of divided regions therein. The generated combination image is called a collage image. The communication controller100F controls the short range wireless communication unit112based on an operation input on the touch panel120, and controls the communication with the printer10. Data of the image to be printed and a print command thereof are transmitted from the smartphone100to the printer10. Meanwhile, the status information and the control signal are transmitted from the printer10to the smartphone100. The communication controller100F functions as a status information reception unit that receives the status information transmitted from the printer10and a control signal reception unit that receives the control signal transmitted from the printer10. Printing Method of Image Display on Top Screen In a case where the printer10prints the image stored in the smartphone100and the image captured in the smartphone100, a predetermined application program (hereinafter, referred to as a print application) is activated on the smartphone side. In a case where the print application is activated, the top screen is displayed on the screen of the smartphone100. As described above, there are two types of top screens (the first top screen and the second top screen). Any one of the top screens is displayed according to the posture of the printer10at the time of activation. That is, the first top screen is displayed in a case where the printer main body14is vertically placed, and the second top screen is displayed in a case where the printer main body is horizontally placed. FIG.12is a flowchart showing a processing procedure for displaying the top screen in a case where the print application is activated. In a case where the print application is activated in the smartphone100(step S1), communication settings are initially performed with the printer10(step S2). That is, the connectable printer10is detected, and a process of establishing connection with the detected printer10through short range wireless communication is performed. Similarly, on the printer10side, a process of establishing connection with the smartphone100through short range wireless communication is performed (step S3). In a case where the connection through the short range wireless communication is established, the movement (installation posture) of the printer10is detected on the printer10side (step S4). Here, it is detected whether the printer main body14is placed vertically (first movement) or horizontally (second movement). The control signal is generated based on the detection result (step S5), and transmitted to the smartphone100(step S6). In a case where the state of the vertical placement (first movement) is detected as the installation posture, the first control signal is transmitted. Meanwhile, in a case where the horizontal placement (second movement) is detected as the installation posture, the second control signal is transmitted. The smartphone100receives the control signal transmitted from the printer10(Step S7). The screen to be displayed as the top screen is selected based on the received control signal. In this case, first, it is determined whether or not the received control signal is the first control signal (step S8). In a case where the received control signal is the first control signal, a first top screen200A (seeFIG.13) is displayed on the touch panel120(step S9). Meanwhile, in a case where the received control signal is the second control signal, a second top screen200B (seeFIG.14) is displayed on the touch panel120(step S10). Screen Configurations of First Top Screen and Second Top Screen FIG.13is a diagram showing an example of the first top screen.FIG.14is a diagram showing an example of the second top screen. As shown inFIGS.13and14, the first top screen200A and the second top screen200B are configured such that the same items are displayed in different layouts. Items to be displayed are a button of a function executable by the print application, a setting button of the print application, status information of the printer10, and a last printed image. The button of the function executable by the print application is a simple print button MB1which is a button of a “simple print” function, a motion picture print button MB2which is a button of a “motion picture print” function, a camera button MB3which is a button of a “camera” function, an affinity diagnosis button MB4which is a button of an “affinity diagnosis” function, a template print button MB5which is a button of a “template print” function, a collage print button MB6which is a button of a “collage print” function, and a combined photograph button MB7which is a button of a “combined photograph” function. The “simple print” function is a function of printing the image (still image) stored in the smartphone100. The present function is activated by touching the simple print button MB1on the screen. The “motion picture print” function is a function of extracting and printing one scene from the motion picture. The present function is activated by touching the motion picture print button MB2on the screen. The “camera” function is a function of performing imaging by using the camera function of the smartphone100and printing the captured image with the printer10. The present function is activated by touching the camera button MB3on the screen. The “affinity diagnosis” function is a function of performing affinity diagnosis from the image. For example, the image is analyzed by using a learned model, and the affinity between persons (two persons) appearing in the image is diagnosed. The present function is activated by touching the affinity diagnosis button MB4on the screen. The “template print” function is a function of combining the template image with the image and printing the combined image. The present function is activated by touching the template print button MB5on the screen. The “collage print” function is a function of generating and printing the collage image. As described above, the collage image is generated by applying the images to the regions of the frame (divided frame) having the plurality of divided regions therein. The present function is activated by touching the collage print button MB6on the screen. The “combined photograph” function is a function of dividing one image into a plurality of regions and printing the image. The present function is activated by touching the combined photograph button MB7on the screen. Each function button is displayed as an icon. That is, a combination of figures, symbols, or patterns is displayed. In the present embodiment, each function button is formed by a figure obtained by combining a circle and a pattern. The circle defines an outer shape of the button. A name (for example, model name) of the connected printer10, the information of the number of printable sheets (the number of remaining films), and the information of the state of charge of the battery are displayed as the status information of the printer10. In a case where the number of printable sheets is N and the total number of instant films12loaded in a new film pack is M, the number of printable sheets is displayed in the form of “N/M”. That is, the number of sheets printed after the film pack is replaced is also displayed in an understandable form. The information of the state of charge of the battery is displayed as a figure. A last printed image LIM is displayed inside an image display frame FLO. The image display frame FLO is an image imitating the instant film12. That is, the image display frame is a figure imitating the frame12iprovided near the observation region12hof the instant film12. The region inside the image display frame FLO is an image display region. The last printed image LIM is displayed being fitted in the image display region. As shown inFIGS.13and14, the function buttons are grouped into two groups (a first group MG1and a second group MG2), and are displayed on the first top screen200A and the second top screen200B. The first group MG1is a group to which the function buttons of the motion picture print and the camera belong. The first group MG1is a group of print modes, and is a group of functions to simply print the image. The second group MG2is a group to which the function buttons of the affinity diagnosis, the template print, the collage print, and the combined photograph belong. The second group MG2is a group of plays modes, and a group of functions including a play element and a creation element. The buttons (the simple print button MB1, the motion picture print button MB2, and the camera button MB3) belonging to the first group MG1are displayed in a first group display region MA1indicated by a broken line inFIGS.13and14. Meanwhile, the buttons (the affinity diagnosis button MB4, the template print button MB5, the collage print button MB6, and the combined photograph button MB7) belonging to the second group MG2are displayed in a second group display region MA2indicated by a broken line inFIGS.13and14. The first group display region MA1is set along the horizontal direction (X direction) at a lower part of the screen. Meanwhile, the second group display region MA2is set along the vertical direction (Y direction) at a right end of the screen. The sizes of the first group display region MA1and a button group (the simple print button MB1, the motion picture print button MB2, and the camera button MB3) displayed in the first group display region MA1are changed on the first top screen200A and the second top screen200B. That is, the first group display region MA1and the button group displayed in the first group display region MA1are displayed on the first top screen200A with a small size as shown inFIG.13, and are displayed on the second top screen200B with a large size as shown inFIG.14. More specifically, the entire region of the lower part of the screen in the width direction (X direction) is the first group display region MA1on the second top screen200B as shown inFIG.14, whereas the width thereof is decreased on the first top screen200A (is decreased in a left direction of the screen) as shown inFIG.13. Accordingly, the size of each button is also reduced. The colors of the first group display region MA1and the button group displayed in the first group display region MA1are changed on the first top screen200A and the second top screen200B.FIGS.13and14show examples in which colors are displayed in reverse. Similarly, the sizes of the second group display region MA2and the button group (the affinity diagnosis button MB4, the template print button MB5, the collage print button MB6, and the combined photograph button MB7) displayed in the second group display region MA2are changed on the first top screen200A and the second top screen200B. That is, the second group display region MA2and the button group displayed in the second group display region MA2are displayed on the first top screen200A with a large size as shown inFIG.13, and are displayed on the second top screen200B with a small size as shown inFIG.14. More specifically, the entire region of the screen right end in the vertical direction (Y direction) is the second group display region MA2on the first top screen200A as shown inFIG.13, whereas a length thereof is decreased on the second top screen200B (is decreased in an up direction of the screen) as shown inFIG.13. Accordingly, the size of each button is also reduced. Similarly to the first group display region MA1, the colors of the second group display region MA2and the button group displayed in the second group display region MA2are changed on the first top screen200A and the second top screen200B.FIGS.13and14show examples in which colors are displayed in reverse. A setting button SEB of the print application is displayed in the second group display region MA2on the first top screen200A as shown inFIG.13. Meanwhile, the setting button SEB is displayed in the first group display region MA1on the second top screen200B as shown inFIG.14. The status information of the printer is displayed in a status information display region MA3. The status information display region MA3is set at the same position on the first top screen200A and the second top screen200B. As shown inFIGS.13and14, the status information display region MA3is set at an upper part of the screen. The last printed image is displayed inside the image display frame FLO. The image display frame FLO is displayed on an upper side of the first group display region MA1and on a left side of the second group display region MA2. As shown inFIG.13, the image display frame FLO is tilted and displayed on the first top screen200A. Meanwhile, the image display frame FLO is displayed straight along the screen the second top screen200B. In an unprinted state, the inside of the image display frame FLO is blank. Alternatively, a predetermined image is displayed. In addition, it is possible to set the turned-on and turned-off of the display of the last printed image in the setting of the print application. It is also possible to constantly display the predetermined image (for example, an image selected by the user). As stated above, operability can be improved by preparing two top screens and switching the display as necessary. That is, in a case where the user wants to print simply, the second top screen200B on which these function buttons (the simple print button MB1, the motion picture print button MB2, and the camera button MB3) are remarkably displayed with the large size is selected and displayed. Meanwhile, when the user wants to create the collage, the first top screen200A on which the function buttons (the affinity diagnosis button MB4, the template print button MB5, the collage print button MB6, and the combined photograph button MB7) are remarkably displayed with the large size is selected and displayed. Accordingly, operability can be improved. It is possible to secure favorable operability easy to understand for the user even on a portable terminal with a small screen such as the smartphone. Since the top screens can be switched simply by changing the installation posture of the printer main body14, the operation thereof can be simply performed. This type of operation is normally performed by setting the application program. According to the system of the present embodiment, it is possible to simply switch between the top screens without performing such a troublesome setting operation. (A) Printing Using Simple Print Function Hereinafter, a procedure in a case where the image stored in the smartphone100is printed by using the simple print function is described. The rough processing procedure is (1) selection of the image to be printed and (2) instructing to print. The image is processed and edited as necessary. Image Selection Screen In a case where the simple print button MB1is touched on the top screen (the first top screen200A or the second top screen200B), the simple print function is activated. In a case where the simple print function is activated, the screen of the touch panel120is switched to the image selection screen201. This screen is a screen for selecting the image to be printed. FIG.15is a diagram showing an example of the image selection screen. As shown inFIG.15, the images stored in the smartphone100is displayed as a list in a thumbnail form on the image selection screen201. That is, the images are displayed as a list in a reduced form. The user touches the thumbnail image of the image to be printed on the screen, and selects the image to be printed. FIG.15shows an example in which all the images stored in the smartphone100are displayed as the list. Only images in a designated folder may be displayed. A cancel button201A is displayed on the image selection screen201as shown inFIG.15. The cancel button201A is a button for instructing to cancel an image selection process. In a case where the cancel button201A is touched, the simple print function ends. In this case, the display of the screen is switched to the top screen200. Print Image Confirmation Screen In a case where the image to be printed is selected, the screen of the touch panel120is switched to a print image confirmation screen202. This screen is a screen for confirming the image to be printed (print image). FIG.16is a diagram showing an example of the print image confirmation screen. As shown inFIG.16, a print image PI, a print button PB for instructing to print the print image PI, and image editing menu buttons are displayed on the print image confirmation screen202. The print image PI is displayed in an image display region EA1set within the screen. A frame FL surrounding the image (print image PI) displayed in the image display region EA1is displayed around the image display region EA1. The frame FL is an image imitating the instant film12. That is, this frame FL is a figure imitating the frame12iprovided around the observation region12hof the instant film12(has the same margin as the printed result (printout)). Accordingly, it is easy to confirm the final printed result on the screen. The print button PB and the image editing menu buttons (an enlargement & rotation button EB1, a filter button EB2, and an image quality correction button EB3) are displayed in a button display region EA2. The button display region EA2is set at a lower part of the screen. The print button PB and the image editing menu buttons (the enlargement & rotation button EB1, the filter button EB2, and the image quality correction button EB3) are displayed while being arranged in a line along the width direction (X direction inFIG.16) of the screen in this button display region EA2. At this time, the print button PB is disposed at the center in the width direction (X direction), and three image editing menu buttons (the enlargement & rotation button EB1, the filter button EB2, and the image quality correction button EB3) are arranged and displayed on both sides thereof. The print button PB and the image editing menu buttons (the enlargement & rotation button EB1, the filter button EB2, and the image quality correction button EB3) are displayed as icons. The print button PB is formed with a size larger than the other buttons (the enlargement & rotation button EB1, the filter button EB2, and the image quality correction button EB3) (the size of the image portion constituting the button is large). In the present embodiment, the color of the print button PB is formed in a color different from other buttons. Specifically, the other buttons are formed in white, whereas the print button PB is formed in red. Accordingly, it easy to understand a print instruction operation. In a case where another button is selected (touched), the color thereof is changed. Accordingly, the selected function can be clarified. Menu titles are displayed below the image editing menu buttons (the enlargement & rotation button EB1, the filter button EB2, and the image quality correction button EB3).FIG.16shows an example in which an enlargement and rotation function, a filter function, and an image quality correction function are prepared as image editing menus. The enlargement and rotation function is a function of enlarging and rotating the image. The enlargement and rotation function is assigned to the enlargement & rotation button EB1. In a case where the enlargement & rotation button EB1is touched on the screen, the enlargement and rotation function is activated, and the image can be enlarged and rotated with respect to the print image PI. The filter function is a function of performing the filter processing on the image. A button of the filter function is assigned to the filter button EB2. In a case where the filter button EB2is touched on the screen, the filter function is activated, and the filter processing on the print image PI can be performed. The image quality correction function is a function of correcting brightness, contrast, and saturation of the image. The image quality correction function is assigned to the image quality correction button EB3. In a case where the image quality correction button EB3is touched on the screen, the image quality correction function is activated, and the image quality correction (the correction of the brightness, contrast, and saturation of the image) on the print image PI can be performed. Each function is turned on (activated) in a case where the corresponding button is touched on the screen, and turned off in a case where the button is touched again. In a case where a button of another function is touched while one function is activated, the function is switched to the touched function. For example, in a case where the image quality correction button EB3is touched while the filter function is activated, the filter function ends, and the image quality correction function is turned on. As shown inFIG.16, a back button BB and a top button TB are displayed on the print image confirmation screen202. The back button BB is a button for instructing to return to the previous screen. The top button TB is a button for instructing to return to the top screen200. The back button BB and the top button TB are arranged at the upper part of the screen. In a case where the screen is returned to the top screen, the top screen corresponding to the installation posture of the printer main body14is displayed. That is, in a case where the printer main body14is vertically placed, the first top screen200A (seeFIG.13) is displayed, and in a case where the printer main body14is horizontally placed, the second top screen200B (seeFIG.14) is displayed. In this case, first, an installation posture detection command is output from the smartphone100to the printer10. The printer10detects the installation posture of the printer main body14by receiving this detection command. The control signal corresponding to the detected installation posture is generated and transmitted to the smartphone100. The smartphone100receives the control signal transmitted from the printer10, and decides the top screen to be displayed. Enlargement and Rotation Operation Screen In a case where the enlargement & rotation button EB1is touched on the screen, the screen is switched to an operation screen for the enlargement and rotation function, that is, an operation screen (enlargement and rotation operation screen)203for performing an image enlargement operation and a rotation operation. FIG.17is a diagram showing an example of the enlargement and rotation operation screen. On the enlargement and rotation operation screen203, an enlargement slide bar SB1for an enlargement operation and a rotation slide bar SB2for a rotation operation are displayed in addition to the display contents on the print image confirmation screen202. The enlargement slide bar SB1is operated by sliding a knob NB1(touching and sliding the knob NB1). In a case where the enlargement slide bar SB1is operated, the image is enlarged according to an operation amount. The print image PI is enlarged in a case where the knob NB1is slid in a right direction of the screen, and is reduced in a case where the knob NB1is slid in the left direction. The rotation slide bar SB2is operated by sliding a knob NB2. In a case where the rotation slide bar SB2is operated, the image is rotated according to an operation amount. The print image PI is rotated clockwise in a case where the knob NB2is slid in the right direction of the screen, and is rotated counterclockwise in a case where the knob NB2is slid in the left direction. In a case where the knob NB2is slid from a left end to a right end of the bar, the image is rotated once. The enlargement slide bar SB1and the rotation slide bar SB2are displayed in an operation region EA3. The operation region EA3is set between the image display region EA1and the button display region EA2in the vertical direction (Y direction) of the screen. As shown inFIG.17, the enlargement slide bar SB1and the rotation slide bar SB2are vertically arranged in this region. Both the enlargement slide bar SB1and the rotation slide bar SB2are displayed in a curved shape. More specifically, the enlargement slide bar and the rotation slide bar are displayed along a circle using a point set on a straight line passing through the center of the screen in the width direction (X direction), and are displayed horizontally symmetric with respect to a straight line passing through the center of the screen in the width direction. As stated above, the entire length can be increased by curving and displaying the image in an arc shape as compared to a case where the image is displayed as a straight line. Accordingly, the resolution of the operation can be improved, and a more precise operation can be performed. This is particularly effective in a case where a display size of the screen is small. Filter Operation Screen In a case where the filter button EB2is touched on the screen, the screen is switched to an operation screen for the filter function, that is, an operation screen (filter operation screen)204for performing the filter processing on the image. FIG.18is a diagram showing an example of the filter operation screen. On the filter operation screen204, a selection button of a filter to be applied is displayed in addition to the display contents on the print image confirmation screen202.FIG.18shows an example in which four buttons are displayed as selection buttons. Specifically, an example in which a normal button FB1for returning to a normal state, a monochrome button FB2for applying a monochrome filter, a sepia button FB3for applying a sepia filter, and an auto button FB4for applying an auto filter are displayed is illustrated. Here, the monochrome filter is a filter that converts an image into black and white. In a case where the monochrome button FB2is touched on the screen, the print image PI displayed in the image display region EA1is converted into black and white. The sepia filter is a filter that changes the color tone of the image to a sepia tone. In a case where the sepia button FB3is touched on the screen, the color tone of the print image PI displayed in the image display region EA1is set to the sepia tone. The auto filter is a filter that automatically optimizes the color tone of the image. In a case where the auto button FB4is touched on the screen, the color tone of the print image PI displayed in the image display region EA1is automatically corrected. In a case where the normal button FB1is touched on the screen, the applied filter is canceled, and the state is returned to the original state. The selection buttons (the normal button FB1, the monochrome button FB2, the sepia button FB3, and the auto button FB4) of the filter have a rectangular shape corresponding to the outer shape of the print image PI displayed in the image display region EA1. More specifically, the selection buttons have a shape similar to the outer shape of the print image PI (including a shape recognized to be substantially similar). A common image on which the same filter processing as the applied filter is performed is displayed in each button. For example, a chrome image even in black and white is displayed as the image constituting the monochrome button FB2. The buttons are expanded and displayed in the operation region EA3, and are displayed radially around a point set at a straight line passing through the center of the screen in the width direction. As stated above, the buttons are radially displayed, and thus, it is possible to increase the number and size of buttons capable of being displayed as compared to a case where the buttons are displayed in a straight line. Accordingly, operability can be improved. The number of buttons to be displayed on one screen can be adjusted by adjusting the curvature of the arc. That is, in a case where the button sizes are the same, the buttons capable of being displayed at once can be increased as the curvature becomes larger (the curve becomes larger). Image Quality Correction Operation Screen In a case where the image quality correction button EB3is touched on the screen, the screen is switched to an operation screen for an image quality correction function, that is, an operation screen (image quality correction operation screen)205for performing the correction operation of the brightness, contrast, and saturation of the image. FIG.19is a diagram showing an example of the image quality correction operation screen. On the image quality correction operation screen205, a brightness adjustment slide bar SB3for adjusting the brightness of the image, a contrast adjustment slide bar SB4for adjusting the contrast of the image, a saturation adjustment slide bar SB5for adjusting the saturation of the image, and a reset button RSB are displayed in addition to the display contents on the print image confirmation screen202. The brightness adjustment slide bar SB3is operated by sliding a knob NB3. In a case where the brightness adjustment slide bar SB3is operated, the brightness of the image is changed according to an operation amount. The knob NB3is located in the center of the bar by default. The print image PI becomes brighter in a case where the knob NB3is slid in the right direction of the screen, and becomes darker in a case where the knob NB3is slid in the left direction. The contrast adjustment slide bar SB4is operated by sliding a knob NB4. In a case where the contrast adjustment slide bar SB4is operated, the contrast of the image is changed according to an operation amount. The knob NB4is located in the center of the bar by default. The print image PI has a high contrast in a case where the knob NB4is slid in the right direction of the screen, and has a low contrast in a case where the knob NB4is slid in the left direction. The saturation adjustment slide bar SB5is operated by sliding a knob NB5. In a case where the saturation adjustment slide bar SB5is operated, the saturation of the image is changed according to an operation amount. The knob NB5is located in the center of the bar by default. The print image PI has high saturation in a case where the knob NB5is slid in the right direction of the screen, and has a low saturation in a case where the knob NB5is slid in the left direction. The reset button RSB is a button for resetting the operation of each slide bar (the brightness adjustment slide bar SB3, the contrast adjustment slide bar SB4, and the saturation adjustment slide bar SB5). In a case where the reset button RSB is touched, the operation of each slide bar is reset. That is, the knob of each slide bar returns to the default position (center). Each slide bar (the brightness adjustment slide bar SB3, the contrast adjustment slide bar SB4, and the saturation adjustment slide bar SB5) and the reset button RSB are displayed in the operation region EA3. As shown inFIG.19, the slide bars are vertically arranged in this region. Each slide bar is displayed in a shape curved in an arc shape. More specifically, the slide bars are displayed along a circle using a point set at a straight line passing through the center in the width direction, and are displayed horizontally symmetric with respect to a straight line passing through the center in the width direction. Accordingly, the resolution of the operation can be improved, and a more precise operation can be performed. The reset button RSB is disposed at a right end of the operation region E3. Operation Screen in Case Printing is Performed In a case where the print button PB is touched on the screen, the printing of the print image PI displayed in the image display region EA1is instructed. In a case where the printing is instructed, the image data of the print image PI is transmitted to the printer10. In a case where the transmission of the print image PI is executed, an animation showing the image transmission is displayed. Specifically, the print image PI moves together with the frame FL, and an animation showing that the image disappears from an edge of the screen is displayed. FIG.20is a diagram showing an example of an animation display in a case where the printing is instructed. In a case where the printing is instructed, the screen is changed to a screen206A, a screen206B, and a screen206C in a sequence of time. As shown in this diagram, the print image PI moves upward along the longitudinal direction of the screen together with the frame FL, and disappears from an upper edge of the screen (imitating a video on which the instant film is sent). Accordingly, it is possible to easily recognize that the image is transmitted to the printer. (B) Printing Using Template Print Function Hereinafter, a procedure in a case where the image stored in the smartphone100is printed by using the template print function is described. As described above, in template printing, the template image is combined with the image, and the combined image is printed. The rough processing procedure is (1) selection of the template, (2) selection of the image to be printed, and (3) instructing to print. The image is processed and edited as necessary. Template Selection Screen In a case where the template print button MB5is touched on the top screen (seeFIGS.13and14), the template print function is activated. In a case where the template print function is activated, the screen of the touch panel120is switched to a template selection screen210. This screen is a screen for selecting the template image to be combined with the image to be printed. FIG.21is a diagram showing an example of the template print selection screen. As shown in this diagram, available template images are displayed as a list in a thumbnail form on the template selection screen210. The user touches and selects a template image having a desired pattern on the screen. Image Selection Screen In a case where the template image to be used is selected on the template selection screen210, the screen of the touch panel120is switched to an image selection screen201(seeFIG.15). The user selects the image to be printed on this screen. Print Image Confirmation Screen In a case where the image to be printed is selected, the screen of the touch panel120is switched to the print image confirmation screen202. This screen is a screen for confirming the image to be printed (print image). FIG.22is a diagram showing an example of a print image confirmation screen in the template printing. The print image confirmation screen202in the template printing has the screen configuration of the print image confirmation screen202of the simple printing except that a template button EB4is added as the image editing menu button. The template button EB4is a button for calling a function for switching between the template images. Template Switching Operation Screen Since the enlargement and rotation function, the filter function, and the image quality correction function are the same as those in the simple printing, a template image switching function will be described here. In a case where the template button EB4is touched, the screen is switched to an operation screen (template switching operation screen)212for performing a template image switching operation. FIG.23is a diagram showing an example of the template switching operation screen. On the template switching operation screen212, template image selection buttons TB1, TB2, . . . of switchable templates are displayed in addition to the display contents on the print image confirmation screen202. The user touches and selects the selection button of the template image desired to be switched on the screen. Each button is an image obtained by reducing the template image selected by the button. Therefore, the outer shape has a shape similar to the outer shape of the print image PI (including a shape recognized to be substantially similar). Similar to the filter selection buttons, the template image selection buttons TB1, TB2, . . . are expanded and displayed in the operation region EA3, and are displayed radially around a point set at a straight line passing through the center of the screen in the width direction. A predetermined number of selection buttons TB1, TB2, . . . are displayed in the operation region EA3.FIG.23shows an example in which four selection buttons are displayed at once (the number of entire buttons capable of being displayed is four). Other selection buttons are scrolled and displayed. The scrolling is performed by performing a swipe operation or a flick operation on the selection button displayed in the operation region EA3. Here, the swipe operation is an operation of sliding a finger while touching the screen. The flick operation is an operation of more vigorously swiping, flipping the screen, and sliding the finger away from the screen. FIG.24is a conceptual diagram of the scrolling of the selection buttons displayed in the operation region. As shown in this diagram, the selection buttons TB1, TB2, . . . displayed in the operation region EA3are scrolled in the right direction (arrow R+ direction) along the arc (scrolled clockwise) by performing the swipe operation or the flick operation on the screen in the right direction. The screen is scrolled in the left direction (arrow R− direction) along the arc (scrolled counterclockwise) by performing the swipe operation or the flick operation on the screen in the left direction. Operation Screen in Case Printing is Performed The execution of the printing is the same as that in a case where the simple printing is performed. That is, the printing is instructed by touching the print button PB on the screen. In a case where the printing is instructed, the image data of the print image PI is transmitted to the printer10. An animation showing the image transmission is displayed as in the simple printing (seeFIG.20). (C) Printing Using Collage Print Function Hereinafter, a procedure in a case where the image stored in the smartphone100is printed by using the collage print function is described. As described above, in collage printing, the printing is performed by applying images to regions of a divided frame. The rough processing procedure is (1) selection of the divided frame, (2) selection of the images to be combined, and (3) instructing to print. The images to be combined are processed and edited as necessary. Divided Frame Selection Screen In a case where the collage print button MB6is touched on the top screen (seeFIGS.13and14), the collage print function is activated. In a case where the collage print function is activated, the screen of the touch panel120is switched to a divided frame selection screen220. This screen is a screen for selecting the divided frame. FIG.25is a diagram showing an example of the divided frame selection screen. As shown in this diagram, on the divided frame selection screen220, images of selectable divided frames (images showing division modes within the frame) are displayed as a list in a thumbnail form. The user touches and selects the image of the desired divided frame on the screen. Collage Image Creation Screen In a case where the divided frame to be used is selected on the divided frame selection screen220, the screen of the touch panel120is switched to a collage image creation screen221. This screen is a screen for creating the collage image. FIG.26is a diagram showing an example of the collage image creation screen. The screen configuration is the same as the screen configuration of the print image confirmation screen202of the simple printing except that the inside of the image display region EA1is divided according to the selected divided frame, a borderline button FBB for turning on and off the display of a divided borderline is displayed, and a divided frame button EB5is added as the image editing menu button. The internal region of the image display region EA1is divided according to the selected divided frame. The borderline button FBB turns on and off the display of a divided borderline FBL. Whenever the user touches the borderline button FBB on the screen, the display of the divided borderline is turned on and off. In a case where the borderline button FBB is turned on, the borderline FBL is displayed in the image display region EA1.FIG.26shows a case where the display of the borderline FBL is turned on. In a case where the display of the borderline is turned on, the borderline is also displayed on the image to be printed. In a case where a region in which the images are to be combined is touched in the image display region EA1, the screen of the touch panel120is switched to the image selection screen (seeFIG.15). The user selects the image to be combined on this screen. In a case where the image is selected, the screen returns to the collage image creation screen221again. At this time, the selected image is displayed by being applied to the selected region. FIG.27is a diagram showing an example of the collage image creation screen after the image is selected. This diagram shows an example of the display of the screen in a case where a region on the upper side of the screen in the divided frame of which the inside is divided into two equal upper and lower regions and the image to be combined is selected. As shown in this diagram, the selected image is displayed by being applied to the selected region. In a case where the user moves the finger while touching the image in the selected region, the position of the image is adjusted. In a case where the selected image is changed, a region in which the image is to be changed is touched and selected, and the back button BB is touched. Due to the present operation, the image can be selected by switching the screen to the image selection screen (seeFIG.15). The images may be switched in order by performing the flick operation on the screen within the region. The images are selected for all the regions of the divided frame, and the collage image is completed. The selected images of the regions can be individually processed and edited by using the enlargement and rotation function, the filter function, and the image quality correction function. The enlargement and rotation function, the filter function, and the image quality correction function are the same as those in the simple printing. Divided Frame Switching Operation Screen The divided frame button EB5displayed in the button display region EA2is a button for calling a function for switching the divided frames. In a case where the divided frame button EB5is touched, the screen is switched to an operation screen (divided frame switching operation screen)222for performing a switching operation of the divided frames. FIG.28is a diagram showing an example of the divided frame switching operation screen. On the divided frame switching operation screen222, divided frame selection buttons SFB1, SFB2, . . . for selecting switchable divided frames are displayed in addition to the display contents on the collage image creation screen221. The user touches and selects the selection button of the divided frame desired to be switched on the screen. Each button includes an image obtained by reducing the image of the divided frame selected by the button. Therefore, the outer shape has a shape similar to the outer shape of the print image (including a shape recognized as being substantially similar). Similar to the template image selection buttons, the divided frame selection buttons SFB1, SFB2, . . . are displayed in the operation region EA3, and are displayed radially around a point set at a straight line passing through the center of the screen in the width direction. A predetermined number of divided frame selection buttons SFB1, SFB2, . . . are displayed in the operation region EA3. Similar to the template image selection buttons, the other divided frame selection buttons are scrolled and displayed (seeFIG.24). In a case where the divided frames are switched, the image of each region is selected again. Operation Screen in Case Printing is Performed In a case where the collage image is completed, the printing can be performed. The execution of the printing is the same as that in a case where the simple printing is performed. That is, the printing is instructed by touching the print button PB on the screen. In a case where the printing is instructed, the image data of the print image PI (the generated collage image) is transmitted to the printer10. An animation showing the image transmission is displayed as in the simple printing (seeFIG.20). (D) Printing Using Combined Photograph Function Hereinafter, a procedure in a case where the image stored in the smartphone100is printed by using the combined photograph function is described. As described above, in the combined photograph, one image is divided into a plurality of images, and the images are printed. The rough processing procedure is (1) selection of the layout, (2) selection of the image, and (3) instructing to print. The image is processed and edited as necessary. Layout Selection Screen In a case where the combined photograph button MB7is touched on the top screen (seeFIGS.13and14), the combined photograph function is activated. In a case where the combined photograph function is activated, the screen of the touch panel120is switched to a layout selection screen230. This screen is a screen for selecting a divided layout. FIG.29is a diagram showing an example of the layout selection screen. As shown in this diagram, images of selectable layouts are displayed as a list on the layout selection screen230. Images having selectable layouts are images in which images imitating the instant films are arranged according to division modes. The user touches and selects the image of the desired layout on the screen. Image Selection Screen In a case where the layout is selected on the layout selection screen230, the screen of the touch panel120is switched to the image selection screen201(seeFIG.15). The user selects the image to be printed on this screen. Print Image Confirmation Screen In a case where the image to be printed is selected, the screen of the touch panel120is switched to a print image confirmation screen231. This screen is a screen for confirming the image to be printed (print image). FIG.30is a diagram showing an example of the print image confirmation screen of the combined photograph. On the print image confirmation screen231of the combined photograph, the image display region is set according to the selected layout.FIG.30shows a display example in a case where the combined photograph divided into two upper and lower images is generated. In this case, two image display regions (a first image display region EA1aand a second image display region EA1b) are set. Frames FL1and FL2are displayed around the image display regions. On the print image confirmation screen231of the combined photograph, the layout button EB6is additionally displayed as the image editing menu button. The layout button EB6is a button for calling a function for changing the layout. Layout Operation Screen In a case where the layout button EB6is touched, the screen is switched to an operation screen (layout change operation screen)232for performing a layout change operation. FIG.31is a diagram showing an example of a template switching operation screen. On the layout change operation screen232, changeable layout selection buttons LB1, LB2, . . . are displayed in addition to the display contents on the print image confirmation screen231. The user touches and selects the selection button of the layout desired to be changed on the screen. Each button is an image obtained by reducing an image of the layout selected by the button. Similar to the filter selection buttons, the layout selection buttons LB1, LB2, . . . are expanded and displayed in the operation region EA3, and are displayed radially around a point set at a straight line passing through the center of the screen in the width direction. The display is scrolled by the swipe operation. Operation Screen in Case Printing is Performed The execution of the printing is the same as that in a case where the simple printing is performed. That is, the printing is instructed by touching the print button PB on the screen. In a case where the printing is instructed, the image data of the print image is transmitted to the printer10. An animation showing the image transmission is displayed on the screen. In the case of the combined photograph, a plurality of images is printed according to the selected layout. Therefore, an animation showing that the images are transmitted one by one is also displayed. (D) Printing Using Camera Function Hereinafter, a procedure in a case where the image is printed by using the camera function will be described. The rough processing procedure is (1) imaging and (2) instructing to print. The image is processed and edited as necessary. Imaging Operation Screen In a case where the camera button MB3is touched on the top screen (seeFIGS.13and14), the camera function is activated. In a case where the camera function is activated, the screen of the touch panel120is switched to an imaging operation screen240. FIG.32is a diagram showing an example of the imaging operation screen. On the imaging operation screen240, a live view image LVI is displayed in the image display region EA1. Live viewing is a function of displaying a video captured by an image sensor in real time. On the imaging operation screen240, camera operation buttons are displayed in the button display region EA2. Specifically, a flash button CB1, an in and out switching button CB2, a shutter button CB3, a timer button CB4, and a date button CB5are displayed. The flash button CB1is a button for switching between flash modes. The in and out switching button CB2is a button for switching between the in-camera and the out-camera. The shutter button CB3is a button for instructing a release. The timer button CB4is a button for turning on and off a timer function. The date button CB5is a button for turning on and off a date function. The date function is a function of imprinting a date on a predetermined position of the print image. The user performs imaging by touching the shutter button CB3while viewing the live view image LVI displayed in the image display region EA1. Print Image Confirmation Screen In a case where the imaging is executed, the screen of the touch panel120is switched to the print image confirmation screen. This screen is the same as the print image confirmation screen202in the simple printing. The user processes and edits the image to be printed on this screen as necessary. That is, in a case where the image is not processed and edited, the printing is instructed by touching the print button PB on the screen. In a case where the printing is instructed, the image data of the print image is transmitted to the printer10. In a case where the image is transmitted, an animation of the image transmission is displayed as in the simple printing (seeFIG.20). Display of Status Information In a case where the printer main body14is lifted in a state in which the connection between the printer10and the smartphone100is established, the status information of the printer10is displayed on the screen of the smartphone100. In a case where the printer main body14is lifted, the movement of the printer10is detected by the movement detection unit66. In a case where the movement (third movement) of lifting the printer main body14is detected by the movement detection unit66, the printer10collects and acquires the status information. Specifically, the printer acquires the information of the number of printable sheets and the information of the state of charge of the battery. The acquired information is transmitted, as the status information, to the smartphone100. In a case where the smartphone100receives the status information, the smartphone displays the status information of the printer10on the touch panel120. FIG.33is a diagram showing an example of the display of the status information. As shown in this diagram, status information SI is displayed so as to be superimposed on the current display.FIG.33shows an example in which the printer main body14is lifted during the display on the print image confirmation screen202in the simple printing. In the example shown inFIG.33, an example in which a circle is displayed, and information SI1of the number of printable sheets (the number of remaining films) and information SI2of the state of charge of the battery are displayed as the status information in the circle is illustrated. In the example shown inFIG.32, the name (for example, model name) of the connected printer10is also displayed. As stated above, for example, the status information of the printer10is displayed, and thus, the state thereof can be grasped even in a case where a printer having no display such as the printer10of the present embodiment is used. Accordingly, the convenience as the system can be improved. Although the status information is also displayed on the top screen (seeFIGS.13and14), the status information SI is displayed similar to a case where the printer main body14is lifted during the display on the top screen. It is preferable that the user can optionally turn on and off the display on the status information SI. That is, it is preferable that a setting performed such that the status information SI is not displayed can be selected even though the printer main body14is lifted. It is more preferable that the display can be individually set to be turned on and off in each scene. For example, it is more preferable that the display can be set to constantly be turned off on the top screen. The turning-on or turning-off of the display is set on a setting screen of the print application. The setting screen is called by touching the setting button SEB on the top screen. Relationship Between Movement of Printer Main Body and Display on Touch Panel of Smartphone FIG.34is a table representing a relationship between the movement of the printer main body and the display on the touch panel of the smartphone. As represented in this table, in a case where the top screen is displayed on the touch panel120of the smartphone100and the printer main body14is vertically placed, the first top screen200A is displayed as the top screen. Meanwhile, in a case where the printer main body14is horizontally placed, the second top screen200B is displayed as the top screen. On the first top screen200A, the function buttons including the play element and the creation element (the affinity diagnosis button MB4, the template print button MB5, the collage print button MB6, and the combined photograph button MB7) are remarkably displayed with a large size. Therefore, in a case where the user wants to create, the user vertically places the printer main body14at the time of displaying the top screen. Accordingly, it is possible to simply activate a target function. Meanwhile, on the second top screen200B, the function buttons (the simple print button MB1, the motion picture print button MB2, and the camera button MB3) capable of being simply printed are remarkably displayed with a large size. Therefore, in a case where the user wants to simply print, the user horizontally places the printer main body14at the time of displaying the top screen. Accordingly, it is possible to simply activate a target function. As shown inFIG.34, in a case where the printer main body14is lifted in a state in which the connection between the printer10and the smartphone100is established, the status information SI is displayed on the screen of the touch panel120of the smartphone100. Accordingly, it is possible to instantaneously grasp the state of the printer10. MODIFICATION EXAMPLES In a case where the connection of the communication with the printer10cannot be established at the time of activating the print application, it is preferable that any one of the first top screen and the second top screen is displayed as the default top screen. For example, in a case where the connection of the communication with the printer10cannot be established within a predetermined time after the print application is activated, the first top screen is displayed as the default top screen. The user can select and set the top screen to be displayed in a case where the connection of the communication with the printer10cannot be established. Alternatively, the top screen previously displayed may be displayed. The top screen may be switched in the relationship with the printer10only in a case where the print application is activated. That is, in a case where the top screen is displayed again after the print application is activated (for example, in a case where the top screen is displayed by touching the top button TB), the top screen at the time of activation is displayed. For example, in a case where the first top screen is displayed at the time of activation, the first top screen is displayed as the top screen until the print application is ended. In a case where the installation posture of the printer main body14is changed during the display of the top screen, the top screen may be changed according to the change of the installation posture. Accordingly, it is possible to simply perform the switching of the top screen. Although it has been described in the present embodiment that two types of top screens are prepared, the type of the top screen is not limited thereto. A plurality of types of top screens can be prepared according to the movement of the printer main body14to be detected. In a case where the printer main body is horizontally placed, the top screens may be prepared so as to be distinguished between a case where the printer main body is turned upward and a case where the printer main body is turned downward. Movements of the printer main body in a case where a right side surface or a left side surface of the printer main body is turned downward may be detected, and the top screens may be prepared for these cases. The configuration of the top screen is not limited to that of the aforementioned embodiment, and may be provided according to the functions of the print application. Although it has been described in the aforementioned embodiment the last printed image is displayed on each top screen, this image may also be omitted. In a case where the last printed image is displayed on the top screen as in the aforementioned embodiment, the image may be functioned as a reprint instruction button. That is, in a case where the user touches the portion of the image, the image is set as the print image, and a simple print screen is activated. Accordingly, a reprint operation can be simply performed on the smartphone side. This image may function as a print history confirmation button. That is, in a case where the user touches the portion of the image, the screen is switched to a screen for reproducing the image printed so far. On the print history reproduction screen, for example, the images printed so far are reproduced in order frame by frame (the images are reproduced from the newest printed image to the oldest printed image frame by frame) according to a frame-frame advance instruction from the user (for example, the swipe operation in the horizontal direction). In order to operate the function, it is necessary to separately retain print history information. Although it has been described in the aforementioned embodiment that the information of the number of printable sheets and the information of the state of charge of the battery are displayed as the status information of the printer10, the information displayed as the status information of the printer10is not limited thereto. For example, in a case where the printer10comprises an image storage unit, information on the number of storable sheets and information on free space may be acquired and displayed. Although it has been described in the aforementioned embodiment that the status information SI is displayed according to the movement lifting the printer main body14, the movement assigned to the display of the status information SI is not limited thereto. In a case where the printer main body comprises a light emitting unit, it is preferable that the light emitting unit emits light in line with the detection of the specific movement. In particular, in a case where the light emitting unit (power button16) capable of performing color light emission is provided as in the printer10of the present embodiment, it is preferable that the light emission controller80E causes the light emitting unit to emit light in a light emission color and/or a light emission pattern corresponding to the movement detected by the movement detection unit66. For example, in a case where it is detected that the printer main body14is vertically placed, the power button16which is the light emitting unit emits red light. Meanwhile, in a case where it is detected that the printer main body is horizontally placed, the power button emits blue light. Accordingly, it is possible to visually recognize that the posture is normally detected. Second Embodiment In the printing system of the aforementioned embodiment, the display on the smartphone100is controlled according to the movement of the printer main body14. In the present embodiment, the printing system further controls the operation of the printer itself according to the movement of the printer main body14. Specifically, the image is reprinted according to a specific movement. The power of the printer10is turned off according to a specific movement. FIG.35is a block diagram of main functions realized by the printer microcomputer of the present embodiment. The printer of the present embodiment is different from the printer10of the aforementioned embodiment in that the print controller80C reprints the previously printed image based on the detection result of the movement detection unit66and the power controller80F turns off the printer10based on the detection result of the movement detection unit66. Therefore, only this difference will be described below. In a case where a state in which the printer main body14is lifted upside down is continued for a predetermined time, the print controller80C executes a reprinting process. The movement of lifting the printer main body14upside down is a movement (fourth movement) in which the printer main body14is lifted and the discharge port18is turned downward. The predetermined time is, for example, 5 seconds. The term “turned downward” mentioned herein includes a range recognized to be substantially turned vertically downward. That is, a range recognized to be substantially turned downward is included. In a case where the movement detection unit66detects the movement of lifting the printer main body14upside down and this state is maintained for the predetermined time, the image data of the previously printed image is read out from the printer storage unit62, and is acquired by the image acquisition unit80A. The acquired image data is provided to the print data generation unit80B, and is converted into a data format capable of being printed in the printing unit. The print controller80C acquires the print data from the print data generation unit80B, and prints the acquired print data on the instant film12. Accordingly, the previously printed image is reprinted. In a case where a movement (fifth movement) of directing the power button16downward (downward in the vertical direction) by horizontally directing the printer main body14is detected by the movement detection unit66and this state is maintained for a predetermined time, the power controller80F turns off the printer10. The predetermined time is, for example, 10 seconds. Accordingly, for example, in a case where the printer main body is horizontally placed in a state in which the power button16is turned downward, the printer is automatically turned off after a predetermined time elapses after the printer is horizontally placed. FIG.36is a table representing a relationship between the movement of the printer main body and the operation of the printer. As represented in this table, in a case where the printer main body14is lifted upside down and a predetermined time elapses, the previously printed image is reprinted. Accordingly, it is possible to simply perform the reprinting. As shown in this diagram, in a case where the power button16is turned downward by horizontally directing the printer main body14, the printer10is turned off after a predetermined time elapses. For example, in a case where the printer main body14is horizontally placed by directing the power button16downward, the printer10is turned off after a predetermined time elapses. Accordingly, the printer can be simply turned off. In a case where the printer is turned off by directing the power button16downward as in the printer10of the present embodiment and the top screen of the print application is changed to the second top screen, the printer main body is horizontally placed by directing the power button16upward. The term “turned downward” mentioned herein includes a range recognized to be substantially turned vertically downward. That is, a range recognized to be substantially turned downward is included. Modification Examples Although it has been described in the aforementioned embodiment that in a case where the printer main body14is set upside down for a predetermined time or more, the previously printed image is reprinted, the operation of the printer main body14assigned to the reprinting process is not limited thereto. For example, in a case where the printer main body14is tilted upside down for a predetermined time or more, the previously printed image can be reprinted. Preferably, in a case where the printer main body14is tilted by directing the discharge port18downward within a range of a predetermined angle, the reprinting is performed. For example, the reprinting is performed in a case where the printer main body14is tilted by directing the discharge port18downward within a range of 30° to 60°. Here, the term “tilted upside down” mentioned herein means a movement of tilting the printer main body14by directing the discharge port18downward. The reprinting may be performed by a combination of the movement of directing the printer main body14upside down, the movement of tilting the printer main body upside down, and the other movements. For example, the reprinting may be performed by shaking the printer main body14up and down after being set upside down for a predetermined time or more. In this case, the number of printed sheets may be set according to the number of times of shaking. For example, in a case where the printer main body14is shaken up and down two times after being set upside down for a predetermined time or more, two sheets may be reprinted. The reprinting may be performed by a combination of the movement and the operation button. For example, in a case where the power button16is pressed while the printer main body14is set upside down or the printer main body14is tilted upside down, the reprinting may be performed. The same is true of a case where the printer10is turned off, and a movement other than the movement of directing the power button16downward may be assigned. For example, the movement of tilting the power button16downward may be assigned. A combination with other movements may be assigned. The power may be turned off by a combination of the movement and the operation button. For example, in a case where the power button16is pressed (short press) by directing the power button16downward, the printer can be turned off (the printer is normally turned off by a long press of the power button16). The operation content of the printer10controlled by the movement of the printer main body14is not limited to that of the aforementioned embodiment. It is possible to perform an appropriate setting according to the function of the printer10. As in the present embodiment, even in a case where the operation of the printer itself is controlled according to the movement of the printer main body14, it is preferable that the light emitting unit (power button16) can emit light according to the detected movement. Third Embodiment In the printing system according to the present embodiment, the smartphone100is remotely controlled by using the printer10as a remote controller of the smartphone100. Hereinafter, an example in which the camera function of the smartphone100is remotely controlled by the printer10will be described. FIG.37is a block diagram of main functions realized by the printer microcomputer of the present embodiment. As shown in this diagram, the printer microcomputer80of the printer10of the present embodiment further has functions of a mode setting unit80J and an operation signal transmission unit80K. The mode setting unit80J sets an operation mode of the printer10. The printer10of the present embodiment has, as the operation mode, a printer mode and a remote control mode. The printer mode is a mode in which the printer10is used as a normal printer. The remote control mode is a mode in which the printer10is used as the remote controller of the smartphone100in a relationship with the smartphone100. The mode setting unit80J sets the operation mode of the printer10according to a mode switching command transmitted from the smartphone100. The printer10is activated in the printer mode at the time of turning on the printer. Therefore, the remote control mode is set when a command to switch the remote control mode is received from the smartphone100. A mode switching operation is performed on the operation screen of the print application. Therefore, the print application has a printer mode setting function as one of menu items. In a case where the operation mode of the printer10is set to the remote control mode, the operation signal transmission unit80K transmits a signal (operation signal) for operating the smartphone100according to the movement of the printer main body14detected by the movement detection unit66and a button operation of the power button16. Specifically, an operation signal for operating a zoom of the camera unit (the in-camera unit108A and the out-camera unit108B) and an operation signal for operating the release are transmitted. The zoom is operated by the movement of the printer main body14. Specifically, the zoom is operated by an operation (seventh movement) of tilting the printer main body back and forth from a standing posture (vertical posture). In the present embodiment, in a case where the printer main body is tilted forward (front side), the zoom is performed to a telephoto side (zoom-in), and in a case where the printer main body is tilted rearward (rear side), the zoom is performed to a wide side (zoom-out). The zoom is step zoom, and the zoom-in and zoom-out is performed at a predetermined zoom magnification whenever the printer main body14is tilted. The zoom operation signal is transmitted in a case where the printer main body14is tilted within a predetermined angle range. In the present embodiment, the zoom-in is performed in a case where the printer main body is tilted forward in a range of 30° to 60° (range of 45°±15°), and the zoom-in is performed in a case where the printer main body is tilted rearward in a range of 30° to 60° (range of 45°±15°). The zoom method is not particularly limited. In a case where the smartphone100to be operated has an optical zoom function, the zoom-in and the zoom-out are performed by an optical zoom. In a case where the smartphone100to be operated has only an electronic zoom function, the zoom-in and the zoom-out are performed by an electronic zoom. In a case where the smartphone100to be operated has both the optical zoom and electronic zoom functions, both the zoom functions may be used. For example, after the zoom-in is performed to a telephoto end by the optical zoom, in a case where the zoom-in is further performed, the zoom function is switched to the electronic zoom. Only one of these zooms may function by the setting of the user. In a case where the movement detection unit66detects that the printer main body14is tilted forward, the operation signal transmission unit80K transmits a zoom-in operation signal to the smartphone100via the wireless communication unit56. In a case where the movement detection unit66detects that the printer main body14is tilted rearward, the operation signal transmission unit80K transmits a zoom-out operation signal to the smartphone100via the wireless communication unit56. In a case where the operation detection unit50detects that the button operation of the power button16is a short press, the operation signal transmission unit80K transmits a release operation signal to the smartphone100via the wireless communication unit56. In a case where the operation mode of the printer10is set to the printer mode and the smartphone100receives the zoom operation signal from the printer10, the smartphone operates the zoom of the camera unit (the in-camera unit108A or the out-camera unit108B) via the imaging controller100C. In a case where the release operation signal is received, the smartphone performs a recording imaging process via the imaging controller100C. The imaging controller100C of the smartphone100is an example of a terminal controller. The communication controller100F is an example of an operation signal reception unit. FIG.38is a table representing a relationship between the movement of the printer main body and the camera operation of the smartphone in the remote control mode. As shown in this diagram, in a case where the operation mode of the printer10is set to the remote control mode and the printer main body14is tilted forward, the zoom-in operation signal is transmitted from the printer10to the smartphone100. The smartphone100receives the zoom-in operation signal, and operates the zoom of the camera unit (the in-camera unit108A or the out-camera unit108B) to the telephoto side. In a case where the printer main body14is tilted rearward, the zoom-out operation signal is transmitted from the printer10to the smartphone100. The smartphone100receives the zoom-out operation signal, and operates the zoom of the camera unit to the wide side. In a case where the power button16is operated (short press), the release operation signal is transmitted from the printer10to the smartphone100. The smartphone100receives the release operation signal, and executes the recording imaging process. As stated above, according to the printing system of the present embodiment, the printer10can be used as the remote controller of the smartphone100. Accordingly, the convenience at the time of imaging can further be improved. Modification Examples Although it has been described in the aforementioned embodiment that the zoom of the camera unit of the smartphone100is operated by the operation of tilting the printer main body14back and forth, the operation assigned to the operation of the zoom is not limited thereto. For example, the operation of the zoom of tilting the printer main body left and right can be performed. The zoom may be operated by operating the operation member provided at the printer main body. The zoom can be operated by a combination of the operation member provided at the printer main body and the movement. Although it has been described in the aforementioned embodiment that the zoom-in and the zoom-out are performed at a predetermined zoom magnification whenever the printer main body14is tilted, the zoom operation mode is not limited thereto. For example, it is possible to perform continuously zoom while tilting. Although it has been described in the aforementioned embodiment that the release is operated by operating the power button16, the operation assigned to the release operation is not limited thereto. For example, the release operation may be assigned to the specific movement (sixth movement) of the printer main body14. For example, the release can be operated by shaking the printer main body14up and down. The release may be operated by a combination of the specific movement of the printer main body14and the operation of the operation member. Although it has been described in the aforementioned embodiment that the camera unit of the smartphone100is remotely operated by the printer10, the target to be operated is not limited thereto. For example, in image reproduction, the frame-frame advance and/or frame-frame return can be operated by tilting the printer main body14back and forth. In a case where the camera unit is remotely operated, the operation to be remotely controlled is not limited to the zoom and the release. Other operations can also be used as the target. For example, switching of imaging modes (a shutter speed priority mode, a stop priority mode, and an auto mode), switching of shutter speeds, switching of F numbers, and switching of sensitivity may be remotely operated by the movement of the printer main body14and/or the operation of the operation member provided at the printer main body14. The user can optionally set the operation of the smartphone100and the movement of the printer main body14assigned to this operation (a so-called customization function). For example, in addition to the operation of tilting the printer main body14as described above, an operation of shaking the printer main body up and down, an operation of shaking the printer main body back and forth, an operation of shaking the printer main body left and right, an operation of diagonally shaking the printer main body, an operation of directing the printer main body upside down, and an operation of directing the printer main body inside out can be employed as the operation to be assigned. These operations may be combined with the operation of the operation member provided at the printer main body14. In a case where the assignment is performed, the movement to be assigned may be actually performed and detected by the movement detection unit66, and the detected movement may be assigned to a specific operation. For example, in a case where the operation of tilting the printer main body14back and forth is assigned to the operation of the zoom of the camera unit, the operation of actually tilting the printer main body14back and forth is performed, this movement is detected by the movement detection unit66, and is assigned to the operation of the zoom. Accordingly, movement habits of each user can be reflected, and usability can be further improved. In the present embodiment, it is also preferable that the light emitting unit (power button16) emits light according to the detected movement of the printer main body14. Although it has been described in the aforementioned embodiment that the terminal (smartphone100) is remotely operated by the printer10, the same operation system (system for remotely operating the terminal) can be constituted by using a device having a function of detecting the movement of the main body (a device comprising the movement detection unit). For example, the operation system that operates the terminal can be constituted by a portable electronic device comprising the movement detection unit that detects the movement of the main body. In particular, it is possible to constitute the operation system that operates the terminal comprising the camera unit by the movement of the portable electronic device or the operation of the operation member provided at the portable electronic device. Other Embodiments Animation Display for Switching Screen In a case where the installation posture of the printer main body14is changed during the display of the top screen, it is preferable that the switching of the screen is displayed by animation. For example, in a case where the installation posture of the printer main body14is switched from the vertical placement to the horizontal placement during the display of the first top screen200A, the top screen is switched from the first top screen200A to the second top screen200B, but it is preferable that the switching is displayed by animation. Similarly, in a case where the installation posture of the printer main body14is switched from the horizontal placement to the vertical placement during the display of the second top screen200B, the top screen is switched from the second top screen200B to the first top screen200A, but it is preferable that the switching is displayed by animation. FIG.39is a diagram showing an example of animation display for switching the top screen. This diagram shows scenes in which animations are switched are displayed in a sequence of time (are displayed frame by frame predetermined intervals). In a case where the switching is performed from the first top screen200A to the second top screen200B, the screen is changed in the order of a screen200a, a screen200b, . . . , a screen200r, and a screen200s, and is switched to the second top screen200B. Meanwhile, in a case where the switching is performed from the second top screen200B to the first top screen200A, the screen is changed in the order of the screen200s, the screen200r, . . . , the screen200b, and the screen200a, and is switched to the first top screen200A. As stated above, the switching of the screen is displayed by animation, and thus, the switching can be clearly grasped. Accordingly, operability can be further improved. The user can easily recognize that the screen is switched depending on the installation posture of the printer main body14, and an intuitive operation can be performed. The user can enjoy the operation. Modification Example of Print Instruction Operation In the aforementioned embodiment, the print button PB displayed in the button display region EA2is touched, and thus, the printing of the image displayed in the image display region EA1is instructed. Instead of the method or in addition to the method, the printing may be instructed by the following method. That is, the printing is instructed by swiping or flicking the screen on the print image PI displayed on the image display region EA1or on the frame FL. FIG.40is a conceptual diagram of the operation in a case where the printing is instructed by the flick operation. As shown in this diagram, the user touches the top of the frame FL displayed on the screen with the finger and slides so as to flip upward, and thus, the printing is instructed. As described above, in a case where the printing is instructed, an animation of the image transmission is displayed. The movement direction of the print image PI at the time of animation display coincides with the operation direction of the print instruction. Accordingly, it is possible to perform an intuitive operation, and operability can be further improved. Cancelation of Printing It is preferable that the printing can be canceled if necessary. In particular, the convenience of the printing system can be further improved by canceling the printing before the printing is started. A method of displaying a button for instructing to cancel the printing on the screen can be employed as a method of instructing to cancel the printing on the portable terminal side. FIG.41is a diagram showing an example of a screen for accepting an input instruction to cancel the printing. This diagram shows an example of a screen in a case where the cancelation of the printing is accepted during the transmission of the image. As described above, in a case where the printing is instructed, an animation of the image transmission is displayed. A message MI1(“image is being transmitted”) indicating that the image is being transmitted and a print cancel button PCB are displayed so as to be superimposed on the print image PI at the time of the animation display. The print cancel button PCB is a button for instructing to cancel the printing. The print cancel button PCB is a button with a text of cancel in a rectangular frame. The message MI1and the print cancel button PCB move together with the print image PI during the animation display. Therefore, the message and the print cancel button will eventually disappear from the upper edge of the screen. The print cancel button PCB is touched during the display, and thus, the printing is canceled. In a case where the print cancel button PCB is touched after the printing is instructed and the printing is canceled, the print image PI moves in the reverse direction, and returns to the original position. That is, the print cancel button moves downward and returns to the position before the start of the movement (see screen206A inFIG.20). The print cancel button PCB is displayed as stated above, and thus, it is possible to cancel the printing. Further, it is possible to grasp a time limit, and operability can be further improved. Modification Example of Operation Method of Image Processing on Screen Operations such as the enlargement and rotation of the image to be printed may be performed by a predetermined gesture. For example, the image is enlarged and reduced by performing pinch-out and pinch-in operations on the image displayed in the image display region EA1. The swipe operation is performed on the image displayed in the image display region EA1, and thus, the image is moved in the operation direction. The image displayed in the image display region EA1is rotated (twisted) while touching the image with two fingers (for example, a thumb and an index finger), and thus, the image is rotated. The pinch-in operation refers to an operation of moving the screen so as to pick while touching the screen with two fingers (for example, a thumb and an index finger). The pinch-out operation refers to an operation of moving the screen so as to enlarge while touching the screen with two fingers (for example, a thumb and an index finger). In a case where operations such as enlargement, movement, and rotation with a gesture on the screen as stated above, it is preferable that the function is turned on and off. For example, the function can be turned on and off by touching the frame FL surrounding the print image PI. In this case, the function is alternately turned on and off whenever the frame FL is touched. In a case where operations such as enlargement, movement, and rotation with the gesture on the screen, it is preferable that an operation guide screen is displayed. FIG.42is a diagram showing an example of the operation guide screen. As shown in this diagram, a message MI2indicating that the image can be enlarged, moved, and rotated by the gesture on the screen (“the image can be edited by inputting a gesture on the image.”) is displayed on the print image confirmation screen202. For example, this message MI2is displayed in a case where the print image confirmation screen202is first displayed. In the example shown inFIG.42, an OK button OKB is displayed to prompt the user to confirm. The message MI2disappears from the screen in a case where the OK button OKB is touched. It is preferable that the message MI2can be displayed or cannot be displayed by setting. As in the present example, in a case where the image is enlarged and rotated by the gesture on the screen, the display of a button (enlargement & rotation button EB1) for calling the enlargement and rotation function can be omitted.FIG.42shows an example in which the display of the enlargement & rotation button is omitted. Modification Example of Button Layout Although it has been described in the aforementioned embodiment that the print button PB is disposed at a straight line passing through the center in the width direction in the button display region EA2, the type of the button disposed at the straight line passing through the center in the width direction is not limited thereto. Other function buttons may be arranged. However, the print button PB is disposed at the straight line passing through the center in the width direction and is displayed with a size larger than other buttons on the operation screen for performing the operations related to the printing. Accordingly, it is possible to clearly perform the print instruction operation. Although it has been described in the aforementioned embodiment that only the print button PB and the image editing menu button are displayed in the button display region EA2, buttons having functions other than these functions may be displayed in the button display region EA2. For example, the setting button SEB may be displayed. Modification Example of Image Editing Menu Although it has been described in the aforementioned embodiment that the image editing menu has the enlargement and rotation function, the filter function, and the image quality correction function, the present invention is not limited thereto. Instead of the aforementioned items, or in addition to the aforementioned items, other image editing operations may be performed. For example, noise removal and sharpness change may be performed. Text may be written on the image, a picture may be drawn, or a stamp may be pressed by using the touch panel (so-called drawing mode). A keyboard may be displayed on the screen, and thus, the input text can be copied. For example, the text may be copied in a margin region. Operation Screen in Case Printer is Not Connected In a case where the printer10is not connected (in a case where communication with the printer10is not established), a communication connection button may be displayed on each operation screen instead of the displayed print button. FIG.43is a diagram showing an example of display of the communication connection button. This diagram shows an example in a case where the communication connection button is displayed on the operation screen of the simple print function. As shown in this diagram, a communication connection button CCB is displayed instead of the print button. The communication connection button CCB is a button for performing communication connection with the printer10. In a case where the communication connection button CCB is touched, a process of detecting the printer10capable of performing communication is performed, and a process of establishing communication with the detected printer10is performed. At this time, a screen for setting the communication is displayed on the touch panel120of the smartphone100. For example, the printers capable of performing the communication are displayed as a list, and a screen for selecting the printer to be connected is displayed. Other Examples of Printer Although it has been described in the aforementioned embodiment that the printer is the instant printer, the configuration of the printer is not limited thereto. For example, the present invention can be applied to various types of printers such as a thermal printer that prints on thermo-sensitive paper, a thermal transfer printer that prints using an ink ribbon, and an inkjet printer that prints using an inkjet method. The type of a medium to be used is not particularly limited, and the present invention can be applied to a printer that prints on roll paper in addition to sheets of paper. The present invention can be applied to a printer that prints on a label (including a sticker). Although it has been described in the aforementioned embodiment that the present invention is applied to the mobile printer, the application of the present invention is not limited thereto. The present invention can also be applied to a so-called stationary printer. Other Examples of Terminal Although it has been described in the aforementioned embodiments that the terminal is the smartphone, the terminal to which this invention is applied is not limited thereto. The present invention can be similarly applied to any device that is wirelessly connected to the printer and includes the screen for performing the operation. Accordingly, the present invention can be applied to, for example, a tablet type terminal, a personal data assistant (PDA), and a mobile computer such as a laptop personal computer and the like can be used as the terminal in addition to the smartphone. A digital camera having a wireless communication function can be used as the terminal in addition to these mobile computers. In this case, the operation screen is displayed on a monitor (such as a rear monitor) provided at the digital camera, and the printer is operated. Similarly, a portable game machine or a cellular phone having the wireless communication function can be used as the terminal. Hardware Configurations of Controllers of Printer and Terminal The functions of the controllers of the printer and the terminal can be realized by various processors. Various processors include a central processing unit (CPU) which is a general purpose processor functioning as various processing units by executing a program, a programmable logic device (PLD) which is a processor capable of changing a circuit configuration after a field programmable gate array (FPGA) is manufactured, and a dedicated electric circuit which is a processor having a circuit configuration designed as a dedicated circuit in order to perform specific processing such as application specific integrated circuit (ASIC). One processing unit constituting an inspection support apparatus may be constituted by one of the various processors described above, or may be constituted by two or more processors of the same type or different types. For example, one processing unit may be constituted by a plurality of FPGAs or a combination of a CPU and an FPGA. Alternatively, the plurality of processing units may be constituted by one processor. Firstly, as the example in which the plurality of processing units is constituted by one processor, there is a form in which one processor is constituted by a combination of one or more CPUs and software and this processor functions as the plurality of processing units as represented by computers such as a client and a server. Second, a processor that realizes the functions of the entire system including the plurality of processing units by using one integrated circuit (IC) chip is used so as to be represented by a System On Chip (SoC). As stated above, various processing units are constituted as hardware structure by using one or more of various processors. More specifically, hardware structures of the various processors are an electric circuitry obtained by combining circuit elements such as semiconductor elements. Modification Example of Communication Aspect Although it has been described in the aforementioned embodiment that the printer and the portable terminal communicate with each other through short range wireless communication, the communication method is not particularly limited. A known wireless communication method can be employed. Movement Detection Unit Any movement detection unit may be used as long as the movement detection unit66detects at least the assigned movement. Therefore, the movement detection unit may be only an acceleration sensor or only a gyro sensor depending on the movement to be detected. Operation Member Provided at Printer Although it has been described in the printer of the aforementioned embodiment that the printer main body comprises only the power button as the operation member, the printer may comprise other operation members (so-called mechanical switches). For example, a reprint button for performing the reprinting may be separately provided. As in the aforementioned embodiment, the configuration can be simplified by using only the power button as the operation member provided at the printer main body. Modification Example of Light Emitting Unit Although it has been described in the printer of the aforementioned embodiment that the power button is configured to emit light, the light emitting unit may be separately provided. The light emitting unit may be provided at multiple locations. EXPLANATION OF REFERENCES 10: printer12: instant film12a: exposure surface12b: observation surface12c: exposure region12d: pod portion12e: developing solution pod12f: trap portion12g: absorbent12h: observation region12i: frame14: printer main body16: power button18: discharge port20: film pack lid22: unlock lever24: USB cable connection portion cover30: film pack loading chamber32: film delivery mechanism32a: claw34: film transport mechanism34A: transport roller pair34B: spreading roller pair36: print head40: film pack42: case42a: exposure opening42b: film discharge port42c: claw opening portion50: operation detection unit52: light source unit56: wireless communication unit56A: antenna58: power supply unit62: printer storage unit66: movement detection unit68: film delivery mechanism drive unit70: film transport mechanism drive unit72: print head controller80: printer microcomputer80A: image acquisition unit80B: print data generation unit80C: print controller80D: representative color detection unit80E: light emission controller80F: power controller80G: control signal transmission unit80H: status information acquisition unit80I: status information transmission unit80J: mode setting unit80K: operation signal transmission unit100: smartphone100A: display controller100B: input controller100C: imaging controller100D: reproduction controller100E: image processing unit100F: communication controller101: CPU102: ROM103: RAM104: built-in memory105: display106: touch pad107: GPS reception unit108A: in-camera unit108B: out-camera unit109: microphone unit110: speaker unit111: wireless communication unit111A: antenna112: short range wireless communication unit112A: antenna113: sensor unit114: media drive115: memory card120: touch panel200: top screen200A: first top screen200B: second top screen200ato200s: screens constituting one frame of animation for switching between top screens201: image selection screen201A: cancel button202: print image confirmation screen203: rotation operation screen204: filter operation screen205: image quality correction operation screen206A to206C: screens constituting one frame of animation in case printing is instructed210: template selection screen212: template switching operation screen220: divided frame selection screen221: collage image creation screen222: divided frame switching operation screen230: layout selection screen231: print image confirmation screen232: layout change operation screen240: imaging operation screenBB: back buttonCB1: flash buttonCB2: in and out switching buttonCB3: shutter buttonCB4: timer buttonCB5: date buttonCCB: communication connection buttonE3: operation regionEA1: image display regionEA1a: first image display regionEA1b: second image display regionEA2: button display regionEA3: operation regionEB1: rotation buttonEB2: filter buttonEB3: image quality correction buttonEB4: template buttonEB5: divided frame buttonEB6: layout buttonF: delivery direction of instant filmFB1: normal buttonFB2: monochrome buttonFB3: sepia buttonFB4: auto buttonFBB: borderline buttonFBL: borderlineFL: frame surrounding print imageFL1: frame surrounding images constituting combined photographFL2: frame surrounding images constituting combined photographFLO: image display frameLB1, LB2, . . . : layout selection buttonLIM: last printed imageLVI: live view imageMA1: first group display regionMA2: second group display regionMA3: status information display regionMB1: simple print buttonMB2: motion picture print buttonMB3: camera buttonMB4: affinity diagnosis buttonMB5: template print buttonMB6: collage print buttonMB7: combined photograph buttonMG1: first groupMG2: second groupMI1: messageMI2: messageNB1: knob of enlargement slide barNB2: knob of rotation slide barNB3: knob of brightness adjustment slide barNB4: knob of contrast adjustment slide barNB5: knob of saturation adjustment slide barOKB: OK buttonPB: print buttonPI: print imageR+: scroll directionR−: scroll directionRSB: reset buttonS1to S10: processing procedure of display of top screen in case print application is activatedSB1: enlargement slide barSB2: rotation slide barSB3: brightness adjustment slide barSB4: contrast adjustment slide barSB5: saturation adjustment slide barSEB: setting buttonSFB1: divided frame selection buttonSFB2: divided frame selection buttonSI: status informationSI1: information of number of printable sheets (remaining films)SI2: information of state of charge of batteryTB: top buttonTB1, TB2, . . . : template image selection button | 130,512 |
11858284 | The accompanying drawings are intended to depict embodiments of the present invention and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. Also, identical or similar reference numerals designate identical or similar components throughout the several views. DETAILED DESCRIPTION In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that have a similar function, operate in a similar manner, and achieve a similar result. Referring now to the drawings, embodiments of the present disclosure are described below. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. While embodiments of the present disclosure will be described below, embodiments of the present disclosure are not limited to the embodiments described below. In an embodiment described below, an information processing apparatus20connected to a printer30, and a printing system10including the information processing apparatus20and the printer30will be described as examples of an information processing apparatus and a printing system. However, the information processing apparatus and the printing system are not limited to the specific embodiments described below. FIG.1illustrates a general arrangement of the printing system10according to the embodiment. The printing system10illustrated inFIG.1includes the information processing apparatus20and the printer30. The information processing apparatus20and the printer30are connected via an appropriate interface such as a dedicated line, a Universal Serial Bus (USB), or a wired or wireless local area network (LAN). The information processing apparatus20, for example, receives an input of an input image set12for light field printing from a terminal connected via a LAN or the like, and generates an image to be printed on a transmissive transfer medium such as a transparent sheet in accordance with a predetermined algorithm. The information processing apparatus20also issues a print command (print instruction) to the printer30based on the generated image. Respective input images constituting the input image set12are referred to as input images12-1to12-N. The input images12-1to12-N are image data corresponding to respective predetermined observation viewpoints. The user prepares the input image set12to obtain a desired light field print. In the embodiment, a generated image includes at least two images to be duplex printed on a transmissive transfer medium such as a transparent sheet. Hereinafter, an image to be printed on the front side is referred to as a front-side image16F, and an image to be printed on the back side is referred to as a back-side image16B. The front-side image16F and the back-side image16B are generated by solving a predetermined optimization problem. The front-side image16F and the back-side image16B are images with specific patterns obtained by solving the optimization problem. The front-side image16F does not have a meaning as an image, and the back-side image16B does not have a meaning as an image. A meaningful image is reproduced by superimposing the front-side image16F and the back-side image16B. This is a feature of light field printing. In response to a print command (print instruction) from the information processing apparatus20, the printer30forms images on both sides of a transmissive transfer medium18S based on print image data including the front-side image16F and the back-side image16B, and outputs a print18. The print18includes the transmissive transfer medium18S, an image layer18F on the front side, and an image layer18B on the back side. The image layer18F and the image layer18B are arranged substantially in parallel and apart from each other. The print18is a light field print having an image to be observed that changes by changing an observation viewpoint. Hereinafter, the print18may be referred to as a light field print18. When a plurality of input images represent images of a predetermined subject observed from a plurality of viewpoints, it is possible to provide a print that stereoscopically expresses the subject. However, the light field print18according to the embodiment is not limited to one providing stereoscopic vision. For example, a plurality of input images may express different subjects. In this case, changing the viewpoint will change the subject being observed. Before describing the light field printing function provided by the printing system10according to the embodiment, hardware configurations of the information processing apparatus20and the printer30constituting the printing system10will be described below. FIG.2illustrates an embodiment of a printer100(corresponding to the printer30illustrated inFIG.1). The printer100illustrated inFIG.2includes an optical device102, an imaging unit125, and a transfer and fixing unit130. The optical device102includes optical elements such as a semiconductor laser element and a polygon mirror104. The imaging unit125includes, for example, photoconductive drums115K,115Y,115C, and115M, charging devices, and developing devices. The transfer and fixing unit130includes, for example, a fixing unit117, a conveyor belt116, and an intermediate transfer belt. The optical device102includes a laser output unit. A light beam L emitted from the laser output unit is focused by a cylindrical lens and deflected by the polygon mirror104toward a reflecting mirror106. The light beam L includes light beams L corresponding to respective colors of cyan (C), magenta (M), yellow (Y), and black (K) in the illustrated embodiment. The light beams L are directed to the respective photoconductive drums115K,115Y,115C, and115M (hereinafter collectively referred to as photoconductive drums115) via corresponding imaging forming lenses to form electrostatic latent images thereon. The diameter of the exposure spot of the light beam L emitted onto the photoconductive drum115is defined in the main-scanning direction and the sub-scanning direction using the spatial size of a predetermined range. The main-scanning direction is defined as a scanning direction of the light beam, and the sub-scanning direction is defined as a direction orthogonal to the main-scanning direction. In the embodiment, the sub-scanning direction corresponds to a conveyance direction of a transfer medium, and the main-scanning direction corresponds to a non-conveyance direction in which the transfer medium is not conveyed. However, the directions are not limited to the above-described definitions and may be determined depending on the specific implementations of the printer100. The electrostatic latent images thus formed are conveyed to the development devices120K,120Y,120C, and120M (hereinafter referred to as development devices120) as the photoconductive drums115rotate, respectively. The development devices120develop the electrostatic latent images with developers of the respective colors to form visible toner images on the photoconductive drums115. The photoconductive drums115rotate while carrying the toner images, and thus convey the toner images to the transfer and fixing unit130. The transfer and fixing unit130includes feed trays108,109, and110, feed units111,112, and113, a vertical conveyance unit114, the conveyor belt116, and the fixing unit117. Each of the feed trays108through110accommodates transfer media such as plastic sheets. The feed units111through113feed the transfer media from the respective feed trays108through110one by one to the vertical conveyance unit114. The vertical conveyance unit114conveys a transfer medium fed by one of the feed units111through113to a position where the transfer medium contacts the closest photoconductive drum115. The transfer medium thus conveyed is then electrostatically attached to the conveyor belt116. The toner images are transferred onto the transfer medium from the respective photoconductive drums115at a transfer bias potential to form a color toner image thereon. The transfer medium carrying the color toner image is then conveyed to the fixing unit117after transferring. The fixing unit117includes, for example, a fixing member such as a fixing roller including silicon rubber or fluororubber. In the fixing unit117, the color toner image is fixed onto the transfer medium under heat and pressure to form a color image thereon. A print after fixing is then conveyed to a discharge unit118that discharges the print onto a discharge tray119. The discharge unit118includes a separation claw121to direct the print to a duplex feed unit122. Upon duplex printing, the discharge unit118does not discharge the print onto the discharge tray119, but directs the print to the duplex feed unit122with the separation claw121set at an upper position. The print conveyed to the duplex feed unit122is fed to the vertical conveyance unit114to consequently carry another image on the back side. After passing through the fixing operation, the print carrying images on both sides reaches the discharge unit118that discharges the print onto the discharge tray119with the separation claw121set at a lower position. FIG.3is a diagram illustrating a hardware configuration of the printer according to the embodiment. As illustrated inFIG.3, a printer900(corresponding to the printer30illustrated inFIG.1) includes a controller910, a short-range communication circuit920, an engine controller930, a control panel940, and a network interface (I/F)950. The controller910includes a central processing unit (CPU)901as a main processor of a computer, a system memory (MEM-P)902, a north bridge (NB)903, a south bridge (SB)904, an Application Specific Integrated Circuit (ASIC)906, a local memory (MEM-C)907as a storage unit, a hard disk drive (HDD) controller908, and a hard disk (HD)909as a storage unit. The NB903and the ASIC906are connected through an Accelerated Graphics Port (AGP) bus921. The CPU901controls the entire operation of the printer900. The NB903couples the CPU901, with the MEM-P902, the SB904, and the AGP bus921. The NB903includes a memory controller for controlling reading or writing of various data from or to the MEM-P902, a Peripheral Component Interconnect (PCI) master, and an AGP target. The MEM-P902includes a read-only memory (ROM)902aas a memory that stores a program and data for implementing various functions of the controller910. The MEM-P902further includes a random access memory (RAM)902bas a memory that deploys the program and data, or as a drawing memory that stores drawing data for printing. The program stored in the RAM902bcan be stored in any computer-readable recording medium, such as a compact disc-read only memory (CD-ROM), a compact disc-recordable (CD-R), or a digital versatile disc (DVD), in a file format installable or executable by the computer, for distribution. The SB904couples the NB903with a PCI device and a peripheral device. The ASIC906is an integrated circuit (IC) having a hardware element for image processing and dedicated to an image processing use, and couples the AGP bus921, a PCI bus922, the HDD controller908, and the MEM-C907to each other. The ASIC906includes a PCI target, an AGP master, an arbiter (ARB) as a central processor of the ASIC906, a memory controller, a plurality of direct memory access controllers (DMACs), and a PCI unit. The memory controller controls the MEM-C907. The DMACs is capable of rotating image data with a hardware logic. The PCI unit transfers data between a scanner engine931and a printer engine932through the PCI bus922. A USB interface or an Institute of Electrical and Electronics Engineers 1394 (IEEE 1394) interface may be connected to the ASIC906. The MEM-C907is a local memory used as a buffer for image data to be copied or coding. The HD909is a storage for storing image data, font data used for printing, and forms. The HD909reads or writes various data from or to the HD909under control of the CPU901. The AGP bus921is a bus interface for a graphics accelerator card proposed for speeding up graphic processing, and can speed up the graphics accelerator card by directly making an access to the MEM-P902with high throughput. The short-range communication circuit920is provided with an antenna920a. The short-range communication circuit920is a communication circuit of Near Field Communication (NFC), Bluetooth (registered trademark), or the like. The engine controller930includes the scanner engine931and the printer engine932. The control panel940includes a panel display940aand an operation panel940b. The panel display940ais implemented by, for example, a touch panel that displays current settings or a selection screen to receive a user input. The operation panel940bincludes a numeric keypad that receives set values of various image forming parameters such as an image density parameter and a start key that receives a command for starting copying. The controller910controls overall operation of the printer900. For example, the controller910controls drawing, communication, or user inputs to the control panel940. The scanner engine931and the printer engine932each performs various image processing, such as error diffusion or gamma conversion. In response to an instruction to select a specific application through the control panel940, for example, using a mode switch key, the printer900selectively performs a document box function, a copier function, a printer function, and a facsimile function. When the document box function is selected, a document box mode is set, when the copier function is selected, a copier mode is set, when the print function is selected, a printer mode is set, and when the facsimile function is selected, a facsimile mode is set. The network I/F950controls data communication with an external device through a network. The short-range communication circuit920and the network I/F950are electrically connected to the ASIC906through the PCI bus922. FIG.4is a diagram illustrating a hardware configuration of a computer that can be used as the information processing apparatus20in the embodiment. In the embodiment, a description is given of a hardware configuration of a personal computer500. The personal computer500inFIG.4is constructed by a general-purpose computer. As illustrated inFIG.4, the computer500includes a CPU501, a ROM502, a RAM503, a HD504, a HDD controller505, a display506, an external device connection I/F508, a network I/F509, a data bus510, a keyboard511, a pointing device512, a DVD rewritable (DVD-RW) drive514, a medium I/F516, a General-Purpose computing on Graphics Processing Units (GPGPU)517. The CPU501controls entire operation of the personal computer500. The ROM502stores a control program such as an initial program loader (IPL) to boot the CPU501. The RAM503is used as a work area for the CPU501. The HD504stores various data such as a program. The HDD controller505controls reading or writing of various data from or to the HD504under control of the CPU501. The display506displays various information such as a cursor, a menu, a window, characters, or an image. The external device connection I/F508is an interface that couples the personal computer500to various external devices. Examples of the external devices include, but not limited to, a USB memory and a printer. The network I/OF509is an interface that controls communication of data through the communication network. The data bus510is, for example, an address bus or a data bus that electrically couples the elements such as the CPU501illustrated inFIG.4. The keyboard511is an example of an input device provided with a plurality of keys for allowing a user to input characters, numerals, or various instructions. The pointing device512is an example of an input device that allows a user to select or execute a specific instruction, select a target for processing, or move a cursor being displayed. The DVD-RW drive514controls reading or writing of various data from or to a DVD-RW medium513as one example of a removable recording medium. The removable recording medium is not limited to the DVD-RW and may be a DVD recordable (DVD-R) or the like. The medium I/F516controls reading or writing (storing) of data from or to a recording medium515such as a flash memory. The GPGPU517is an arithmetic device capable of handling image processing or processing having a large load other than the image processing, at high speed. The hardware configurations of the printer30and the information processing apparatus20have been described above referring toFIGS.2to4. However, the hardware configurations of the information processing apparatus20and the printer30are not limited thereto. In the case of a printer or a computer of another type, it is possible to constitute the printer or the computer in a way similar to that illustrated inFIGS.2to4by appropriately adding or deleting a hardware component, or adding and deleting a hardware component. Hereinafter, the light field printing function according to the embodiment will be described in more detail with reference toFIG.5. FIG.5is a diagram illustrating a functional block200of the printing system10for implementing the light field printing function according to the embodiment.FIG.5illustrates a functional block210on the information processing apparatus20and a functional block250on the printer30. As illustrated inFIG.5, in the embodiment described here, the functional block210of the information processing apparatus20includes an input unit220, an image generation unit230, and a print command unit240. The input unit220receives an input image set12including a plurality of input images12-1to12-N corresponding to respective viewpoints. The input image set12desirably includes three or more input images12-1to12-N (N≥3) corresponding to three or more viewpoints. A predetermined viewpoint (1, . . . x, . . . , N) is set for each of the input images12-1to12-N, and viewpoint information14describing a correspondence relationship between each viewpoint and a corresponding one of the input images12-1to12-N may also be provided to the input unit220. The viewpoint information14may be provided separately from data of each of the input images12-1to12-N, or may be embedded in a file name according to a predetermined rule (such as a serial number) and provided together with each of the input images12-1to12-N. In the latter case, the input unit220can interpret the correspondence relationship with the viewpoint from the file name. The input image set12defines an image desirable when observed from each of a plurality of viewpoints, and is prepared by the user so as to obtain a desirable light field print. The input image set12and the viewpoint information14input to the input unit220are passed to the image generation unit230. In order to improve the quality of the reproduced image, in addition to the input image set12and the viewpoint information14, information such as the thickness, transmissivity, and refractive index of the transmissive transfer medium, and characteristics such as the transmissivity and dot gain of the toner of the printer may be provided. The image generation unit230generates a pair of output images to be duplex printed on the transmissive transfer medium by an optimization process based on the input image set12and the viewpoint information14. More particularly, the pair of output images to be duplex printed is the front-side image16F and the back-side image16B. When image layers are formed on both sides of transmissive transfer media, the optimization process is performed to reproduce, at each of respective viewpoints at a time of observation, at least part of a corresponding one of input images, in at least one transmissive transfer medium having image layers on the front side and the back side thereof. Normally, a plurality of input images, desirably three or more input images, are compressed into two images on the front side and the back side, and the amount of information decreases. Therefore, in the optimization process, the input images are approximately reproduced. In the embodiment described here, input images are reproduced by one transmissive transfer medium having image layers formed on both sides thereof. However, the disclosure is not limited thereto. An embodiment is also included in which a plurality of input images are reproduced by bonding a plurality of transfer media including at least one transmissive transfer medium having image layers formed on both sides thereof. For example, four images, that is, a front-side image and a back-side image for a first transfer medium and a front-side image and a back-side image for a second transfer medium may be generated from a plurality of input images by the optimization process, the four images may be duplex printed on the two transfer media, and the two transfer media may be bonded to each other. Accordingly, the image quality is expected to be improved as compared with the case where the image is reproduced on one transmissive transfer medium. When a plurality of transfer media are bonded together, it is not required that all the transfer media be duplex printed transmissive transfer media. That is, at least one transmissive transfer medium may be one transmissive transfer medium subjected to duplex printing, or may be a laminate of a plurality of transfer media including at least one transmissive transfer medium subjected to duplex printing. The expression “to reproduce, at each of respective viewpoints at a time of observation, at least part of a corresponding one of input images, in at least one transmissive transfer medium” may include approximate reproduction of input images by one duplex-printed transmissive transfer medium, approximate reproduction of input images by a plurality of duplex-printed transmissive transfer media, and approximate reproduction of input images by a plurality of transfer media including at least one duplex-printed transmissive transfer medium and a simplex-printed transfer medium. In the embodiment described here, more particularly, the image generation unit230includes an optimization unit232and an inversion unit234. The optimization unit232executes an optimization process based on the input image set12and the viewpoint information14. The optimization process optimizes a pair of output images based on the input image set12to minimize a difference between each of reproduced images reproduced at respective viewpoints using a plurality of image layers, in which a pair of temporary output images during trial are arranged apart from each other, and a corresponding one of the input images for the viewpoint. In this stage, the optimization calculation does not include that the plurality of image layers arranged apart from each other are duplex printed on both sides of the transfer medium, and an error between the image reproduced using the plurality of image layers arranged apart from each other (an image reproduced at each viewpoint is referred to as a reproduction image) and the input image is minimized. The error between the reproduced image and the input image is the total sum of differences over a plurality of viewpoints, and this is an objective function. The optimization process can be performed using an existing technique such as gradient descent. The inversion unit234performs image inversion on one of the pair of output images generated by the optimization process in accordance with an opening direction of duplex printing to obtain a final front-side image16F and a final back-side image16B. Typically, the output image corresponding to the back-side image is inverted. By inverting the image, the front-side image16F and the back-side image16B that minimize the total sum of errors between the reproduced image and the input image in the case of duplex printing on the transmissive transfer medium are obtained. The print command unit240outputs print image data and issues a print command (print instruction) to the printer30based on the generated front-side image16F and back-side image16B. The print command is added with the designation of the feed tray that accommodates transmissive transfer media, and the setting of duplex printing of the front-side image16F and the back-side image16B. The print command may be also added with settings such as a document direction, and an opening direction and a binding direction of duplex printing. The functional block250of the printer30includes a printing unit260. The printer30has a duplex printing function of forming images on both sides of a transfer medium. The printer30also includes a feed tray that accommodates transmissive transfer media. The printing unit260feeds a transfer medium from a designated feed tray based on a print command for duplex printing from the information processing apparatus20, and prints a front-side image16F and a back-side image16B on the front side and the back side of the transfer medium, respectively. As described above, when the feed tray that accommodates the transmissive transfer media is designated, image layers18F and18B corresponding to the front-side image16F and the back-side image16B are formed on the front side and the back side of the transmissive transfer medium18S, respectively. In the embodiment described here, an inverted image is obtained by performing an inversion process on one of a pair of output images, and a print command is issued using the inverted image. However, the method of obtaining one inverted image is not limited thereto. For example, when image inversion is performed as a function of the printer driver or the printer30, instead of performing the inversion process on one of the output images to issue a print command, a print setting indicating that image inversion is to be performed may be added and a print command may be issued without performing image inversion on the output image. Also, in the embodiment described here, the optimization calculation by the optimization unit232does not include printing of the plurality of spaced apart image layers on both sides of the transfer medium. However, in another embodiment, the image generation unit230may directly optimize the front-side image16F and the back-side image16B based on a plurality of input images under a condition that a plurality of image layers are duplex printed in a predetermined opening direction to minimize a difference between a reproduction image reproduced at each of viewpoints using a plurality of image layers arranged apart from each other and a corresponding one of the input images for the viewpoint. In this case, the inversion unit234can be omitted. FIG.6illustrates a light field print18having images printed on both sides of a transmissive transfer medium18S such as a transparent sheet by the light field printing function according to the embodiment. In the light field print18, an image layer18F of a front-side image16F is formed on the front side of the transmissive transfer medium18S, and an image layer18B of a back-side image16B is formed on the back side thereof. In addition, since the front and back sides of the transmissive transfer medium18S are flat and spaced apart from each other, the image layer18F on the front side and the image layer18B on the back side are arranged substantially in parallel and apart from each other. Image formation by the printer30is performed by applying and fixing a developer such as toner or ink to both sides of the transmissive transfer medium18S. By performing image formation on both sides, the operation of bonding transparent layers, which has been performed in JP-T-2018-537046, is no longer required and the light field print18can be easily obtained. In addition, deterioration of an image due to entry of air or a material such as an adhesive between the bonded layers can be prevented. The light field print18is based on the principle that the combination of pixels passing through the front-side image16F and the back-side image16B differs depending on the viewpoint because the transmissive transfer medium18S has a certain thickness. By utilizing that the combination of pixels differs depending on the viewpoint, the light intensity can be changed for each viewpoint. Accordingly, it is possible to obtain a print in which images viewed from respective viewpoints are different from each other. An image viewed from such a predetermined observation viewpoint is a reproduced image obtained by light field printing. The reproduced image may be an approximate image of the input image that is determined for each of the angles of the viewpoints with respect to the surface of the transfer medium. The observer can view the approximate images of the corresponding input images one by one by changing the viewing angle of the light field print18. The positional relationship between the pixels in the combination of pixels through which the line of sight passes defines the viewpoint. The transmissive transfer medium is a medium that transmits visible light and has two flat transfer surfaces, and includes a case where the medium is a transparent medium and a case where the medium is a semitransparent medium through which printing of a back-side image can be seen through. This is because the intensity of light passing through the front-side image16F and the back-side image16B varies depending on the viewpoint even when the image is not completely transparent but is semitransparent. Hereinafter, the light field printing process will be described in more detail with reference toFIGS.7and8.FIG.7is a flowchart illustrating the light field printing function that is executed by the information processing apparatus20according to the embodiment. The process illustrated inFIG.7starts in response to a light field print instruction including designation of an input image set12. In step S101, the information processing apparatus20receives a set of input image data corresponding to respective predetermined viewpoints. In step S102, the information processing apparatus20initializes a front-side image16F and a back-side image16B. The optimization process is performed with the initial front-side image and back-side image as starting points. The front-side image and the back-side image during the trial are referred to as a temporary front-side image and a temporary back-side image. In step S103, the information processing apparatus20calculates a reproduction image of each viewpoint from the pair of the temporary front-side image and the temporary back-side image during the trial. In step S104, the information processing apparatus20calculates an error between the input image and the reproduced image at each viewpoint, and calculates the total sum of errors over the viewpoints. In step S105, the information processing apparatus20determines whether a predetermined end condition is satisfied. The end condition may be a convergence determination condition that the total sum of errors falls within a certain range, or may be an end condition of detecting that iteration has been performed a predetermined number of times. When it is determined in step S105that the end condition is not satisfied (NO), the process proceeds to step S106. In step S106, the information processing apparatus20updates the temporary front-side image and the temporary back-side image currently being tried, and causes the process to loop to step S103. In step S106, the temporary front-side image and the temporary back-side image can be desirably updated in a direction in which the error decreases. After the initialization in step S102, step S103to step S106are repeated until the end condition is satisfied. Thus, the optimization process is performed with the initial front-side image and back-side image serving as the starting points, and a pair of images are generated such that the input image corresponding to each viewpoint at which the observer observes is at least partly reproduced, or desirably reproduced best, in the transmissive transfer medium in which respective image layers are formed on both sides thereof. The pair of images serve as the pair of the front-side image16F and the back-side image16B. In contrast, when it is determined in step S105that the end condition is satisfied (YES), the process proceeds to step S107. In step S107, the information processing apparatus20inverts the obtained back-side image16B based on the print setting. The back-side image after the inversion process is referred to as a back-side image16B′. FIG.8is a table presenting the inversion process based on the print settings by the information processing apparatus20according to the embodiment. In the table presented inFIG.8, the row indicates the direction of the document, and the column indicates the binding direction of duplex printing. Note that each of the four cells having a predetermined gradation inFIG.8schematically illustrates the correspondence relationship, and is irrelevant to an actual back-side image or the like. The direction of the document includes vertical and lateral directions. The binding direction of duplex printing includes long-side binding and short-side binding. There is also an opening direction for duplex printing. For example, when the document direction is vertical and long-side binding is performed, the document is opened leftward. When the document direction is vertical and short-side binding is performed, the document is opened upward. When the document direction is lateral and short-side binding is performed, the document is opened leftward. When the document direction is lateral and long-side binding is performed, the document is opened upward. In the case of a vertically written document, the leftward opening is changed to the rightward opening. In step S107, when the print setting indicates leftward opening or rightward opening, the inversion unit234of the information processing apparatus20performs left-right inversion on the back-side image. In contrast, when the print setting is upward opening, in step S107, the inversion unit234of the information processing apparatus20performs up-down inversion on the back-side image. Accordingly, the pair of the front-side image16F and the back-side image16B′ suitable for the case of duplex printing with the predetermined print settings is generated. Referring back toFIG.7, in step S108, the information processing apparatus20transmits print data including the obtained front-side image16F and back-side image16B′ to the printer30, and commands the printer30to duplex print the front-side image16F and the back-side image16B′. As described above, in duplex printing, the feed tray that accommodates the transmissive transfer media is designated, duplex printing is designated, and the settings such as the binding direction, the printing direction, and the opening direction may be added. According to the embodiment described above, it is possible to reduce time and effort for bonding transfer media such as a plurality of transparent layers together. In addition, since image layers are accurately formed on the front and back sides of a transfer medium so as to be arranged apart from each other, it is possible to prevent an air layer or a material such as an adhesive from entering between the bonded media, and it is possible to reduce deterioration of a reproduced image. Further, a transmissive transfer medium having image layers formed on both sides thereof has an image to be observed that changes as the viewpoint changes. Such a transmissive transfer medium can be used for a stereoscopic expression and a wide range of expressions and applications. With the above-described configuration, it is possible to create a print having an image that changes depending on the observation viewpoint without time and effort. Also in the case of using a plurality of transmissive transfer media, the operation of bonding is reduced by duplex printing, and hence deterioration of an image is prevented. Second Embodiment In the above description, position alignment accuracy between a front-side image and a back-side image in duplex printing has not been particularly mentioned. In duplex printing by the printer30, an error in position alignment generally occurs between pixels on both sides. Further, in the printer30, the main-scanning direction (non-conveyance direction) and the sub-scanning direction (conveyance direction) are not mechanically symmetrical. Thus, in duplex printing, the position alignment accuracy in the conveyance direction generally differs from the position alignment accuracy in the non-conveyance direction. Hereinafter, with reference toFIGS.9to11B, a description will be given of a second embodiment capable of preventing deterioration in quality of a print due to the position alignment accuracy of duplex printing. FIG.9is a diagram illustrating functional blocks provided on an information processing apparatus20and a printer30for implementing a light field printing function according to the second embodiment. Since the second embodiment has a configuration similar to that of the embodiment illustrated inFIG.5, the following description will focus on the differences. Elements having functions similar to those in the embodiment illustrated inFIG.5are denoted by the same reference numerals. In the embodiment illustrated inFIG.9, a functional block210A of the information processing apparatus20includes a direction alignment processing unit270in addition to the input unit220, the image generation unit230, and the print command unit240. The input unit220according to the embodiment receives an input image set12and viewpoint information14, and passes the input image set12and viewpoint information14to the direction alignment processing unit270. In the input image set12according to the embodiment, it is assumed that the number of viewpoints in the vertical direction differs from the number of viewpoints in the lateral direction. A larger number of viewpoints are allocated in one of the vertical and lateral directions than that in the other direction. For example, when a plurality of viewpoints are set only in the lateral direction of an input image, the lateral direction is a direction in which viewpoints are allocated more. When a plurality of viewpoints are set only in the vertical direction of an input image, the vertical direction is a direction in which viewpoints are allocated more. Further, when viewpoints of M×N are set in the vertical and lateral directions of an input image, the direction in which a larger number of M and N of viewpoints are allocated is the direction in which viewpoints are allocated more. In the printing unit260according to the embodiment, it is assumed that the position alignment accuracy of duplex printing in the conveyance direction of a medium differs from that in the non-conveyance direction of the medium. Whether the position alignment accuracy in the conveyance direction is higher or the position alignment accuracy in the non-conveyance direction is higher depends on the specific configuration (model or the like) of the printer30. In response to an inquiry from the information processing apparatus20, the printer30returns information indicating the position alignment accuracy in the conveyance direction and the non-conveyance direction. The information indicating the position alignment accuracy may be information directly indicating the position alignment accuracy in each of the conveyance direction and the non-conveyance direction, may be information indicating which one of the conveyance direction and the non-conveyance direction has a higher position alignment accuracy, or may be information associated with the information on the position alignment accuracy in the conveyance direction and the non-conveyance direction by being combined with other known information such as model information. The information indicating the position alignment accuracy is also input to the input unit220. The way of providing the information indicating the position alignment accuracy is not limited to the way in which the printer30inFIG.9provides the information indicating the position alignment accuracy in response to the inquiry of the information processing apparatus20. The information indicating the position alignment accuracy may be acquired when the information processing apparatus20receives a user input. FIGS.10A and10Bare diagrams each illustrating the position alignment accuracy of a light field print18according to the embodiment.FIG.10Aillustrates an ideal case where the positions of images on the front and back sides are aligned, andFIG.10Bschematically illustrates a case where images have a deviation of position alignment observed when the images are actually printed. The printer30conveys a transfer medium and performs printing on both sides of the transfer medium. However, as described above, since the conveyance direction and the non-conveyance direction are not mechanically symmetrical, the accuracy in terms of the positional deviation of pixels between the front side and the back side in the conveyance direction differs from that in the non-conveyance direction. That is, having a high accuracy in each of the directions differs from having a small deviation. FIGS.11A and11Bare diagrams each illustrating an influence on a light field print18due to a positional deviation between the front side and the back side. When a positional deviation is generated, an image observed from each viewpoint in the light field print18may be inclined from the image illustrated inFIG.11Ato the image illustrated inFIG.11B. The larger the deviation, the larger the inclination. Accordingly, there may occur a situation where any viewpoint image is not viewable from the front of the light field print18, or a situation where any viewpoint image becomes not viewable when the viewpoint is slightly inclined from the front of the light field print18. An observer typically views the light field print18from the front when holding the light field print18. Thus, when the deviation is large, any viewpoint image is no longer viewable from the vicinity of the front, and the observer may determine the light field print18as a defective product. Therefore, in the embodiment described here, in order to increase the rate of non-defective products of the light field print18, duplex printing is performed by matching the direction in which viewpoints are allocated more with one of the conveyance direction and the non-conveyance direction in which the position alignment accuracy between the front side and the back side is lower. Increasing the number of viewpoints can widen the viewing angle, and widening the viewing angle can increase the rate at which a viewpoint image within a certain angle from the front is viewed even when a deviation is generated, that is, the rate at which the light field print18is determined as a non-defective product. However, increasing the number of viewpoints deteriorates reproducibility of an image. Thus, in view of reproducibility, the number of viewpoints is desirably small. Thus, in the second embodiment to be described, in order to reduce the degree of deterioration in reproducibility as much as possible while increasing the rate of non-defective products, as described above, the allocation of the numbers of viewpoints is changed depending on the accuracy in terms of the positional deviation between the front side and the back side, and viewpoints are allocated more in the direction in which the position alignment accuracy is lower. The direction alignment processing unit270provides a function of matching the direction of the image with the direction of the position alignment accuracy. More particularly, based on the information indicating the position alignment accuracy and the viewpoint information14, the direction alignment processing unit270performs a process such that the direction in which viewpoints are allocated more matches one of the conveyance direction and the non-conveyance direction in which the position alignment accuracy is lower. The process may be a process of rotating an image in accordance with a conditional branch. For example, when the lateral direction is the direction in which viewpoints are allocated more, the lateral direction corresponds to the conveyance direction, and the position alignment accuracy in the conveyance direction is lower than the position alignment accuracy in the non-conveyance direction, the direction alignment processing unit270passes the input image set12to the image generation unit230without performing any particular process. In contrast, for example, when the vertical direction is the direction in which viewpoints are allocated more, the lateral direction corresponds to the conveyance direction, and the position alignment accuracy in the conveyance direction is lower than the position alignment accuracy in the non-conveyance direction, the direction alignment processing unit270rotates images of the input image set12clockwise (or counterclockwise) by 90 degrees, and passes the input image set12whose images have been rotated to the image generation unit230. In the embodiment described here, the direction alignment process is performed on the input image set12before image generation. The timing of the direction alignment process is not limited thereto. In another embodiment, the direction alignment process may be performed on the front-side image16F and the back-side image16B after image generation. Further, when images can be rotated as a function of the printer driver or the printer30, instead of issuing a print command after performing an image rotation process on images, a print setting indicating that the front-side image16F and the back-side image16B are rotated by 90 degrees and printed can be added to the print command. In addition, the conveyance direction and the non-conveyance direction with respect to the image can be also changed by designating the direction of the document. The larger the number of viewpoints, the wider the viewing angle and range in which the image is viewable. By performing the above-described direction alignment process, the direction in which the position alignment accuracy is lower can be matched with the direction in which the viewing angle and the range are wider. Thus, even when a positional deviation in pixels is generated between the front side and the back side, it is possible to properly observe the image in a range in which the angle is slightly changed from the front. Accordingly, deterioration in quality of a print can be prevented, and the yield is also improved. Modifications of Second Embodiment In the above-described second embodiment, the direction in which viewpoints are allocated more is matched with one of the non-conveyance direction and the conveyance direction in which the position alignment accuracy is lower, thereby reducing the rate of defective products due to the positional deviation. Alternatively, decreasing the resolution of an image can also widen the viewing angle without changing the number of viewpoints. Thus, by generating each of the front-side image and the back-side image to have different resolutions in the vertical and lateral directions and by printing the images while the direction in which the resolution is lower is matched with the direction in which the position alignment accuracy of the front and back sides is lower, the rate of determination as a non-defective product can be increased. Hereinafter, with reference toFIGS.12A and12B, a description will be given of a modification of the second embodiment capable of preventing deterioration in quality of a print due to the position alignment accuracy of duplex printing. Since the modification has a configuration similar to that of the second embodiment, the modification will be described below with reference to the functional blocks of the second embodiment. Also in an embodiment of the modification, the direction alignment processing unit270provides a function of performing a process corresponding to position alignment accuracy. FIGS.12A and12Bare diagrams illustrating input images according to another embodiment.FIG.12Aillustrates an input image whose resolution in one direction is decreased. The input unit220according to the embodiment of the modification described here receives an input image set12and viewpoint information14, and passes the input image set12and viewpoint information14to the direction alignment processing unit270. In the input image set12, it is assumed that the input images each have different resolutions in the vertical and lateral directions as illustrated inFIG.12A, and a set corresponding to the input images with the different resolutions is prepared. In the printing unit260according to the embodiment, it is also assumed that the position alignment accuracy of duplex printing in the conveyance direction of a medium differs from that in the non-conveyance direction of the medium. The input unit220also receives information indicating the position alignment accuracy. The resolution in the lateral direction (with reference to an orientation in which an English character R in the image stands upright) is low, and henceFIG.12Aillustrates a rectangular image having pixels each being laterally elongated. However,FIG.12Aillustrates an image indicating pixels each having a square shape corresponding to the resolution in the vertical direction. The direction alignment processing unit270according to the embodiment performs a process based on the information on the resolution of the input image and the information indicating the position alignment accuracy such that the direction in which the resolution is lower matches one of the conveyance direction and the non-conveyance direction in which the position alignment accuracy is lower. The process may be a process of rotating an image in accordance with a conditional branch like the second embodiment. For example, when the lateral direction is the direction in which the resolution is lower, the lateral direction corresponds to the conveyance direction, and the position alignment accuracy in the conveyance direction is lower than the position alignment accuracy in the non-conveyance direction, the direction alignment processing unit270passes the input image set12to the image generation unit230without performing any particular process. In contrast, for example, when the vertical direction is the direction in which the resolution is lower, the lateral direction corresponds to the conveyance direction, and the position alignment accuracy in the conveyance direction is lower than the position alignment accuracy in the non-conveyance direction, the direction alignment processing unit270rotates images of the input image set12clockwise (or counterclockwise) by 90 degrees, and passes the input image set12whose images have been rotated to the image generation unit230. By performing the optimization calculation based on the input images having different resolutions in the vertical and lateral directions, a front-side image16F and a back-side image16B having different resolutions in the vertical and lateral directions are generated, and printing can be performed based thereon. In the embodiment described here, the direction alignment process is performed on the input image set12before image generation. The timing of the direction alignment process is not limited thereto. In another embodiment, the direction alignment process may be performed on the front-side image16F and the back-side image16B after image generation. Further, when images can be rotated as a function of the printer driver or the printer30, instead of issuing a print command after performing the image rotation process on an image, a print setting indicating that the front-side image16F and the back-side image16B are rotated by 90 degrees and printed can be added to the print command. In addition, the conveyance direction and the non-conveyance direction with respect to the image can be also changed by designating the direction of the document. In addition, since the printing unit260of the printer30normally performs printing with the same resolution in the vertical and lateral directions, the printing unit260performs printing after performing a resolution conversion process of returning the aspect ratio to the original aspect ratio as illustrated inFIG.12Bon the front-side image16F and the back-side image16B. Note that the predetermined images inFIGS.12A and12Bare schematically illustrated, and are irrelevant to an actual input image, a front-side image, a back-side image, or the like. The lower the resolution, the wider the viewing angle and range in which the image is viewable. By performing the above-described direction alignment process, the direction in which the position alignment accuracy is lower can be matched with the direction in which the viewing angle and the range are wider. Thus, even when a positional deviation in pixels is generated between the front side and the back side, it is possible to properly observe the image in a range in which the angle is slightly changed from the front. Accordingly, deterioration in quality of a print can be prevented, and the yield is also improved. In the above description, it is assumed that the process of matching the direction in which the resolution is lower with one of the conveyance direction and the non-conveyance direction in which the position alignment accuracy is lower according to the embodiment of the modification is independently performed. However, in another embodiment, in addition to the process of matching the direction in which the resolution is lower, a process of matching to the direction in which viewpoints are allocated more according to the second embodiment may be performed. In this case, it is possible to determine which direction is to be aligned with the direction in which the position alignment accuracy is lower, by the number of substantial vertical and lateral viewpoints regarding the ratio of the vertical and lateral resolutions of the input image. For example, the resolution of each input image is (600 dpi in the lateral direction)×(200 dpi in the vertical direction). When an input image set12having 17 viewpoints in the lateral direction and 5 viewpoints in the vertical direction is used, the following is established. That is, since the viewpoints in the vertical direction are equivalent to 5 viewpoints×(600/200)=15 viewpoints with respect to 17 viewpoints in the lateral direction, the lateral direction can be matched to a direction in which the positioning accuracy is lower. That is, the direction alignment processing unit270can match a direction in which the number of substantial viewpoints obtained based on the ratio of the resolutions in the vertical direction and the lateral direction and the numbers of viewpoints in the vertical direction and the lateral direction is larger, with one of the conveyance direction and the non-conveyance direction in which the position alignment accuracy is lower. Third Embodiment In the light field printing, since input images of a plurality of viewpoints, typically, input images of three or more viewpoints are reproduced by two images, information on input images corresponding to the number of viewpoints is compressed into two images. Thus, reproducibility may be defective for a certain type of input image. That is, there is a possibility that the light field printing is appropriate or not depending on the characteristics of the input image, a change in image is not sufficiently reproduced at the time of printing, or image deterioration such as an afterimage is apparent. A third embodiment capable of determining whether an input image is appropriate or not will be described below with reference toFIGS.13to14E. FIG.13is a diagram illustrating functional blocks provided on an information processing apparatus20and a printer30for implementing a light field printing function according to the third embodiment. Since the third embodiment has a configuration similar to that of the embodiment illustrated inFIG.5, the following description will focus on the differences. Elements having functions similar to those in the embodiment illustrated inFIG.5are denoted by the same reference numerals. In the embodiment illustrated inFIG.13, a functional block210B of an information processing apparatus20includes an image processing unit280in addition to the input unit220, the image generation unit230, and the print command unit240. In the embodiment described here, it is assumed that the direction alignment processing unit270provided in the second embodiment or the modification thereof is not provided. However, the position alignment processing unit270may be provided. More particularly, the image processing unit280includes a detection unit282and a determination unit284. FIGS.14A to14Eare a diagram and graphs presenting a change in image transmissivity over a plurality of viewpoints of a print obtained by the light field printing function.FIG.14Aillustrates input images for 13 viewpoints. The example illustrated inFIG.14Arepresents input images in which the density (image transmissivity when printed on a transparent sheet) is uniform and the density appears to change when the viewpoint is changed. InFIG.14A, 13 viewpoints are set in one direction.FIG.14Aillustrates an input image set12which becomes gradually lighter and brighter as the viewpoint is changed from a state viewed from the front (viewpoint7) to a state viewed obliquely (viewpoint1or viewpoint13). For convenience of explanation, the images are illustrated as gray scale images, but in the case of color images, the density changes depending on each color version. FIGS.14B and14Dpresent four input image sets12exhibiting changes similar to those inFIG.14A, and plots the density (image transmissivity) of each input image set12with respect to the viewpoint. InFIGS.14B to14E, the vertical axis represents the image transmissivity of the input image. In this case, the image transmissivity of 1.0 represents white, and the image transmissivity of 0.0 represents black. The horizontal axis corresponds to each viewpoint of the 13 viewpoints. An “image1” is an input image set in which the transmissivities at the viewpoints1and13at both ends are 0.37 and the transmissivity at the viewpoint7in the front is 0.12. The amount of change in transmissivity is 0.25. An “image2” is an image in which the amount of change in transmissivity is 0.25 similarly to the image1, but is lighter than the “image1” as a whole. An “image3” and an “image4” both have a change in transmissivity of 0.50; however, the “image3” is a darker image as a whole. That is, among the four sets, two sets indicated by the “image1” and the “image2” have the same difference in density between the viewpoint7in the front and the viewpoint1(viewpoint13); however, the “image2” is offset in a direction in which the image is brighter. Two sets indicated by the “image3” and the “image4” also have the same difference in density between the viewpoint7in the front and the viewpoint1(viewpoint13); however, the “image4” is offset in a direction in which the image is brighter. The “image1” and the “image2” are different from the “image3” and the “image4” for the difference in density between the viewpoint7in the front and the viewpoint1(viewpoint13). The sets of the “image3” and the “image4” have larger changes in density. FIGS.14C and14Epresent simulated densities (transmissivities) of reproduced images at respective viewpoints obtained from the front-side image and the back-side image when the four input image sets ofFIGS.14B and14Dare used. As illustrated inFIG.14C, the reproduced image of the “image1” can reproduce the change in image of the input image (the “image1” inFIG.14B), that is, about 75% of the value (the maximum value−the minimum value) of the transmissivities. In contrast, in the reproduced image of the “image2”, about 25% of the change in image of the input image (the “image2” inFIG.14B) is reproduced. The reproduced image of the “image3” can reproduce the change in image of the input image (the “image3” inFIG.14D), that is, about 65% of the value (the maximum value−the minimum value) of the transmissivities. In contrast, in the reproduced image of the “image4”, about 30% of the change in image of the input image (the “image4” inFIG.14D) is reproduced. Regarding the above, in the light field printing, even when the change in density of the input image is small, the reproducibility is not necessarily improved. The “image2” has a half of the change in image due to the viewpoint as compared with the “image3”, and the change is small; however the reproducibility of the “image2” is not good. In contrast, the reproducibility of the “image1” is good in spite of that the “image1” has twice as much change in image as the “image4” due to the viewpoint and the change is large. Then, when the front-side image and the back-side image generated by the “image1” and the “image3” are actually printed by a printer and checked, the image quality is sufficient. Thus, in order to obtain a high-quality image by the light field printing, it is desirable to use an input image in which the transmissivity of the image at the brightest viewpoint is about 0.6 or less. The value 0.6 does not mean that the reproducibility rapidly deteriorates if exceeds this value even slightly, and therefore the value is not a strict threshold value and includes a case where the value exceeds the threshold value to such an extent that there is no difference when viewed by human eyes. Since an input image can be faithfully reproduced regardless of the image density in an image region in which the image does not change even when the viewpoint changes, there is no problem although an image brighter than the above-described transmissivity of 0.6 is included. The situation “the image does not change depending on the viewpoint” includes a case where a change is so small that the change is not recognized by human eyes. Based on the above, the detection unit282in the image processing unit280according to the third embodiment detects, in the input image set12, an image region in which a change in image is generated by an amount greater than or equal to a determined amount in accordance with a change in viewpoint. An image region in which a change in image generated by an amount equal to or greater than a determined amount can be detected by examining the distribution of gradation levels over all viewpoints for each pixel of an input image. For example, the detection unit282can detect such an image region by comparing the difference between the brightest gradation level and the darkest gradation level across all viewpoints with a predetermined threshold value for each pixel. As long as the difference between the brightest gradation level and the darkest gradation level is small, it represents that the change in image is small although the viewpoint changes. Alternatively, the detection unit282can detect such an image region by calculating the total sum of differences in gradation level between adjacent viewpoints for each pixel. The determination unit284determines whether a gradation level over a plurality of viewpoints in an image region in which a change in image is generated by an amount equal to or greater than a determined amount falls within a predetermined darkness range. The determination of whether to fall within the predetermined darkness range may be based on that the image transmissivity for the gradation level that is significantly the brightest among the gradation levels at all the viewpoints in the image region in which a change in image is generated by an amount equal to or greater than the determined amount is 0.6 or less. For example, the determination unit284counts the number of appearances of the gradation level of each image region in which a change in image is generated by an amount equal to or greater than the determined amount, and creates a histogram. Then, the determination unit284detects the brightest gradation level among the gradation levels having a certain frequency or higher, and compares the detected gradation level with the threshold value of the image transmissivity of 0.6. Accordingly, the determination unit284can determine whether or not the gradation level falls within the predetermined darkness range. Note that a countermeasure when the determination unit284determines that the gradation level does not fall within the predetermined darkness range is not particularly limited. In a certain embodiment, printing may be stopped and the user may be notified of an error or warning. Alternatively, while printing is continued, the user may be notified of an error or warning. In a desirable embodiment, when it is determined that the gradation level does not fall within the predetermined darkness range, image processing can be performed on the input image so that the gradation level falls within the predetermined darkness range. FIG.13illustrates a desirable embodiment, and the image processing unit280further includes a gradation correction unit286. When the gradation level does not fall within the predetermined darkness range, the gradation correction unit286performs gradation correction on the input image set12in a stage before the front-side image and the back-side image are generated. For the gradation process, for example, a gradation process such as of a tone curve can be performed so that the brightest gradation level among those having a certain frequency or higher in the above-described histogram falls within the threshold value of the image transmissivity of 0.6. According to the above-described configuration, by limiting or correcting the characteristics of the input image to a range in which the characteristics can be properly reproduced by the light field printing, a change in image due to the viewpoint can be reliably reproduced, while preventing deterioration in image quality such as an afterimage. As described above, according to the embodiments described above, an information processing apparatus, an image processing method, an image processing program, and a printing system are provided, each capable of creating a print whose image changes depending on an observation viewpoint, with increased efficiency. The apparatus according to the above-described embodiments is merely illustrative of one of a plurality of computing environments for implementing the embodiments disclosed in the description. In one embodiment, an information processing apparatus includes a plurality of computing devices, such as a server cluster. The plurality of computing devices are configured to communicate with each other via any type of communication link, including a network, a shared memory, or the like and perform the processes disclosed in the description. Respective elements of the information processing apparatus may be integrated into one computing device or may be divided into a plurality of devices. Each of the functions of the described embodiments may be implemented by one or more processing circuits or circuitry. Processing circuitry includes a programmed processor, as a processor includes circuitry. A processing circuit also includes devices such as an Application Specific Integrated Circuit (ASIC), a digital signal processor (DSP), a field programmable gate array (FPGA), and conventional circuit components arranged to perform the recited functions. The above-described embodiments are illustrative and do not limit the present invention. Thus, numerous additional modifications and variations are possible in light of the above teachings. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted for each other within the scope of the present invention. Any one of the above-described operations may be performed in various other ways, for example, in an order different from the one described above. | 68,547 |
11858285 | DETAILED DESCRIPTION Provided are processes of using a disperse dye composition containing stamp pad to deposit a heat transfer dye ink onto an intermediate substrate. The processes and stamp pads provided herein overcome prior issues by providing a functional and environmentally friendly system for allowing custom decorating of objects or surfaces. The processes utilize a stamp pad whereby a stamp, illustratively a rubber or other material stamp as is recognized in the art, is used to transfer a disperse dye composition to an intermediate substrate for subsequent transfer to a dye receptive object by application of sufficient heat and/or pressure. In general, the structure and materials forming stamp pads are known in the art and are stamps where by an ink composition is delivered from the stamp pad to a substrate or surface. The processes as provided utilize a stamp to deliver ink from a stamp pad to an intermediate substrate whereby the disperse dye ink is in the form of an image. Optionally, an intermediate substrate is plain paper, although the processes are suitable for many other substrates that could include, but not be limited to: coated papers, plastic films, or metal sheets. The image may be optionally dried on the intermediate substrate. The disperse dye composition is transferred from a stamp pad to a stamp by contacting the stamp face with the stamp pad to thereby ink the stamp. The stamp is then contacted to an intermediate ink receptive surface. The imaged intermediate substrate is contacted on or directly on a surface or object to be decorated and heat applied such as via an iron, hot plate, heat transfer press or similar device or process such that the heat transfer dye is transferred from the intermediate substrate to the surface or object. The surface or object to be decorated optionally has a surface or composition that is receptive to sublimation dyes present in the ink. For example, the surface or object is optionally a textile that is receptive to these dyes or object that is coated with a polymer that is receptive to the dyes. Examples of polymers that may be receptive to heat transfer dyes of the disclosure include but are not limited to certain polyester, epoxy and polyamide polymers. In some aspects, the dye transfer requires a specific combination of heat, pressure and time to achieve the desired level of optical density. In some aspects, the dye transfer is performed at a transfer temperature of 250° F. to 400° F. Optionally the transfer temperature is at least 250° F., optionally at least 275° F., optionally at least 300° F., optionally at least 325° F., optionally at least 350° F., optionally at least 375° F., optionally at least 400° F. Optionally, a transfer temperature does not exceed 400° F. In practice use of higher temperature requires less time to transfer a sufficient amount of dye. The exact amount of pressure will vary depending on the substrate to be decorated. Substrates with smooth surfaces will utilize lower pressure than a substrate with texture surface. Also provided are processes of using a stamp to transfer a disperse dye composition from a stamp pad to deposit the disperse dye composition as provided herein directly onto an object that has a dye-receptive surface such as a polymer coated ceramic tile or other object. Optionally, a nonporous, non-ink receptive, heat resistant material is placed directly on the disperse dye composition image and the dye transferred as in is described above. Rubber stamp pads as are commonly used by the craft industry for diverse decorating applications are useful herein. A typical construction may include a pad to hold the specific ink and an image-based rubber applicator. The applicator is inked and the image transferred to a surface such as paper, plastic, wood, etc. Requirements for the ink fluid would include suitable fluidity, ability to adhere to the rubber surface but be easily released from the surface, and resistance to premature drying. Stamp pad inks fluids are usually based on water with limited use of water miscible solvents such as alcohols and glycerin. The colorant is usually a dye that is soluble in the fluid system. Additional components could include surfactants to adjust viscosity and biocides to prevent mold. Pigment-based stamp pad inks are provided where improved light stability is desired and for those inks a pigment dispersant is probably required. Disperse or sublimation dye inks would have the characteristics of pigment inks where the disperse dye is insoluble in the fluid matrix. The processes as used herein employ a novel disperse dye composition that is suitable for use in a stamp pad application. As such, also provided in this disclosure are sublimable dye-based ink compositions (disperse dye composition) that are have the appropriate physical properties for use in stamp-pad applications, but are also environmentally safe and non-toxic to users. The inventors determined that many of the sublimation toner patents mentioned above and otherwise known in the art include disperse dyes that result in toners that provide a positive Ames test. To solve this problem the inventors have researched both the type and concentration of disperse dye and the effect on Ames Test, as well as place these materials in a dye composition that has the appropriate physical properties to be useful in a stamp pad application. The Ames test was developed by Professor Bruce Ames in the 1970s as a convenient method of determining if a chemical poses a potential mutagenic hazard. The test uses different strains of bacteria to predict probabilities of a compound to cause DNA mutations. Although a positive Ames test in itself does not mean that an ink is necessarily harmful to humans, it can create a negative perception by users of such a product. A good reference to Ames test and imaging materials can be found in Peter Gregory's publication Chemistry and Technology of Printing and Imaging Systems. Some disperse dyes mentioned in earlier patents are not Ames negative. Relative to prior disperse dye compositions that may be considered child and environmentally safe, the disperse dye compositions provided herein are specifically suited for use with stamp pads. Specifically, the present disperse dye compositions not only include the Ames negative safety parameters, but also possess tailored ink viscosities, flow, etc. so as to prevent ink drying in or on the stamp pad. The inventors of this disclosure accomplished this feat through the use of appropriate concentrations of water-miscible cosolvents such as, for example, glycerin or propylene glycol as well as optional suitable surfactants. Wetting agents may also be included for adhesion of the ink to the rubber stamp portion. The specific dye concentration may be less than for typical ink jet inks as the higher stamp pad ink viscosity results in higher ink lay down on a substrate. A child and environmentally friendly sublimable disperse dye heat transfer ink composition as provided herein includes one or more disperse dyes. The number and identity of the disperse dyes yields the resulting color of the dye composition. For example, there is no pure black disperse dye. Instead mixtures of different dyes must be used to achieve the desired hue and density of the dyed image. This mixture might include cyan, magenta and yellow dyes. Or it might include a blue plus orange, brown or some combination of those. A similar situation exists for selecting magenta, yellow or cyan dye mixtures that will provide the desired full color transferred image. It has also been discovered by the inventors that one dye by itself might be Ames positive but when used at low concentration within a toner will produce an Ames negative toner. As such, provided are disperse dye compositions suitable for use in a stamp pad that include one or more disperse dyes where the disperse dye composition exhibits a negative Ames test with strains TA98 and TA100. The inventors found that specific combinations of disperse dyes at desirable concentrations or single dyes that are themselves Ames negative and/or when used at specific concentrations when in a final disperse dye composition can yield excellent color transfer results as well as create a toner that is Ames test negative in both TA98 and TA100. Optionally, a disperse dye composition includes one disperse dye. Optionally, a disperse dye composition includes two or more disperse dyes. Optionally, a disperse dye composition includes 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more disperse dyes. Illustrative examples of disperse dyes that may be used in some aspects of a disperse dye composition as provided herein include but are not limited to Disperse Yellow 3 (CAS 2832-40-8), Disperse Yellow 23 (CAS 6250-23-3), C.I. Disperse Yellow 27 (CAS 73299-30-6), Yellow 54 (CAS 12223-85-7), Yellow 82 (CAS 27425-55-4), Yellow 119 (CAS 57308-41-5), Disperse Orange 1 (CAS 2581-69-3), Disperse Orange 3 (CAS 730-40-5), Orange 25 (CAS 31482-56-1), Red 1 (CAS 2872-52-8), Red 4 (CAS 2379-90-0), Disperse Red 9 (CAS 82-38-2), Red 11 (CAS 2872-48-2), Disperse Red 13 (CAS 3180-81-2), Red 60 (CAS 17418-58-5), Red 364 (CAS 522-75-8), Disperse Violet 1 (CAS 128-95-0), Violet 17 (CAS 12217-92-4), Disperse Blue 3 (CAS 2475-46-9), Blue 14 (CAS 2475-44-7), Blue 19 (CAS 4395-65-7), Blue 60 (CAS 12217-80-0/56548-64-2), Blue 72 (CAS 12217-81-1), Blue 359 (CAS 62570-50-7), Blue 360 (CAS 885474-63-5), and Brown 26 (optionally as available from AAKASH CHEMICALS), or any combination thereof. In some aspects, particular combinations of disperse dyes are used in a disperse dye composition. Optionally, a composition includes Yellow 54, Orange 25, Blue 60, Blue 72, Red 60, and Violet 17. Optionally, a disperse dye composition includes Red 60 and Violet 17. Optionally, the Red 60 is present at 2 to 6 wt %. Optionally, the violet 17 is preset at 0 to 3 wt %. Optionally, the toner composition includes from 2 to 6 wt % Red 60 and from 0 to 3 wt % Violet 17. In some aspects a disperse dye composition is a yellow composition that includes one or more disperse dyes so as to impart a yellow color to the composition. Optionally, a yellow disperse dye composition includes as a disperse dye Yellow 54. Yellow 54 is optionally present at 1 to 5 wt %. In other aspects, a disperse dye composition is a cyan disperse dye composition. Optionally a cyan disperse dye composition includes one or more disperse dyes the combination of which imparts a cyan color to the disperse dye composition. Optionally, a cyan disperse dye composition includes as disperse dyes Blue 60, Blue 72, or combinations thereof. Optionally, a cyan toner includes 0 to 3 wt % Blue 60 and from 0 to 3 wt % Blue 72. In some aspects, a disperse dye composition includes one or more disperse dyes so as to impart a black color to the disperse dye composition. A black disperse dye composition optionally includes one or more of Violet 17, Yellow 54, Orange 25, and Blue 72. Optionally, the disperse dye composition includes 0 to 0.2 wt % Violet 17, from 1 to 2 wt % Yellow 54, from 1 to 2 wt % Orange 25, and from 5 to 8 wt % Blue 72. In some aspects a disperse dye composition includes a single disperse dye. Optionally, a single disperse dye is Blue 60. Blue 60 is optionally present at 1 to 5 wt %, optionally 3 wt %. The disperse dye compositions as provided herein are not limited to specific disperse dyes and could include or exclude ones that are typically used to decorate textile fibers of coated novelty items. Optionally, the disperse dyes are free of impurities and toxic components and are environmentally friendly. Optionally, one or more of the disperse dyes used in a composition as provided herein that pass an AMES test for potential mutagenicity. The while individual disperse dyes when used at different concentrations may not be considered child or environmentally safe, the overall disperse dye compositions as provided herein include one or more disperse dyes at a concentration and/or combination with other compounds that result in an overall disperse dye composition that is child and environmentally safe as measured by conforming to ASTM-D4236 and/or European Toy Safety Directive EN 71. In some aspects, an overall disperse dye composition exhibits a negative Ames test with strains TA98 and TA100. Optionally, a disperse dye may be modified by chemical treatment such that the treated pigment is self-dispersing in water. The disperse dye may optionally be treated with a silane or titanate compound to aid dispersion stability. Techniques for chemical treatment or encapsulating of dyes for improved dispersion are well known in the art. Optionally, a disperse dye composition includes one or more additional non-sublimable dye or color pigments. One disadvantage of disperse dyes is that they have a particular hue when printed on a paper substrate. However, when transferred to the final object the hue and brightness can be significantly different. A solution to this issue is to include in the disperse dye composition a dye or color pigment that has a hue more representative of the heat transferred image but is not sublimable. Suitable non-sublimable colorants could include FDA approved food dyes or color pigments typically used in commercial inks, with the understanding that inks produced with these additional colorants must still meet the requirements under ASTM D4236 and/or EN 71. These colorants could be included during the initial disperse dye dispersion process or they could be added either as an aqueous solution or pigment dispersion during the final ink mixing process. A disperse dye composition for use herein requires more than the selection and/or concentration of disperse dye or combinations thereof, but such disperse dye compositions must also have the appropriate physical characteristics to enable their use with stamp pads. In some aspects, a disperse dye composition has an appropriate viscosity. A disperse dye composition as provided and used herein optionally has a desired viscosity as measured by a standard viscosity analyzer as used in the art. A disperse dye composition optionally has a viscosity of at or greater than 10 centipoise (cps) at 25° C. Optionally, a disperse dye composition has a viscosity at or above 15 cps, optionally at or above 20 cps, optionally at or above 30 cps. Optionally, a disperse dye composition has a viscosity that is optionally at or above 11 cps, 12 cps, 13 cps, 14 cps, 15 cps, 16 cps, 17 cps, 18 cps, or 19 cps. Preparation of the disperse dye compositions as provided herein is similar to that typically used in the art. The disperse dye is typically milled with a type and quantity of water and dispersant required to produce a particle size dispersion that once combined with additional ink components will provide a dye dispersion that will remain in a stable dispersed form for an extensive time period even under varying environmental conditions. The disperse dyes in the disperse dye composition is provided as a particulate material with a particle size. Particle size is that measured by a standard particle size analyzer as an equivalent sphere particle size (D50). A particle size of a dye particle is optionally from 5 nanometers (nm) to 400 nm, or any value or range therebetween. Optionally, a particle size is 5 nm to 150 nm, 5 nm to 350 nm, optionally 5 nm to 200 nm, optionally 10 to 350 nm, optionally 20 to 350 nm. Optionally, a particle size is less than 350 nm, optionally less than 300 nm, less than 250 nm, less than 200 nm, less than 150 nm, or less than 100 nm. The particular technique used to mill the dye particles can be one common to the pigment milling industry and could include (for example) ball mills, attritors, or continuous media mills. In forming an ink as provided herein, the disperse or solvent dye (pigment, or heat transfer dye as used herein) may be first milled with water and optionally a dispersant to produce a pigment concentrate of 10% to 30% by weight pigment and with the desired pigment average particle size optionally of 5 to 400 nm. The disperse dye composition optionally includes water. Water is optionally purified or otherwise treated by techniques known in the art so as to be free or substantially free of undesirable impurities. The final concentration of water in the disperse dye composition is optionally less than 50% by weight water, optionally 20% to 50% by weight water. A disperse dye composition as provided herein optionally includes one or more biocides. A biocide is optionally present at 0% to 1% by weight or any value or range therebetween. Optionally, a biocide is present at less than 1 wt %. Optionally, a biocide is present at from 0.01 to 1% by weight, optionally 0.01% to 0.5% by weight, optionally 0.01% to 0.2% by weight. Illustrative examples of a biocide that may be included in a disperse dye composition include but are not limited to quaternary ammonium salts derived from hexamethylenetetramine such as 1-(3-chloroallyl)-3,5,7-triaza-1-azoniaadamantane chloride (Dowicil 75), or other such molecules. Optionally, a disperse dye composition includes a dispersant suitable for dispersing a disperse dye (e.g. pigment dispersant). If a dispersant is used, the quantity and specific type will depend on the chemistry of the particular disperse dye and could range (typically) by weight from 0.1 to 50% of the weight of pigment or the overall disperse dye composition. A dispersant is optionally present from 0.5 wt % to 50 wt %, optionally 0.1 to 10 wt %, optionally 0.1 to 5 wt %. The specific dispersant is limited to one that provides the desired pigment dispersion stability and also meets the environmental and safety criteria as described above. Optionally, a dispersant includes but is not limited to polymeric acrylic acids, oxazolines, ethoxylated compounds, silanes, titanates, and block and graft polymers. Optionally, the type of dispersant is one not based on a polymer and could include organic compounds with polar functional groups such as carboxylic acid, ammonium, polyoxyethylene, or sulfonate. Oxalic and citric acid are two specific examples. Additional ink components, if desired, could be included during the process of preparing the dye dispersion or alternatively added during dilution of the dispersion. In some aspects, an ink composition includes one more cosolvents or humectant(s) that are water-miscible solvent or mixture of solvents. The cosolvent(s) or humectant(s) optionally reduces evaporation and prevents premature ink drying on the stamp pad. The total quantity of water-miscible cosolvents or humectants may be in the 0.5 to 75% by weight range, optionally in the 0.5% to 70% by weight, optionally in the 10% to 70% by weight, optionally 10% to 30% by weight. Examples of suitable co-solvents or humectants include alcohols such as ethanol or isopropanol, glycols such as polyethylene or polypropylene, polyethylene glycol, propylene glycol, glycerin, diols such as propanediol or pentanediol, dimethyl sulfoxide, or bio-derived solvents based on lactic acid. Optionally, a cosolvent may also act as a viscosity modifier. Any suitable composition imparting the desired safety characteristics to the ink composition and will result in the desired viscosity as described herein may be used as a cosolvent. Optionally, a cosolvent is a polyethylene glycol of molecular weight less than 5000 Da that will contribute to a low viscosity ink. Optionally, PEG is less than 4000 Da, optionally less than 3500 Da, optionally less than 3000 Da. The ink may also include additional modifying components such as pH adjusters or surfactants. Illustrative examples of surfactants include but are not limited to Dioctyl sulfosuccinate sodium salt (Aerosol OT-100), nonylphenol ethoxylatse (e.g. Tergitol NP-9 and NP-30), triethanolamine, and polyethylene glycol p-(1,1,3,3-tetramethylbutyl)-phenyl ether (Triton X-100). A surfactant may be present at 0 wt % to 5 wt %, optionally 0.01 wt % to 1 wt %, optionally 0.1 wt % to 2 wt %. Optionally, a surfactant is triethanolamine at 0.1 wt % to 2 wt %. A disperse dye composition optionally has a pH of 6.5 to 8. This pH may be achieved by the inclusion of one or more pH adjusters, such as acids or bases depending on the desired pH of the system and other components therein. Optionally, a pH adjuster is or includes a buffering agent. Optionally, a pH adjuster is excluded. A disperse dye composition optionally includes a defoamer. Illustrative examples of defoamers include but are not limited to silicone based anti-foam compounds such as TEGO Antifoam 1-85 and BYK-017, and mineral or vegetable oil based defoamers such as TRAMFLOC 11271GA and AV1525. Optionally, a defoamer is excluded. Defoamers, if present, may be presented at 0.01 wt % to 10 wt %, or greater. In some aspects, a defoamer also serves as a pH adjuster. In such circumstances, a separate pH adjuster that does not serve a defoaming function is optionally absent. Each of these chemical components, if used, optionally meets the same environmental and safety criteria as mentioned for the remainder of the disperse dye composition. Although not required for the successful operation of the disperse dye compositions as provided herein, an additional FDA approved dye or consumer friendly color pigment is optionally included in the disperse dye composition. Additional modifying components could be included during the process of preparing the dye dispersion or alternatively added during dilution of the dispersion. Following preparation of the disperse dye as a dispersion, the above dispersion is then diluted with water, co-solvents and additional ink components such that the final dye concentration will optionally be in the 1% to 20% by weight, optionally 2% to 20% by weight depending on the particular dye and its tinctorial strength. The final concentration of water is optionally 30% to 60% by weight of the total disperse dye composition. A secondary water-miscible solvent or mixture of solvents is used to reduce evaporation and prevent premature disperse dye composition drying. The total quantity of water-miscible cosolvents is optionally in the 40-70% range. Examples of suitable cosolvents include alcohols, glycols, glycerin, and pyrrolidine. The disperse dye composition may also include additional components such as pH adjusters, surfactants, biocides, viscosity modifiers, defoamers and light stabilizers. Optionally, a disperse dye composition includes 2 wt % to 10 wt % disperse dye, 0 wt %-5 wt % dispersant, 0 wt % to 30 wt % propylene glycol, 0 wt % to 25 wt % glycerin, 0 wt % to 14 wt % polyethylene glycol, 0 wt % to 4 wt % poly(2-ethyl-2-oxazoline) (Aquazol), and 0 wt % to 4 wt % other additives, with the composition including 0 wt % to 98 wt % water. In some aspects, a disperse dye composition optionally excludes one or more solvents, oils or resins. Illustrative solvents, oils or resins optionally excluded include but are not limited to: chlorinated solvents, linseed oil; hydrophilic resins; C1-C4alkyl alcohols, e.g. methanol, ethanol, n-propanol, isopropanol, n-butanol, sec-butanol, tert-butanol, and iso-butanol; amides, e.g. dimethylformamide and dimethylacetamide; ketones or keto alcohols, e.g. acetone and diacetone alcohol; ethers, e.g. tetrahydrofuran and dioxane; polyalkylene glycols, e.g. polyethylene glycol and polypropylene glycol; alkylene glycols having 2 to 6 carbon atoms in the alkylene group, e.g. ethylene glycol, propylene glycol, butylene glycol, triethylene glycol, 1,2,6-hexanetriol, thiodiglcol, hexylene glycol, and diethylene glycol; glycerol; lower alkyl ethers of polyhydric alcohols, e.g. ethylene glycol methyl (or ethyl) ether, diethylene glycol methyl (or ethyl) ether, and triethylene glycol monomethyl (or monoethyl) ether; N-methyl-2-pyrrolidone; and 1,3-dimethyl-2-imidazolidinone. The disperse dye composition may be loaded into any stamp pad device as are commonly used, such as self-inking stamp pads as described in WO 2005/084953 and US 2004/250719, as well as traditional stamp pads (e.g. as described in U.S. Pat. No. 3,326,180) made of a foam rubber, felt, or other foam material housed in a container. Illustratively, a stamp pad may include a shallow tray closed by a hinged or non-hinged cover and containing a porous pad that includes the disperse dye composition as provided herein. The stamp pad may be saturated, substantially saturated, or otherwise wetted with the disperse ink composition during or following formation of the stamp pad material. Various aspects of the present disclosure are illustrated by the following non-limiting examples. The examples are for illustrative purposes and are not a limitation on any practice of the present invention. It will be understood that variations and modifications can be made without departing from the spirit and scope of the invention. EXAMPLES Example 1 An example of a composition usable for stamp pad sublimation is made by media milling a mixture of 15 grams (g) Disperse Red 60, 5 g styrene acrylic acid-based dispersant and 80 g water to produce a dye dispersion. The dye dispersion was diluted with 30 g PEG 400, 20 g glycerin, 1 g Triton X-100 surfactant, 0.5 g Dowicil 96 biocide and 0.5 g defoamer. The ink was added to a pad of a standard stamp pad so as to be ready for use. Example 2 A yellow ink dispersion was prepared as in Example 1 above using 10 g Disperse Yellow 54, 80 g water and 2 g naphthalenesulfonic acid polymer sodium salt (Demol N, Kao). This was diluted with 40 g PEG 400, 10 g glycerin, 1 g Aerosol OT-100 and 0.5 g Bioban CS 132 biocide to produce a pad printing ink. The forgoing description of particular embodiment(s) is merely exemplary in nature and is in no way intended to limit the scope of the invention, its application, or uses, which may, of course, vary. The invention is described with relation to the non-limiting definitions and terminology included herein. These definitions and terminology are not designed to function as a limitation on the scope or practice of the invention but are presented for illustrative and descriptive purposes only. While the processes or compositions are described as an order of individual steps or using specific materials, it is appreciated that steps or materials may be interchangeable such that the description of the invention may include multiple parts or steps arranged in many ways as is readily appreciated by one of skill in the art. It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present therebetween. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. It will be understood that, although the terms “first,” “second,” “third” etc. may be used herein to describe various elements, components, regions, layers, and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer, or section. Thus, “a first element,” “component,” “region,” “layer,” or “section” discussed below could be termed a second (or other) element, component, region, layer, or section without departing from the teachings herein. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms, including “at least one,” unless the content clearly indicates otherwise. “Or” means “and/or.” As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof. The term “or a combination thereof” means a combination including at least one of the foregoing elements. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Various modifications of the present disclosure, in addition to those shown and described herein, will be apparent to those skilled in the art of the above description. Such modifications are also intended to fall within the scope of the appended claims. Patents, publications, and applications mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. These patents, publications, and applications are incorporated herein by reference to the same extent as if each individual patent, publication, or application was specifically and individually incorporated herein by reference. The foregoing description is illustrative of particular aspects of the invention, but is not meant to be a limitation upon the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the invention. | 29,952 |
11858286 | DETAILED DESCRIPTION In many commercial inkjet printing applications, the ink formulation space is constrained by the capability of inkjet nozzles to reliably jet the fluid. One important limitation is the amount of binder that can be used in the ink. Ink formulations with low amounts of binder loading tend to have durability challenges which presents challenges to adopting inkjet technology in durability intensive applications such as magazines, direct mail, post cards, etc. The default solution today for improving print durability of inkjet and offset alike, is by using an overprint varnish (OPV) to protect the ink layer against abrasive forces. OPV coatings are often applied inline, at the tail end of the printing process. As a result, they serve as a protective barrier for any post-print processes that have the potential to damage the image layer such as cutting, stacking, folding, gluing, transportation, etc. While overprint varnishes significantly enhance print durability, they come with added cost and logistics of managing the application of an additional fluid, necessitating purchase of coating hardware, energy costs to operate the OPV coater, factory floorspace to house the hardware, and upkeep of the equipment. In addition, OPV coating does nothing to protect the print before the OPV fluid is applied to the web. In this critical stage between deposition of ink on page and coating of OPV fluid, the inked web comes into contact with many surfaces which have the potential to damage the print. To facilitate entry of thermal inkjet printing processes into commercial printing applications without modifying existing processes, the easiest way to gain improvements in print durability is through modification of the printing substrate itself. The problem solved with this invention disclosure involves a rub durability enhancing additive into the media coating composition to improve print durability for downstream processing. The solution presented from this disclosure involves a coating formulation and the printable recording media containing it which creates image receiving layer for high-speed inkjet web press printing with excellent durability and imaging quality. In one example, the present disclosure is drawn to a printable recording media, or printable medium, comprising a base substrate with an image-side and a back-side and an coating layer, applied to at least the image-side of the base substrate, The coating composition comprises, at least, particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain, having a mean particle size (D50) above 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm; inorganic pigment particles and/or mixture inorganic particles; and polymeric binders and/or mixture of polymeric binders. In another example, the present disclosure is drawn to a printable recording media, or printable medium, with coating composition forming, image receiving surface, that are applied to both sides of the base substrate. The present disclosure also relates to a method for forming said printable recording media and to the printing method using said printable medium. The method for forming a printable recording media comprises providing a base substrate, with an image-side and a back-side; applying a coating composition comprising, at least, particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain having a mean particle size (D50) above 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm; inorganic pigment particles and/or mixture inorganic particles; and polymeric binders and/or mixture of polymeric binders; to the image-side of the base substrate and drying the coating composition to remove water from the media substrate to leave a coating composition thereon. The printable recording media, or printable medium, according to the present disclosure is particularly well suited for inkjet printing technology and application. In some examples, the printable media is well adapted to be used in web press applications with high speed print rates, e.g., using the HP T200 Web Press or HP T300 Web Press at rates of 1000 feet per minute or more. In some other examples, printable media is to be printed with inkjet printing technology such as “HP Page Wide Array printing” where more than hundreds of thousand tiny nozzles on a stationary print-head that spans the width of a page, delivering multi-colors ink onto a moving sheet of paper under a single pass to achieve the super-fast printing speed. Printing applications which benefit from high grade printing media (such as magazines, catalogs, books, manuals, direct mails, labels, or other similar print jobs) where large volumes of high-quality glossy image are printed very quickly, are particularly advantaged by the printable recording media described herein. The media, according to the present disclosure, is a coated printable recording media. By “coated”, it is meant herein that the printable recording media has been applied a composition. It is noted that the term “coating composition” refers to either a composition used to form a coating layer as well as the coating layer itself, the context dictating which is applicable. For example, a coating composition or coating that includes an evaporable solvent is referring to the compositional coating that is applied to a media substrate. Once coated on a media substrate and after the evaporable solvent is removed, the resulting coating layer can also be referred to as a coating. The coating composition can be applied to various media to improve, for example, printing characteristics and attributes of an image. In some examples, the coating composition is a composition that is going to be applied to an uncoated printable recording media. By “uncoated”, it is meant herein that the printable recording media has not been treated or coated by any composition in one example, however, the top surface of the paper web might have been applied with some chemicals such as starch or other chemicals known as surface sizing agent on a paper machine. The coated media, according to the present disclosure, is a printable recording medium (or printable media) that provide printed images that have outstanding print durability and excellent scratch resistance while maintaining good printing characteristics and image quality (i.e. printing performance). As good printing characteristics, it is meant herein good black optical density, good color gamut and sharpness of the printed image. The images printed on the printable recording media will thus be able to impart excellent image quality: vivid color, such as higher gamut and high color density. High print density and color gamut volume are realized with substantially no visual color-to-color bleed and with good coalescence characteristics. The images printed on the printable recording media will also have excellent durability and excellent scratch resistance; specifically, it will have excellent durability under mechanical actions such as rubbing and scratching. By “scratch resistance”, it is meant herein that the composition is resistant to any modes of scratching which include, scuff and abrasion. By the term “scuff”, it is meant herein damages to a print due to dragging something blunt across it (like brushing fingertips along printed image). Scuffs do not usually remove colorant, but they do tend to change the gloss of the area that was scuffed. By the term “abrasion”, it is meant herein the damage to a print due to wearing, grinding or rubbing away due to friction. Abrasion is correlated with removal of colorant (i.e. with the OD loss). FIG.1andFIG.2schematically illustrate some examples of the printable recording media (100) as described herein.FIG.3is a flowchart illustrating an example of a method for producing the printable recording media. As will be appreciated by those skilled in the art,FIG.1andFIG.2illustrate the relative positioning of the various layers of the printable media without necessarily illustrating the relative thicknesses of the various layers. It is to be understood that the thickness of the various layers is exaggerated for illustrative purposes. FIG.1illustrates the printable recording media (100) as described herein. The printable recording media (100) encompasses a base substrate or media substrate or bottom supporting substrate (110) and a coating composition (120). The coating composition is applied on, at least, one side of the substrate (110) in order to from a coating layer (120) that could be called ink-receiving coating layer. The coating layer composition is thus applied on one side, i.e. the image side, only and no other coating is applied on opposite side. The image side with the coating layer is considered as the side where the image will be printed. The printable media (100) has two surfaces: a first surface which might be referred to as the “coating side”, “image surface” or “image side” (101) when coated with the coating layer and a second surface, the opposite surface, which might be referred to as the “back surface” or “back-side” (102). FIG.2illustrates another example of the printable recording media (100) as described herein. The printable media (100) encompasses a base substrate (110) with coating layers (120) that are applied to both the “image side” (101) and the “back-side” (102) of the print media. In theory, both the image side and the back-side could be printed and functionalized as ink-receiving coating layer. An example of a method (200) for forming a printable recording media in accordance with the principles described herein, by way of illustration and not limitation, is shown inFIG.3. As illustrated inFIG.3, such method encompasses providing (210) a base substrate, with an image-side and a back-side, applying (210) a coating layer comprising, at least, particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain having a mean particle size (D50) above 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm, inorganic pigment particles and/or mixture inorganic particles, and polymeric binders and/or mixture of polymeric binders to the image-side of the base substrate and drying (220) the coating composition to remove water from the media substrate to leave a coating layer thereon in order to obtain the printable recording media. The present disclosure relates thus also to a coated printable recording media, with an image-side (101) and a back-side (102), comprising a base substrate (110) and a coating layer (120). The coating layer comprises, at least, particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain, having a mean particle size (D50) above 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm; inorganic pigment particles and/or mixture inorganic particles, and polymeric binder and/or mixture of polymeric binders. Such layer is called “coating layer” or “ink-receiving layer” and can also be called coating layer since, during the printing process, the ink will be directly deposited on its surface. In some other examples, the printable recording media comprises a base substrate (110) and coating layers (120) with particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain, having a mean particle size (D50) above 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm; inorganic pigment particles and/or mixture inorganic particles, and polymeric binder and/or mixture of polymeric binders, that are applied to both opposing sides of the base substrate. In some examples, the coating composition can further comprise, as optional ingredients, fixative agents. In some other examples, the coating composition can further comprise, as optional ingredients, COF (coefficient of friction) controlling agents. In some other examples, the coating composition might further comprise, as optional ingredients, ink colorant fixing agents, surfactant and/or other processing aids such as pH control agent, deformer and biocide. The coating composition (120) can be disposed on the image-side (101) of the base substrate (110), at a coat-weight in the range of about 0.5 to about 40 gram per square meter (g/m2or gsm), or in the range of about 3 gsm to about 20 gsm, or in the range of about 5 to about 15 gsm. In some other examples, coating layers (120) are disposed on the image-side (101) and on the back-side (102) of the base substrate (110), at a coat-weight in the range of about 0.5 to about 40 gram per square meter (g/m2or gsm), or in the range of about 3 gsm to about 20 gsm, or in the range of about 5 to about 15 gsm. In some examples, the printable recording media, comprising a base substrate (110) and coating layers (120) can further encompasses a “base-coating layer” (not illustrated in the figure provided herein). Such base-coating layer would be positioned between the base substrate (110) and the coating layer (120). Such base-coating layer would then be in a sandwich position between the base substrate (110) and the coating layer (120) and could be applied to both opposing sides of the base substrate (120), i.e. image-side and a back-side. When present, such base-coating layer can comprise at least a polymeric binder and an inorganic filler. In some examples, the polymeric binder can be present in a dry weight amount representing from about 5% to about 25% of the base-coating layer. In some examples, the inorganic filler can be present in a dry weight amount representing from about 50% to about 95% of the base-coating layer. The polymeric binder could be identical or could be different from the polymeric binder that has been defined for the coating layer (120). The inorganic filler could be identical or could be different from the pigment particles that has been defined for the coating layer (120). The base-coating layer can also include other processing additives such PH control agents, surfactants, and rheological control agents. When present, the total coat dry weight of base-coating layer could range from about 5 gsm to about 30 gsm. In some examples, the base coating composition might also further comprise, as an optional ingredient, an ink colorant fixing agent or fixative agent as described for the coating composition mentioned herein. The printable recording media of the present disclosure comprises, at least, a coating composition (120) that includes particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain, having a mean particle size (D50) above 3 μm (1×10−6m, micrometer or micron) and having about 99.5% of the particle size distribution which is less than 80 μm. Without being linked by any theory, it is believed that the particles of metallic salt having a C8-C30alkyl acid chain or alkyl ester chain used the specific particle size (PS) and particle size distribution (PSD) as defined herein would act as a rub durability enhancer that has the ability to improve scuff-resistance of downstream processes. Such particles of metallic salt could thus be used as the scuff resistance additive. In some examples, the particles of metallic salt are organic particles that are dispersed in aqueous solution and that are present in an emulsion form. In some examples, the printable recording media of the present disclosure comprises, at least, a coating composition (120) that includes particles of metallic salt having a C12-C20alkyl acid chain or alkyl ester chain with an average having a mean particle size (D50) greater than 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm. In some examples, the printable recording media of the present disclosure comprises a coating composition (120) that includes particles of metallic salt having a C17alkyl acid chain or alkyl ester chain with an average a mean particle size (D50) greater than 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm. In some examples, the particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain can be pre-emulsified with surfactants into the dispersed aqueous emulsion of particles with an average a mean particle size (D50) greater than 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm. The coating composition (120) can include particles of metallic salt that are calcium salt of stearic acid with an average a mean particle size (D50) greater than 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm. In some examples, the particles of metallic salt have an alkyl acid chain or alkyl ester chain comprising from 8 to 30 carbon atoms, i.e. is a has a C8to C30alkyl chain. In some other examples, the alkyl acid chain or alkyl ester chain comprise from 12 to 20 carbon atoms. In yet some examples, the chain is a C17alkyl chain. In yet some other examples, the particles of metallic salt are calcium stearate (i.e. Calcium octadecenoate). Said calcium stearate can be produced by the reaction of by stearic acid with calcium oxide under heating. These C8to C30and C12to C20alkyl chain can be alkyl chain polymeric derivatives which may contain carboxy functional groups initially and transformed then into metallic salt or react into ester with another hydroxyl function chemical. The metallic ion on the polymeric salt can be, for example, but not limited to, sodium, calcium, magnesium or zinc ions. In some examples, the metallic ion on the polymeric salt is calcium. In some examples, the printable recording media of the present disclosure comprises a coating composition that includes a calcium stearate dispersion in water. Depending on the method of production, stearic acid may contain large amounts of other organic acids ranging from lauric acid to behenic acid or unsaturated acids such as oleic or linoleic. Accordingly, a stearate may contain significant amounts of laurate, palmitate, or oleate. Without being linked by any theory, it is found that scratch enhancement effectiveness of the organic acid salt and ester is not only associated with chemical structure such as chain length, metallic ion type, charge density, etc, but also greatly depends on the particle size (PS) and particle size distribution (PSD) of the organic particulate. A mean particle size (D50) ranged from 5 to 15 micrometer have proven to be more effective at improving scuff resistance of printed substrate as illustrated inFIG.4.FIG.4is a graph demonstrating the influence of the Malvern particle size distribution of particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain on the Sutherland dry rub score according to one example of the present disclosure.FIG.5is a graph illustrating the particle size distribution of particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain, according to one example of the present disclosure. The particle size distribution (PDS) plays also an important role in the scratch resistance properties of the particles of the present disclosure. Indeed, particles of metallic salt as defined herein with “narrow” and single bell curve distribution will perform better over the particles of metallic salt having non-single bell curves (i.e. bimodal shapes, J-shapes or skew shapes).FIG.5illustrates this distribution shape related effectiveness. All tested particles have metallic salt particles of C8-C30alkyl acid chain or alkyl ester chain and but do not have the same particle size distribution. The particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain have a mean particle size (D50) above 3 μm and have about 99.5% of the particle size distribution which is less than 80 μm. In some examples, the particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain have a mean particle size (D50) that is ranging from about 5 μm to about 30 μm and have about 99.5% of the particle size distribution which is less than 80 μm. In some other examples, the particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain have a mean particle size (D50) that is ranging from about 8 μm to about 20 μm and have about 99.5% of the particle size distribution which is less than 80 μm. In some examples, the particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain, have a mean particle size (D90) above 10 μm and have about 99.5% of the particle size distribution which is less than 80 μm. The particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain can also have a mean particle size (D90) that is ranging from about 15 μm to about 40 μm and have about 99.5% of the particle size distribution which is less than 80 μm. In some examples, the printable recording media of the present disclosure comprises, at least, a coating composition (120) that includes a calcium stearate dispersion having a mean particle size (D50) above 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm. In some other examples, the printable recording media of the present disclosure comprises, at least, a coating composition (120) that includes a calcium stearate dispersion having a particle size that is from about 5 μm to about 20 μm and having about 99.5% of the particle size distribution which is less than 80 μm. The particle size, as used herein, refers herein to the D50particle size. The “D50” particle size is defined as the particle size at which about half of the particles are larger than the D50particle size and about half of the other particles are smaller than the D50particle size (by weight based on the metal particle content of the particulate build material). Likewise, the “D90” is defined as the particle size at which about 5 wt % of the particles are larger than the D90particle size and about 90 wt % of the remaining particles are smaller than the D90particle size. Likewise, the “D10” is defined as the particle size at which about 5 wt % of the particles are larger than the D10particle size and about 10 wt % of the remaining particles are smaller than the D10particle size As used herein, the particle size (PS) is based on volume of the particle size normalized to a spherical shape for diameter measurement, for example. The particle size is expressed in micrometer (μm) (i.e., 1×10−6m or micron). As used herein, the particle size distribution (PSD) of a material is a value, expressed in percentage % of total volume of the particle, that defines the relative quantity of particles present according to specific size. The PSD is defined in terms of discrete size ranges. Particle sizes and particles size distribution are measured using a Malvern Dynamic Light Scattering Instrument or are measured using dynamic light scattering (DLS) on a Malvern Mastersizer 3000 with Aero S attachment. The particles of the present disclosure, i.e. the metallic salt of C8-C30alkyl acid chain or alkyl ester chain, have a mean particle size (D50) above 3 μm, and have about 99.5% of the particle size distribution, which is less than 80 μm, in one example. In another example, the particles of the present disclosure, i.e. the metallic salt of C8-C30alkyl acid chain or alkyl ester chain, have a mean particle size (D50) above 3 μm, and have about 99% of the particle size distribution which is less than 50 μm. In some examples, the coating composition includes particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain, have a mean particle size (D50) above 3 μm and have about 99.5% of the particle size distribution which is less than 80 μm, in an amount ranging from about 1 wt % to about 10 wt % by total weight of the coating composition. In some other examples, the particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain are present, the coating composition, in an amount ranging from about 1.5 to 5 wt % by total weight of the coating composition. In yet some other examples, the particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain are present, the coating composition, in an amount ranging from about 1.5 to 3 wt % by total weight of the coating composition. The printable recording media of the present disclosure comprises a coating composition (120) containing inorganic pigment particles and/or mixture inorganic particles. The coating composition (120) composition includes at least one type of pigment particles, or a mixture of different types of particulate fillers. The wording “type” refers to chemical composition, crystalline structure, particle size and size distribution, and chemical and physical condition of the particle surface such as surfactant treated and high temperature calcined. In one example, the particulate filler is clay or calcium carbonate particles, such as ground calcium carbonate (GCC) or precipitated calcium carbonate (PCC). In some examples, the clay particles and calcium carbonated particles of the various types described above, can be co-dispersed in the coating layer with other particulate fillers. The dispersion of the particles or mixture of the particles is compatible with the reactive crosslinking agent, meaning thus that there is no precipitation when mixing. Other particulate fillers that can be used in addition to the calcium carbonate particles include inorganic fillers which can generate micro-porous structure to improved ink absorbing. Examples include fumed silica and silica gels, as well as certain structured pigments. Structured pigments include those particles which have been prepared specifically to create a micro-porous structure. Examples of these structured pigments include calcine clays or porous clays that are reaction products of clay with colloidal silica. Other inorganic particles such as particles of titanium dioxide (TiO2), silicon dioxide (SiO2), aluminum trihydroxide (ATH), calcium carbonate (CaCO3), or zirconium oxide (ZrO2) can be present, or these compounds can be present in forms that are inter-calcined into the structured clay. In one example, the inorganic pigment particles may be substantially non-porous mineral particles that have a special morphology that can produce a porous coating structure when solidified into a coating layer. The coating composition (120) can include at least one type of particulate filler, or a mixture of different types particulate fillers. There is no specific limitation in selecting chemistry of particulate fillers, as long as these fillers have no chemical reactions in the solution of image receiving coating mixture before coating, where the pH of mixture is normally ranged between 4.5 to 6.5. The particulate fillers can be selected from, for example, kaolin, Kailin clays, barium sulfate, titanium dioxide, zinc oxide, zinc sulfide, satin white, aluminum silicate, diatomite, calcium silicate, magnesium silicate, synthetic amorphous silica, colloidal silica, colloidal alumina, pseudo-boehmite, aluminum hydroxide, alumina, lithopone, zeolite, and various combinations. In one example, particulate fillers are selected from the group consisting of silica, clay, kaolin, talc, titanium dioxide, and zeolites. In another example, the filler particles used are in a dry-powder form or in a form of an aqueous suspension referred as slurry with cationic charged dispersion agent since most anionic charged dispersing agent will be crashed by reactive cross-linking agent described above. Further, in another embodiment, the inorganic pigments are porous inorganic pigments. Porous inorganic pigments refer to pigment that include a plurality of pore structures to provide a high degree of absorption capacity for liquid ink vehicle via capillary action or other similar means. Examples of porous inorganic pigments include, but are not limited to, synthesized amorphous silica, colloidal silica, alumina, colloidal alumina, and pseudo-boehmite (aluminum oxide/hydroxide). In another embodiment, the porous inorganic pigments are mixed with low surface area inorganic pigments and/or organic pigments at a weight percent ratio raging from about 5% to about 40% of porous inorganic pigments. This mixture has the benefit of improving the ink absorption while not sacrificing other physical performance attributes such as gloss. Precipitated calcium carbonate can be commercially available, for example, under the tradenames Albacar® (available from Minerals Technologies Inc.). Ground calcium carbonate is commercially available, for example, under the trade names Omyafil®, Hydrocarb®70 and Omyapaque® (all of which are available from Omya North America). Examples of commercially available filler clays are Kaocal®, EG-44, and B-80 (available from Thiele Kaolin Company). An example of commercially available talc is Finntalc®F03 (available from Mondo Minerals). In some examples, inorganic pigment particles and/or mixture inorganic particles can be present, in the coating composition in an amount representing from about 50 wt % to about 92 wt %, or in an amount representing from about from about 70 wt % to about 90 wt %, or in an amount representing from about from about 80 wt % to about 88 wt % based on the total dry weight of the coating layer(s). The printable recording media of the present disclosure comprises a coating composition (120) containing polymeric binders and/or mixture of polymeric binders. In one example, the polymeric binder and/or mixture of polymeric binders can be present in the coating composition, in an amount representing from about 1 wt % to about 18 wt % with respect to the total dry weight of the coating layer. In another example, the polymeric binder and/or mixture of polymeric binders can be present in the coating composition in an amount from about 3 wt % to about 13 wt % with respect to the total dry weight of the coating layer. As a further example, the polymeric binder and/or mixture of polymeric binders can be present in the coating composition in an amount of from about 5 wt % to about 12 wt % with respect to the total dry weight of the coating layer. The polymeric binder can be selected from synthetic and natural polymeric compounds as long as they are compatible with the reactive crosslinking agent, meaning thus that no precipitation occurs when mixing. In some examples, the polymeric binder is a water-dispersible polymeric binder or a water-soluble polymeric binder or a combination thereof. In some other examples, the polymeric binder can include both water-dispersible polymeric binder and water-soluble polymeric binder. The ratio of water-soluble polymeric binders to water-dispersible polymeric binders can be of any value as long as such mixture provides a good adhesion to the substrate, to coating layers and to inorganic particles. In some examples, the polymeric binders can be a mixture of a water-dispersible polymeric binders and water-soluble polymeric binders that are present, in the coating layer, at a dry weight ratio of 1:25 to 1:1, 1:20 to 3:10, or 1:20 to 4:7, for example. Water-dispersible binders can include conjugated diene copolymer latexes, such as styrene-butadiene copolymer or acrylonitrile-butadiene copolymer; acrylic copolymer latexes, such as polymer of acrylic acid ester or methacrylic acid ester or methyl methacrylate-butadiene copolymer; vinyl copolymer latexes, such as ethylene-vinyl acetate copolymer and vinyl chloride-vinyl acetate copolymer; urethane resin latexes; alkyd resin latexes; unsaturated polyester resin latexes; and thermosetting synthetic resins, such as melamine resins and urea resins, and combinations thereof. In some examples, the water-dispersible polymer can include polymeric latex or polymeric emulsion where the polymeric core surrounded by surfactant with mid to large molecular weight polymer. The polymeric core can be dispersed by a continuous liquid phase to form an emulsion-like composition. Examples of water-dispersible polymers include, but are not limited to, acrylic polymers or copolymers latex, vinyl acetate latex, polyesters latex, vinylidene chloride latex, styrene-butadiene latex, acrylonitrile-butadiene copolymers latex, styrene acrylic copolymer latexes, and/or the like Generally, the water-dispersible polymer can include particles having a weight average molecular weight (Mw) of 5,000 to 500,000. In one example, the water-dispersible polymer can range from 50,000 Mw to 300,000 Mw. In some examples, the average particle diameter can be from 10 nm to 5 μm and, as other examples. The particle size distribution of the water-dispersible polymer is not particularly limited, and either polymer having a broad particle size distribution or latex having a mono-dispersed particle size distribution may be used. It is also possible to use two or more kinds of polymer fine particles each having a mono-dispersed particle size distribution in combination. The water-soluble polymer can be a macromolecule having hydrophilic functional groups, such as —OH, —COOH, —COC. Examples of the water-soluble polymers include, but are not limited to, polyvinyl alcohol, starch derivatives, gelatin, cellulose and cellulose derivatives, polyethylene oxide, polyvinyl pyrrolidone, or acrylamide polymers. By “water-soluble,” it is noted that the polymer can be at least partially water-soluble, mostly water-soluble (at least 50%), or in some examples, completely water-soluble (at least 99%). Water-soluble binders can include starch derivatives such as oxidized starch, etherified starch, and phosphate starch; cellulose derivatives such as methylcellulose, carboxymethylcellulose, and hydroxyethyl cellulose; polyvinyl alcohol derivatives such as polyvinyl alcohol or silanol modified polyvinyl alcohol; natural polymeric resins such as casein, and gelatin or their modified products, soybean protein, pullulan, gum arabic, karaya gum, and albumin or their derivatives; vinyl polymers such as sodium polyacrylate, polyacrylamide, and polyvinylpyrrolidone; sodium alginate; polypropylene glycol; polyethylene glycol; maleic anhydride; or copolymers thereof. In some examples, the binder of the base coating layer can include polyvinyl alcohol and a latex having a glass transition temperature from −50° C. to 35° C. In one example, the binder of the base coating layer can include a styrene-butadiene copolymer, such Litex® PX 9740 (Synthomer) and a polyvinyl alcohol, such as Mowiol® 4-98 (Kuraray America Inc.). In some examples, the polymeric binder comprises a water-soluble binder that is a polyvinyl alcohol, a starch derivative, gelatin, a cellulose derivative, a copolymer of vinylpyrrolidone or an acrylamide polymer. In some examples, the polymeric binder comprises a water-dispersible binder that is polyurethane polymer, acrylic polymer or copolymer, vinyl acetate latex, polyester, vinylidene chloride latex, styrene-butadiene or acrylonitrile-butadiene copolymer. In some examples, the coating composition might also further comprise, as an optional ingredient, an ink colorant fixing agent or fixative agent. It is believed that the fixing agent can chemically, physically, and/or electrostatically bind a marking material, such as an inkjet ink, at or near an outer surface of the coated print media to provide acceptable water-fastness, smear-fastness, and overall image stability. A function of the fixative agent can be thus to reduce ink dry time. The fixative agents can be a metallic salt, a cationic amine polymer, a quaternary ammonium salt, or a quaternary phosphonium salt. The metallic salt may be a water-soluble mono- or a multi-valent metallic salt. The water-soluble metallic salt can be an organic salt or an inorganic salt. The fixative agent can be an inorganic salt. In some examples, the fixative agent is a water-soluble and multi-valent charged salts. Multi-valent charged salts include cations, such as Group I metals, Group II metals, Group III metals, or transition metals, such as sodium, calcium, copper, nickel, magnesium, zinc, barium, iron, aluminum and chromium ions. The associated complex ion can be chloride, iodide, bromide, nitrate, sulfate, sulfite, phosphate, chlorate, acetate ions. The fixative agent can be an organic salt; in some examples, the fixative agent is a water-soluble organic salt; in yet some other examples, the fixative agent is a water-soluble organic acid salt. Organic salt refers to associated complex ion that is an organic specifies, where cations may or may not the same as inorganic salt like metallic cations. Organic metallic salt are ionic compounds composed of cations and anions with a formula such as (CnH2n+1COO−M+)*(H2O)m where M+is cation species including Group I metals, Group II metals, Group III metals and transition metals such as, for example, sodium, potassium, calcium, copper, nickel, zinc, magnesium, barium, iron, aluminum and chromium ions. Anion species can include any negatively charged carbon species with a value of n from 1 to 35. The hydrates (H2O) are water molecules attached to salt molecules with a value of m from 0 to 20. Examples of water-soluble organic acid salts include metallic acetate, metallic propionate, metallic formate, metallic oxalate, and the like. The organic salt may include a water-dispersible organic acid salt. Examples of water-dispersible organic acid salts include a metallic citrate, metallic oleate, metallic oxalate, and the like. In some examples, the fixative agent is a water-soluble, divalent or multi-valent metal salt. Specific examples of the divalent or multi-valent metal salt used in the coating include, but are not limited to, calcium chloride, calcium acetate, calcium nitrate, calcium pantothenate, magnesium chloride, magnesium acetate, magnesium nitrate, magnesium sulfate, barium chloride, barium nitrate, zinc chloride, zinc nitrate, aluminum chloride, aluminum hydroxy-chloride, and aluminum nitrate. Divalent or multi-valent metal salt might also include CaCl2, MgCl2, MgSO4, Ca(NO3)2, and Mg(NO3)2, including hydrated versions of these salts. In some examples, the water-soluble divalent or multi-valent salt can be selected from the group consisting of calcium acetate, calcium acetate hydrate, calcium acetate monohydrate, magnesium acetate, magnesium acetate tetrahydrate, calcium propionate, calcium propionate hydrate, calcium gluconate monohydrate, calcium formate and combinations thereof. In some examples, the fixative agent is calcium chloride and/or calcium acetate. In some other examples, the fixative agent is calcium chloride (CaCl2). When present, the fixative agent can be present in the coating composition in an amount representing from about 0.5 wt % to about 20 wt % or in an amount representing from about 1 wt % about 20 wt % of the total dry weight of the coating layer, for example. In some examples, the coating composition (120) can include a fixative agent and a binder system wherein the ratio of fixative agent to binder system is from about 1:5 to about. 1:30. In some other examples, the coating layer includes a fixative agent and a binder system wherein the ratio of fixative agent to binder system is from about 1:6 to about 1:15. In some examples, the coating composition night also further comprise a COF (coefficient of friction) controlling agent as an optional ingredient. The addition of the COF controlling agent in the coating layer may advantageously assist in maintaining the appropriate COF (coefficient of friction) of the surface of coating layer in the desired range. The Coefficient of Friction (COF) can be evaluated using the TMI slips and friction tester (model #32-90) per the TAPPI T-549 om-01 method. Such COF controlling agent can also be called “slip aid agent”. In some examples, COF controlling agent can be thermoplastic materials in the form of a dispersion or in the form of an emulsion. The thermoplastic material may be a single thermoplastic material or a combination of two or more thermoplastic materials. Whether used alone or in combination, each thermoplastic materials may have a melting temperature ranging from about 40° C. to about 250° C. The COF controlling agent, i.e. thermoplastic material, may be natural materials or polyolefin-based materials. In some examples, the thermoplastic material is a non-ionic material, an anionic material, or a cationic material. In some examples, the thermoplastic material is selected from the group consisting of a beeswax, a carnauba wax, a candelilla wax, a montan wax, a Fischer-Tropsch wax, a polyethylene-based wax, a high density polyethylene-based wax, a polybutene-based wax, a paraffin-based wax, a polytetrafluoroethylene-based material, a polyamide-based material, a polypropylene-based wax, and combinations thereof. In some other examples, the thermoplastic material is an anionic polyethylene wax emulsion, a poly-propylene based thermoplastic material, a high-density polyethylene non-ionic wax micro-dispersion or a high melt polyethylene wax dispersion. In yet some other examples, the thermoplastic material is a high-density polyethylene non-ionic wax micro-dispersion. Examples of suitable thermoplastic materials include Michem® and ResistoCoat™ products that are available from Michelman, Inc., Cincinnati, Ohio, and Ultralube® products that are available from Keim Additec Surface GmbH, Kirchberg/Hunsrück. Some specific examples of the polyethylene-based wax include polyethylene (e.g., Michem® Wax 410), an anionic polyethylene wax emulsion (e.g., Michem® Emulsion 52830, Michem® Lube 103DI, and Michem® Lube 190), an anionic polyethylene wax dispersion (e.g., Michem® Guard 7140), a non-ionic polyethylene wax dispersion (e.g., Michem® Guard 25, Michem® Guard 55, Michem® Guard 349, and Michem® Guard 1350) a non-ionic polyethylene wax emulsion (e.g., Michem® Emulsion 72040), or a high melt polyethylene wax dispersion (e.g., Slip-Ayd® SL 300, Elementis Specialties, Inc., Hightstown, NJ). In some other examples, the thermoplastic material(s) may be an anionic paraffin/ethylene acrylic acid wax emulsion (e.g., Michem® Emulsion 34935), a cationic water based emulsion of polyolefin waxes (e.g., Michem® Emulsion 42035A), anionic microcrystalline wax emulsions (e.g., Michem® Lube 124 and Michem® Lube 124H), or a high density polyethylene/copolymer non-ionic wax emulsion (e.g., Ultralube® E-530V). The coating composition may also include other optional coating additives such as surfactants, rheology modifiers, defoamers, optical brighteners, biocides, pH controlling agents, dyes, and other additives for further enhancing the properties of the coating. The total amount of optional coating additives may be in the range of 0 to 10 wt % based on the total amount of ingredients. Among these additives, rheology modifier or rheology control agent is useful for addressing runnability issues. Suitable rheology control agents include polycarboxylate-based compounds, polycarboxylated-based alkaline swellable emulsions, or their derivatives. The rheology control agent is helpful for building up the viscosity at certain pH, either at low shear or under high shear, or both. In certain embodiments, a rheology control agent is added to maintain a relatively low viscosity under low shear, and to help build up the viscosity under high shear. It is desirable to provide a coating formulation that is not so viscous during the mixing, pumping and storage stages, but possesses an appropriate viscosity under high shear. The printable recording media (100) of the present disclosure, that can also be called herein printable recording media, is a media that comprises a base substrate (110). The base substrate (110) can also be called bottom supporting substrate or substrate. The word “supporting” also refers to a physical objective of the substrate that is to carry the coatings layer and the image that is going to be printed. In some examples, the base substrate (110) is a cellulose base substrate meaning thus that the substrate is a cellulose paper. Such cellulose base substrate can be a cellulose paper web. The cellulose base substrate, or cellulose paper web, can be made of any suitable wood or non-wood pulp. Non-limitative examples of suitable pulp compositions include, but are not limited to, mechanical wood pulp, chemically ground pulp, chemi-mechanical pulp, thermo-mechanical pulp (TMP) and combinations of one or more of the above. In some examples, the cellulose paper web comprises a bleached hardwood chemical kraft pulp. The bleached hardwood chemical kraft pulp has a shorter fiber structure (about 0.3 to about 0.6 mm length) than soft wood pulp. The shorter fiber structure contributes to good formation of the paper product in roll or sheet form, for example. Moreover, a filler may be incorporated into the pulp, for example, to substantially control physical properties of the paper product in roll or sheet form. Particles of the filler fill in the void spaces of the fiber network and substantially result in a denser, smoother, brighter and opaque sheet than without a filler. The filler may substantially reduce cost also, since filler is generally cheaper than the pulp itself. Examples of fillers that are incorporated into the pulp include, but are not limited to, ground calcium carbonate, precipitated calcium carbonate, titanium dioxide, kaolin clay, silicates, plastic pigment, alumina trihydrate and combinations of any of the above. An amount of the filler in the pulp may include as much as 15 percent (%) by weight, for example. In some examples, the amount of filler in the pulp ranges from about 0% to about 20% of the paper product in roll or sheet form. In another example, the amount of filler ranges from about 5% to about 15% of the paper product in roll or sheet form. In some examples, if the percentage of filler is more than 20% by weight, pulp fiber-to-fiber bonding may be reduced, which subsequently may decrease stiffness and strength of the resulting paper product in roll or sheet form. Moreover, an internal sizing may be included, for example. Internal sizing may improve internal bond strength of the pulp fibers, and also may control resistance of the paper product in roll or sheet form to wetting, penetration, and absorption of aqueous liquids. Internal sizing processing may be accomplished by adding a sizing agent to a fiber furnish (or source of the pulp fiber) in the wet-end of paper manufacture. Non-limitative examples of suitable internal sizing agents include a rosin-based sizing agent, a wax-based sizing agent, a cellulose-reactive sizing agent and another synthetic sizing agent, and combinations or mixtures thereof. The degree of internal sizing may be characterized by Hercules Sizing Test (HST) value. In some examples, the cellulose-based paper web has an internal sizing with a low HST value ranging from 1 to 150. In some examples, the HST value ranges from about 10 to about 50. Excessive internal sizing may affect the print quality on the paper product, for example, it may cause color-to-color bleed of inks printed on the paper product. The surface sizing composition according to the principles described herein comprises a macromolecular material, either natural or synthetic, in an amount from about 25% to about 75% dry weight; optionally, an inorganic metallic salt in an amount from about 3% to about 20% dry weight; and an amount of an inorganic pigment ranging from greater than 15% to about 60% dry weight in an aqueous mixture, such that a total dry weight equals about 100%. The aqueous mixture is a size press (SP)-applied surface sizing composition in online paper manufacture. In particular, the SP surface sizing composition according to the principles described herein has one or more of a lower content of macromolecular material, a lower content of salt and a higher content of inorganic pigment (filler) than a surface sizing of commercially available office printing paper in the marketplace. In some examples, the SP surface sizing composition according to the principles described herein has each of a lower content of macromolecular material, a lower content of salt and a higher content of inorganic pigment (filler) than the commercially available office printing paper. The macromolecular material is a high molecular weight material, such as a high molecular weight polymeric material, that functions as both a sizing agent and a binder for the SP surface sizing composition. In some examples, the macromolecular material includes one or both of synthetic polymers and natural polymers. In particular, by definition, the macromolecular material one or more of is water-soluble or water-dispersible, has strong film forming capability, and can bind particles of the inorganic pigment to form a coating layer. Moreover, by definition, the macromolecular material is inert to the inorganic metallic salt. The term ‘film-forming’ as used herein means that, during drying, or i.e., when aqueous solvent is removed from the cellulose-based paper web, the macromolecules can form continuous network, or latex particles can aggregated together to form a continuous film, or a continuous barrier layer to the aqueous solvent or moisture at a macroscopic level. The term ‘inert’ as used herein means that the macromolecular material will not interact with a fixative so as to cause the polymers to be precipitated, gelled, or form any kind of solid particle, which would adversely reduce a binding capability of the macromolecular material and a coating ability of the SP surface sizing composition. Examples of a synthetic polymer useful in the macromolecular material include, but are not limited to, polyvinyl alcohol, polyvinyl pyrrolidone, acrylic latex, styrene-butadiene latex, polyvinyl acetate latex, and a copolymer latex of any of the above-named monomers, and combinations or mixtures thereof. Examples of a natural polymer useful in the macromolecular material include, but are not limited to, casein, soy protein, a polysaccharide, a cellulose ether, an alginate, a virgin starch and a modified starch, and a combination of any of the above-named polymers. The starch species includes, but is not limited to, corn starch, potato starch, derivatized starch and modified starch including, but not limited to, ethylated starch, oxidized starch, anionic starch, and cationic starch. For example, an ethylated starch, such as K96F from Grain Processing Corp., Muscatine, IA, or a hydroxyethyl ether derivatized corn starch, such as Penford® 280 Gum (i.e., 2-hydroxyethyl starch ether, hydroxyethyl starch or ethylated starch) from Penford Products Co., Cedar Rapids, IA, may be used. The printable recording media, described herein, is prepared by using several surface treatment compositions herein named a coating layer or coating composition. A method of making a coated print media includes applying a coating composition as a layer to a media substrate and drying the coating composition to remove water from the media substrate to leave a coating composition thereon. In some examples, as illustrated inFIG.3, a method (200) of making a printable recording media encompasses: providing (210) a base substrate (110) with an image-side and a back-side; applying (210) a coating composition(120) comprising particles of metallic salt of C8-C30alkyl acid chain or alkyl ester chain having a mean particle size (D50) above 3 μm and having about 99.5% of the particle size distribution which is less than 80 μm, inorganic pigment particles and/or mixture inorganic particles, and polymeric binders and/or mixture of polymeric binders to the image-side of the base substrate; and drying (220) the coating composition to remove water from the media substrate to leave a coating composition hereon in order to obtain the printable media. In some examples, the coating composition(120) is applied to the base substrate (110) on the image receiving side of the printable media. In some other examples, the coating composition(120) is applied to the supporting base substrate (110) on the image receiving side (101) and on the backside (102) of the printable media. The coating layer (120) can be applied to the base substrate (110) by using any method appropriate for the coating application properties, e.g., thickness, viscosity, etc. Non-limiting examples of methods include size press, slot die, blade coating, Meyer rod coating and roll coater. In some examples, the coating layer can be applied in one single production run. When the coating layer is present on both sides of the base substrates, depending on set-up of production machine in a mill, both sides of the substrate may be coated during a single manufacture pass, or each side is coated in a separate pass. Subsequently, when the coating composition is dried, it can form a coating layer. Drying can be by air drying, heated airflow drying, heated dryer can, infrared heated drying, etc. Other processing methods and equipment can also be used. For one example, the coated media substrate can be passed between a pair of rollers, as part of a calendering process, after drying. The calendering device can be any kind of calendaring apparatus, including but not limited to off-line super-calender, on-line calender, soft-nip calender, hard-nip calender, or the like. Once applied to the image-side (101) of the base substrate (110), the coating composition(120) can be calendered. The calendaring can be done either in room temperature or at an elevated temperature and/or pressure. In one example, the elevated temperature can range from 40° C. to 60° C. In one example, the calender pressure can range from about 100 psi to about 2,000 psi. The coating layer (120) can be dried using any drying method in the arts such as box hot air dryer. The dryer can be a single unit or could be in a serial of 3 to 7 units so that a temperature profile can be created with initial higher temperature (to remove excessive water) and mild temperature in end units (to ensure completely drying with a final moisture level of less than 6% for example). The peak dryer temperature can be programmed into a profile with higher temperature at begging of the drying when wet moisture is high and reduced to lower temperature when web becoming dry. The web temperature during drying can be controlled in the range of about 80 to about 120° C. In some examples, the operation speed of the coating/drying line is 300 to 500 meters per minute. Once the coating compositions are applied to the base substrate and appropriately dried, ink compositions can be applied by any processes onto the printable recording media. In some examples, the ink composition is applied to the printable recording media via inkjet printing techniques. A printing method could encompasses obtaining a coated printable media as defined herein and applying an ink composition onto said printable recording media to form a printed image. Said printed image will have, for instance, enhanced image quality and image permanence. In some examples, when needed, the printed image can be dried using any drying device attached to a printer such as, for instance, an IR heater. The method for producing printed images, or printing method, includes providing a printable recording media such as defined herein; applying an ink composition on the coating layer of the print media, to form a printed image; and drying the printed image in a hot air or IR heated dryer in order to complete crosslink reaction and then provide, for example, a printed image with enhanced quality and enhanced image permanence. In some examples, the printing method for producing images is an inkjet printing method. By inkjet printing method, it is meant herein a method wherein a stream of droplets of ink is jetted onto the recording substrate or media to form the desired printed image. The ink composition may be established on the recording media via any suitable inkjet printing technique. Examples of inkjet method include methods such as a charge control method that uses electrostatic attraction to eject ink, a drop-on-demand method which uses vibration pressure of a Piezo element, an acoustic inkjet method in which an electric signal is transformed into an acoustic beam and a thermal inkjet method that uses pressure caused by bubbles formed by heating ink. Non-limitative examples of such inkjet printing techniques include thus thermal, acoustic and piezoelectric inkjet printing. In some examples, the ink composition is applied onto the recording media using inkjet nozzles. In some other examples, the ink composition is applied onto the recording method using thermal inkjet printheads. In some examples, the printing method is a capable of printing more than about 50 feet per minute (fpm) (i.e. has a print speed that is more than about 50 fpm). The printing method described herein can be thus considered as a high-speed printing method. The web-speed could be from about 100 to about 4 000 feet per minute (fpm). In some other examples, the printing method is a printing method capable of printing from about 100 to about 1 000 feet per minute. In yet some other examples, the printing method is capable of printing at a web-speed of more than about 200 feet per minute (fpm). In some example, the printing method is a high-speed web press printing method. As “web press”, it is meant herein that the printing technology encompasses an array of inkjet nozzles that span the width of the paper web. The array is thus able, for example, to print on 20″, 30″, and 42″ wide web or on rolled papers. In some examples, the printing method as described herein prints on one-pass only. The paper passes under each nozzle and printhead only one time as opposed to scanning type printers where the printheads move over the same area of paper multiple times and only a fraction of total ink is used during each pass. The one-pass printing puts 100% of the ink from each nozzle/printhead down at once and is therefore more demanding on the ability of the paper to handle the ink in a very short amount of time. As mentioned above, a print media in accordance with the principles described herein may be employed to print images on one or more surfaces of the print media. In some examples, the method of printing an image includes depositing ink that contains particulate colorants. A temperature of the print media during the printing process is dependent on one or more of the nature of the printer, for example. Any suitable printer may be employed such as, but not limited to, offset printers and inkjet printers. In some examples, the printer is a HP T350 Color Inkjet Webpress printer (Hewlett Packard Inc.). The printed image may be dried after printing. The drying stage may be conducted, by way of illustration and not limitation, by hot air, electrical heater or light irradiation (e.g., IR lamps), or a combination of such drying methods. In order to achieve best performances, it is advisable to dry the ink at a maximum temperature allowable by the print media that enables good image quality without deformation. Examples of a temperature during drying are, for examples, from about 100° C. to about 205° C., or from about 120° C. to about 180° C. The printing method may further include a drying process in which the solvent (such as water), that can be present in the ink composition, is removed by drying. As a further step, the printable recording media can be submitted to a hot air-drying systems. The printing method can also encompass the use of a fixing agent that will retain with the pigment, present in the ink composition that has been jetted onto the media. In some examples, the ink composition is an inkjet ink composition that contains one or more colorants that impart the desired color to the printed message and a liquid vehicle. As used herein, “colorant” includes dyes, pigments, and/or other particulates that may be suspended or dissolved in an ink vehicle. The colorant can be present in the ink composition in an amount required to produce the desired contrast and readability. In some examples, the ink compositions include pigments as colorants. Pigments that can be used include self-dispersed pigments and non-self-dispersed pigments. Any pigment can be used; suitable pigments include black pigments, white pigments, cyan pigments, magenta pigments, yellow pigments, or the like. Pigments can be organic or inorganic particles as well known in the art. As used herein, “liquid vehicle” is defined to include any liquid composition that is used to carry colorants, including pigments, to a substrate. A wide variety of liquid vehicle components may be used and include, as examples, water or any kind of solvents. Reference throughout the specification to “one example”, “another example”, “an example”, and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the example is included in at least one example described herein, and may or may not be present in other examples. In addition, it is to be understood that the described elements for any example may be combined in any suitable manner in the various examples unless the context clearly dictates otherwise. In describing and claiming the examples disclosed herein, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint. The degree of flexibility of this term can be dictated by the particular variable and would be within the knowledge of those skilled in the art to determine based on experience and the associated description herein. As used herein, “liquid vehicle” or “ink vehicle” refers to a liquid fluid in which colorant, such as pigments, can be dispersed and otherwise placed to form an ink composition. A wide variety of liquid vehicles may be used with the systems and methods of the present disclosure. Such liquid vehicles may include a mixture of a variety of different agents, including, water, organic co-solvents, surfactants, anti-kogation agents, buffers, biocides, sequestering agents, viscosity modifiers, surface-active agents, water, etc. As used herein, “pigment” generally includes pigment colorants. As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. Concentrations, dimensions, amounts, and other numerical data may be presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity and should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a weight ratio range of about 1 wt % to about 20 wt % should be interpreted to include not only the explicitly recited limits of about 1 wt % and about 20 wt %, but also to include individual weights such as 2 wt %, 11 wt %, 14 wt %, and sub-ranges such as 10 wt % to 20 wt %, 5 wt % to 15 wt %, etc. All percent additions are by dry weight, unless otherwise indicated. To further illustrate the present disclosure, an example is given herein. It is to be understood this example is provided for illustrative purposes and is not to be construed as limiting the scope of the present disclosure. EXAMPLES The raw materials and chemical components used in the illustrating samples are listed in Table 1. TABLE 1IngredientsNature of the ingredientsSupplierDisponil ®AFXSurfactant - aqueous solution ofBASF Co4030a modified fatty alcoholpolyglycol etherCovercarb ® 85Particulate filler - groundOmya Cocalcium carbonate availableHydragloss ® 90Particulate filler - kaolin clayKaminLitex ® PX9740Polymeric binder - carboxylatedSynthomerstyrene butadiene copolymerMowiol ® 13-88Polymeric binder - polyvinylSigma-AldrichalcoholCaCl2Colorant fixing agentAldrichSodium HydroxidepH control agentAldrichKamin ® 2000ccalcined kaolin clayPerformanceMineralsEC1722Calcium StearateAmerican eChemCD205Calcium StearateAmerican eChemCD220Calcium StearateAmerican eChemCalsan ® 55Calcium StearateBASF Example 1—Preparation of Printable Recording Media Samples Different media were made using different coating compositions. Such compositions are prepared by mixing the ingredients, in water, as illustrated in Table 2. The coating composition chemicals are mixed together in a tank by using normal stirring equipment. Each coating layer compositions is applied on the on the image side of a raw base substrate (110) at a coat-weight of about 10 gram/square meter (gsm) using a Meyer rod in lab in view of obtaining the different media samples. Coating composition A, B, C, and D are coated at a coat-weight of 10 gsm on a 45 #book paper base from Evergreen Packaging LLC® as a base supporting paper substrate in order to obtain the coated media Sample A, B, C and D. Coating composition A1, A2, A3and A4are coated at a coat-weight of 10 gsm on 75 #uncoated plain paper as a base supporting paper substrate in order to obtain the coated media Sample A1, A2, A3and A4. The recording media are then calendered through a lab soft nip calendar machine (at 160° F./2000 psi at room temperature). Coating composition A1, B and D are comparative coating compositions. Coated media A1, B and D are comparative media samples. The formulations of the coating composition are illustrated in the Table 2 below. Each number represent the dry weight percent (wt %) of each ingredient in the dry composition. TABLE 2Coating Compositions (in wt %)ChemicalA1BDComponents(comp)A2A3A4A(comp)C(comp)Covercarb ® 8563.663.162.662.062.662.662.662.6Litex ® PX974010.210.110.09.910.010.010.010.0Disponil ® AFX 40300.30.30.30.20.30.30.30.3Kamin ® 2000c8.58.48.38.38.38.38.38.3Hydragloss ® 9012.712.612.512.412.512.512.512.5Mowiol ® 13-881.71.71.71.71.71.71.71.7Calcium Chloride3.02.92.92.92.92.92.92.9Sodium Hydroxide0.10.10.10.10.10.10.10.1EC1722—0.81.72.51.7———CD205—————1.7——CD220——————1.7Calsan ® 55———————1.7Base Paper75# Uncoated Plain PaperEvergreen 45# Book Paper Several dosage levels of calcium stearate are also tested in the coating formulations spanning from 0.8% by dry weight up to 2.5% by dry for coating composition formulation A2, A3and A4. The formula A1does not include any calcium stearate. Four different grades of calcium stearate are also tested with median particle diameters (D50) ranging from about 2 μm to about 11 μm (Coating composition formulation A, B, C, and D). The particle sizes and particle size distribution of each grade are expressed in table 3. FIG.4is a graph demonstrating the influence of the Malvern particle size (PS) of the different grades of calcium stearate tested (i.e. having about 99.5% of the particle size distribution which is less than 80 μm) that are present in Formula A2-4, C and, D, on the Sutherland dry rub score.FIG.5illustrates the particle size distribution (PSD) of the different grades of calcium stearate tested that are present in Formula A2, A3, A4, A, B, C and, D. InFIG.5, all tested particles are calcium stearate and have similar D50but not the same particle size distribution. The particle sizes (PS) and particle size distribution (PSD) are measured using dynamic light scattering (DLS) on a Malvern Mastersizer. TABLE 3PSDCalcium StearatePSabout 99.5%GradeD10D50D90of the PDS isFormulaSample Name(μm)(μm)(μm)less than 80 μmDAverage of0.3082.8310.8no‘Calsan ® 55BAverage of ‘CD205’3.286.6216.1noCAverage of ‘CD220’3.26.4813.6yesA2-4Average of ‘EC17225.0910.924.5yes Example 2—Samples Performances The same images are printed on the coated media samples A1, A2, A3, A4, A, B, C and D. The samples are printed using an HP CM8060 MFP printer with web press inkjet inks in the pens. The prints are made in 2 pass/6 dry spin mode. The resulting printed medias are evaluated for their gloss and durability performances. The durability performances are measured with a Sutherland® Ink Rub tester. Sutherland dry rub test is designed to evaluate the scuffing or rubbing resistance of the printed or coated surface of paper, paperboard, film and other materials and, specifically, to simulate paper-on-paper contact typical of many downstream manufacturing and distribution processes. Sutherland dry rub testing is completed 24 hours after printing, by rubbing an unprinted sheet against the printed sheet with 100 cycles under 4 lbs of force. The Sutherland® Ink Rub tester features a digital counter with a fiber optic sensor for accuracy and is compatible with the requirements of the ASTM D-5264 test method (on normal and heated condition). Durability test samples are ranked visually with a 1-5 score (Sutherland rub Score), where a score of 1 corresponds to severe ink scuffing/removal and a score of 5 corresponds to no ink scuffing/removal. The surface gloss of each media sample is measured using a Micro Tri-Gloss Meter (available from BYK Gardner Inc) according to the standard procedures described in the instrument manual provided by the manufacturer. The Micro-Tri Gloss Meter is calibrated at seventy-five (75°) degrees using the standard supplied by the unit. The mean particle sizes of each grade of calcium stearate dispersion, the gloss, and the associated durability test scores (Sutherland Dry Rub score) are listed below in Table 4 and Table 5. The results are different for the coated media samples A1, A2, A3and A4and for coated media samples B, C, D and E due to the different nature of the base substrate that has been used. TABLE 4BDFormulaA(comparative)C(comparative)Sutherland Dry Rub score5241Sheet Gloss (75°)71706872 TABLE 5A1Formula(comparative)A2A3A4Sutherland Dry Rub score1455Sheet Gloss (75°)83828081 FIG.4, Table 4 and Table 5 demonstrate that the calcium stearate particle size has a strong impact on rub durability when incorporated into the media at 1.7 dry weight percent. The graph and tables show a trendline that has a strong correlation between larger particle sizes and normal distribution and strong Sutherland dry rub performance, when the particles have about 99.5% of the particle size distribution which is less than 80 μm.FIG.5demonstrates the influence of the particle size distribution on the durability: samples that do not have about 99.5% of the particle size distribution which is less than 80 μm show poor durability performance (i.e., Sample B) The Sutherland rub results also show that when calcium stearate is omitted from the coating composition, rub durability performance is very poor. Adding in the particles, as defined in the present disclosure, boosts the rub durability performance to good and perfect performances (score of 4/5 and 5/5). The sheet gloss levels demonstrate that this mechanism of rub durability enhancement does not hurt the sheet gloss. Therefore, it can be seen that the examples of recording media sample with the coating layer defined according to the present disclosure, have increased durability while not compromising gloss and image quality. | 71,794 |
11858287 | The accompanying drawings are intended to depict embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. Also, identical or similar reference numerals designate identical or similar components throughout the several views. DETAILED DESCRIPTION In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that have a similar function, operate in a similar manner, and achieve a similar result. It will be understood that if an element or layer is referred to as being “on,” “against,” “connected to” or “coupled to” another element or layer, then it can be directly on, against, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, if an element is referred to as being “directly on,” “directly connected to” or “directly coupled to” another element or layer, then there are no intervening elements or layers present. Like numbers referred to like elements throughout. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements describes as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, term such as “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors herein interpreted accordingly. The terminology used herein is for describing particular embodiments and examples and is not intended to be limiting of exemplary embodiments of this disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Referring now to the drawings, embodiments of the present disclosure are described below. In the drawings for explaining the following embodiments, the same reference codes are allocated to elements (members or components) having the same function or shape and redundant descriptions thereof are omitted below. FIG.1is a schematic diagram illustrating an overall configuration of an image forming system according to an embodiment of the present disclosure. An image forming system400according to the present embodiment includes a sheet laminator200inside a body of an image forming apparatus300. The image forming apparatus300mainly includes a plurality of feeding units5that load and convey recording media, an image forming unit4as an image forming device that forms an image on a recording medium, and a heat fixing unit3that fixes the formed image on the recording medium. In the image forming system400, an inner sheet to be inserted into a lamination sheet can be fed from the image forming apparatus300or from a sheet feed tray of the sheet laminator200. Accordingly, a desired image can be inserted in an in-line manner by a method utilizing copying or printing onto the inner sheet. FIG.2is a schematic view illustrating an overall configuration of a sheet laminator according to an embodiment of the present disclosure. The sheet laminator200according to the present embodiment is to separate a two-ply sheet (hereinafter referred to as a lamination sheet S) from each other, insert and sandwich a sheet medium (hereinafter referred to as an inner sheet P) into and between separated pieces of the lamination sheet S, and applies heat and pressure to the lamination sheet S to bond the lamination sheet S. The lamination sheet S is a two-ply sheet constructed of two overlapping sheets (plies) and bonded (or joined) at one portion (or on one side). For example, there is a two-ply sheet in which a first side is a transparent sheet such as a transparent polyester sheet and the opposite side is a transparent or opaque sheet and bonded to the other sheet on one side thereof. The two-ply sheet also includes a lamination film. The insertion sheet P is an example of a sheet medium that is inserted into the two-ply sheet. Examples of the sheet medium include thick paper, postcards, envelopes, plain paper, thin paper, coated paper, art paper, tracing paper, and overhead projector (OHP) transparencies. As illustrated inFIG.2, the sheet laminator200includes a sheet tray102serving as a sheet loader to stack lamination sheets S and/or inner sheets P, a pickup roller105to feed the lamination sheets S and/or the inner sheets P from the sheet tray102, and a conveyance roller pair107. The sheet laminator200includes, for example, an entrance roller pair108serving as a first conveyor, a winding roller109serving as a rotating member, an exit roller pair113serving as a second conveyor. The entrance roller pair108, the winding roller109, and the exit roller pair113are disposed downstream of the conveyance roller pair107in a sheet conveyance direction. The sheet laminator200includes a conveyance path125and a relay conveyance path126. The conveyance path125extends from the sheet tray102toward the entrance roller pair108. The inner sheet P fed from the image forming apparatus300is conveyed through the relay conveyance path126. The downstream side from the exit roller pair113in the sheet conveyance direction is separated into the upper side and the lower side by a separation claw118. The upper side includes heat pressing rollers120that are heat pressers to heat and press a lamination sheet S, and the lower side includes a conveyance roller pair122. An ejection roller121and an ejection tray104are disposed downstream from the heat pressing rollers120and the conveyance roller pair122. The sheet laminator200further includes separation claws116between the winding roller109and the exit roller pair113. The separation claws116are movable in the width direction of the lamination sheet S. Note that the entrance roller pair108, the exit roller pair113, the winding roller109, and the separation claws116are some examples of a separation mechanism that separates the lamination sheet S. The pickup roller105, the conveyance roller pair107, the entrance roller pair108, and the winding roller109are some examples of a first feeder. A conveyance sensor C1that detects the conveyance position of the lamination sheet S is disposed downstream from the conveyance roller pair107in the conveyance direction. A conveyance sensor C3that detects the conveyance positions of the lamination sheet S and the inner sheet P is disposed downstream from the entrance roller pair108in the conveyance direction. An abnormal condition detection sensor C4that detects the condition of the lamination sheet S is disposed downstream from the winding roller109in the conveyance direction. A conveyance sensor C5that detects the conveyance position of the lamination sheet S is disposed downstream from the exit roller pair113in the conveyance direction. The relay conveyance path126is also provided with a conveyance sensor C2that detects the conveyance position of the lamination sheet S and the inner sheet P. The conveyance sensors C1to C5also serve as sheet detectors that detects whether the lamination sheet S and/or the inner sheet P is in the conveyance path. The conveyance sensors C1to C5are implemented by sensors such as optical sensors and ultrasonic sensors. The sheet laminator200includes determination sensors127serving as a sheet determination device that determines the type of a conveyed sheet on the conveyance path125. Details of the determination sensors127is described later. An operation panel10(so-called operation panel) and a power ON/OFF button are disposed on an exterior of the sheet laminator200. The operation panel10(so-called operation panel) is a notification device that displays information of a laminator main unit and inputs a processing instruction to the laminator main unit. The operation panel10also serves as a notification device that issues a perception signal to the user. The operation panel10may notify such a signal with, e.g., a liquid crystal panel or a liquid emitting diode (LED). For example, a buzzer may be separately provided as the notification device to perform notification by sound. Instead of the operation panel10, for example, a switch or a button may be disposed to input a processing instruction. FIG.3is a configuration diagram illustrating a main part of the sheet laminator illustrated inFIG.2. As illustrated inFIG.3, each of the entrance roller pair108and the exit roller pair113is, for example, two rollers paired with each other and driven by a driving device (e.g., a motor). The entrance roller pair108rotates in one direction. The exit roller pair113rotates in forward and reverse directions, thereby nipping and conveying the lamination sheet S and the inner sheet P. The entrance roller pair108conveys the lamination sheet S and the inner sheet P toward the exit roller pair113. The sheet conveyance direction indicated by arrow A inFIG.3is hereinafter referred to as a “forward conveyance direction” or a sheet conveyance direction A. The exit roller pair113is capable of switching the direction of rotation between the forward direction and the reverse direction. The exit roller pair113conveys the lamination sheet S nipped by the rollers of the exit roller pair113toward the ejection tray104(seeFIG.2) in the forward conveyance direction and also conveys the lamination sheet S toward the winding roller109in the direction opposite the forward conveyance direction (to convey the lamination sheet S in reverse). The sheet conveyance direction of the lamination sheet S toward the winding roller109(that is, the direction opposite the forward conveyance direction) indicated by arrow B inFIG.3is hereinafter referred to as a reverse conveyance direction or a sheet conveyance direction B. The sheet laminator200is provided with the winding roller109as a rotator and the separation claws116that are disposed between the entrance roller pair108and the exit roller pair113. The winding roller109is driven by a driver such as a motor to rotate in the forward and reverse directions. The direction of rotation of the winding roller109is switchable between the forward direction (clockwise direction) and the reverse direction (counterclockwise direction). A main controller500of the sheet laminator200causes the driver to control rotations of the winding roller109and operations of the separation claws116. The winding roller109includes a roller111and a sheet gripper110movably disposed on the roller111to grip the lamination sheet S. The sheet gripper110that is movable grips a trailing end of the lamination sheet S in the forward conveyance direction together with the roller111. The sheet gripper110may be formed on the outer circumference of the roller111as a single unit or may be formed as a separate unit. The main controller500causes a driver to move the sheet gripper110. Next, the separating operation of the lamination sheet S of the sheet laminator200is described with reference toFIGS.1to9. InFIGS.3to9, elements identical to those illustrated inFIG.1or2are given identical reference numerals, and the descriptions thereof are omitted. InFIG.2, the lamination sheets S are stacked on the sheet tray102such that the bonded side is on the downstream side in the direction of feeding (conveyance direction) of the pickup roller105. In the sheet laminator200, the pickup roller105picks up the lamination sheet S from the sheet tray102, and the conveyance roller pair107conveys the lamination sheet S toward the entrance roller pair108. Next, as illustrated inFIG.3, the entrance roller pair108conveys the lamination sheet S toward the winding roller109. In the sheet laminator200, the entrance roller pair108conveys the lamination sheet S with the bonded end, which is one of four sides of the lamination sheet S, as the downstream side in the forward conveyance direction A as indicated by arrow A inFIG.2. The sheet laminator200temporarily stops conveyance of the lamination sheet S when the trailing end of the lamination sheet S in the forward conveyance direction has passed the winding roller109. Note that these operations are performed by conveying the lamination sheet S from the lamination sheet sensor C3by a specified amount in response to the timing at which the lamination sheet sensor C3detected the leading end of the lamination sheet S. Next, as illustrated inFIG.4, the main controller500of the sheet laminator200causes the sheet gripper110to open and the exit roller pair113to rotate in the reverse direction to convey the lamination sheet S in the reverse conveyance direction (sheet conveyance direction B) toward the opened portion of the sheet gripper110. Subsequently, as illustrated inFIG.5, the main controller500of the sheet laminator200causes the exit roller pair113to stop rotating to stop conveyance of the lamination sheet S when the end of the lamination sheet S is inserted into the opened portion of the sheet gripper110and causes the driver to close the sheet gripper110to grip the end of the lamination sheet S. Note that these operations are performed when the lamination sheet S is conveyed by the specified amount. Then, as illustrated inFIG.6, the main controller500of the sheet laminator200causes the driver to rotate the winding roller109in the counterclockwise direction inFIG.6to wind the lamination sheet S around the winding roller109. The lamination sheet S is wound around the winding roller109from the side where the two overlapping sheets of the lamination sheet S are not bonded. As illustrated inFIG.7A, when the lamination sheet S that is the two-ply sheet is wound around the winding roller109, a winding circumferential length difference is created between the two sheets in the amount of winding of the lamination sheet S around the circumference of the winding roller109. There is a surplus of the sheet on the inner circumferential side to the center of the winding roller109, which generates a slack toward the bonded end. As a result, a space is created between the two sheets constructing the two-ply sheet. As illustrated inFIG.7B, as the separation claws116are inserted into the space generated as described above, from both sides of the lamination sheet S, the space between the two sheets is reliably maintained. Note that in response to detection of the leading end of the lamination sheet S with the conveyance sensor C5, the lamination sheet S is conveyed from the conveyance sensor C5by a designated amount to perform these operations. In the sheet laminator200, the winding roller109is rotated clockwise in a state where the separation claws116are inserted into the space formed in the lamination sheet S (seeFIG.7B). As illustrated inFIG.8A, the main controller500causes the space generated in the lamination sheet S to shift to the trailing end of the lamination sheet S in the forward conveyance direction (sheet conveyance direction A). After the winding roller109has been rotated by a specified amount, the main controller500causes the driver to open the sheet gripper110. As a result, the trailing end of the lamination sheet S is separated into the upper and lower sheets (seeFIG.8B). In this state, the main controller500of the sheet laminator200causes the driver to temporarily stop the conveyance of the lamination sheet S and to further move the separation claws116in the width direction of the lamination sheet S to separate the whole area of the trailing end of the lamination sheet S. Note that in response to detection of the leading end of the lamination sheet S with the conveyance sensor C5, the lamination sheet S is conveyed from the conveyance sensor C5by a designated amount to perform these operations. As illustrated inFIG.9, after the separation claws116have separated the whole area of the trailing end of the lamination sheet S, the main controller500causes the driver to rotate the exit roller pair113in the counterclockwise direction inFIG.9to convey the lamination sheet S in the reverse conveyance direction (sheet conveyance direction B). Then, the separation claws116guide the two separated sheets of the lamination sheet S in the upper and lower directions, respectively, and the sheets are fully separated. The main controller500of the sheet laminator200causes the driver to temporarily stop the conveyance of the lamination sheet S, so that the bonded portion of the lamination sheet S is held (nipped) by the exit roller pair113. Accordingly, one end of the lamination sheet S is bonded as the bonded side of the lamination sheet S and the other end of the lamination sheet S is opened largely. Note that in response to detection of the leading end of the lamination sheet S with the conveyance sensor C5, the lamination sheet S is conveyed from the conveyance sensor C5by a designated amount to perform these operations. A series of operations starting from the conveyance of the lamination sheet S up to this point is referred to as “separation operation”. A description is given below of a configuration of a sheet laminator according to an embodiment of the present disclosure. A first embodiment is described below. A sheet laminator200according to the present embodiment is capable of loading at least one of a two-ply sheet (lamination sheet S) and a sheet medium (inner sheet P) on a sheet tray102, and has a “mixing mode” in which the lamination sheet S or the inner sheet P is fed one by one. The mixing mode is a mode in which a two-ply sheet (e.g., a lamination sheet S) and a sheet medium (e.g., an inner sheet P) are fed from the sheet tray102of the sheet laminator200, the sheet medium (inner sheet P) is sandwiched between separated sheets of the two-ply sheet (e.g., the lamination sheet S), and lamination is performed by the heat pressing rollers120. The mixing mode corresponds to a third mode according to an embodiment o the present disclosure. Thus, an automatic off-line mode for performing lamination by the sheet laminator can be selected, thus enhancing the convenience of the user. During this period, since it is not necessary to discharge the inner sheet P, the operation of the image forming apparatus300is stopped. Thus, the image forming apparatus does not operate as an image forming apparatus main in the off-line mode, thereby contributing to energy saving. When the mixing mode is executed, not only the lamination sheet S but also the inner sheet P can be fed from the sheet tray102. Accordingly, as the inner sheet P, not only a sheet (serving as a medium) printed by the image forming apparatus300but also a sheet (serving as a medium) loaded on the sheet tray102can be used. When the mixing mode is executed, which of the lamination sheet S and the inner sheet P is fed from the sheet tray102is determined. Accordingly, as illustrated inFIG.2, the sheet laminator200according to the present embodiment includes the determination sensors127that determine the type of the conveyed sheet on the conveyance path125. FIGS.10A and10Bare schematic diagrams illustrating a configuration of determination sensors according to an embodiment of the present disclosure. The determination sensors127serving as a sheet determination device are a pair of ultrasonic sensors, one of which includes an ultrasonic wave transmitter and the other of which includes an ultrasonic wave receiver. The type of a sheet (a two-ply sheet or a sheet medium) can be determined by the reduction amount of the ultrasonic wave when the sheet passes between the determination sensors127. For example, (a) when a two-ply sheet (e.g., a lamination sheet S) passes, the reduction amount of the ultrasonic wave is relatively large since an air layer exists between separated sheets of the two-ply sheet. By contrast, (b) when the inner sheet P passes, the reduction amount of the ultrasonic wave is relatively small since the inner sheet P is one sheet. Accordingly, the type of the sheet conveyed from the sheet tray102can be determined using the determination sensors127. In the sheet laminator200according to the present embodiment, the main controller500changes the lamination processing (sheet processing) according to the determination result of the determination sensors127. Next, the sheet processing (lamination processing) in performing the mixing mode is described in detail. Example 1 FIG.11is a schematic view of the sheet laminator200that executes the mixing mode in a state in which a lamination sheet S already separated is present in the sheet laminator200. Lamination sheets S and inner sheets P are loaded on the sheet tray102, and the sheet detectors (conveyance sensors C1to C5) detect a lamination sheet S already separated on the conveyance path of a laminator body. Here, it is assumed that an inner sheet P is fed newly (as a first sheet) from the sheet tray102when the mixing mode is executed. In such a case, the sheet laminator200determines the sheet type as a sheet medium by the determination sensors127and inserts the inner sheet P into the already separated portions of the lamination sheet S. For example, as illustrated inFIG.12, the sheet laminator200rotates the entrance roller pair108to convey the inner sheet P conveyed from the sheet tray102(seeFIG.11) toward the exit roller pair113in the forward conveying direction (sheet conveyance direction A). Subsequently, as illustrated inFIGS.13and14, the main controller500of the sheet laminator200causes the exit roller pair113to rotate so that the lamination sheet S and the inner sheet P meet to insert the inner sheet P into the lamination sheet S from the open portion (on the other end) of the lamination sheet S. This series of operations starting from the conveyance of the inner sheet P is referred to as an “inserting operation”. The lamination sheet S sandwiching the inner sheet P is subsequently subjected to lamination processing (or is not subjected to lamination processing), and is then ejected to the ejection tray104. Example 2 FIG.15is also a schematic view of the sheet laminator200during execution of the mixing mode in a state in which a lamination sheet S already separated is present in the laminator body. As inFIG.11, lamination sheets S and inner sheets P are loaded on the sheet tray102, and a lamination sheet S that has already been separated is present on the conveyance path in the laminator body. Here, it is assumed that a lamination sheet S1(two-ply sheet) is fed newly (as a first sheet) from the sheet tray102when the mixing mode is executed. In such a case, when the sheet type is determined to be a two-ply sheet by the determination sensors127, the sheet laminator200ejects the lamination sheet S in the laminator body and newly separates the lamination sheet S1. Such a configuration can prevent a plurality of two-ply sheets from being mixed in the sheet laminator200and obviate the need for the user to remove the lamination sheet S in the sheet laminator200, thus preventing occurrence of a downtime. Alternatively, the pickup roller105and the conveyance roller pair107may be configured to be rotatable in the forward and reverse directions, and the lamination sheet S1may be conveyed in the reverse direction and returned to the sheet tray102. In such a case, the user only needs to remove the lamination sheet S1from the sheet tray102, and the operation time can be shortened. As another alternative, when the sheet type is determined to be a two-ply sheet in execution of the mixed mode, feeding of a new lamination sheet S1may be stopped to terminate the mixed mode, and an inner sheet P conveyed from the image forming apparatus300may be inserted into the lamination sheet S in the sheet laminator200. Example 3 FIG.16is a schematic view of the sheet laminator200that executes the mixing mode in a state in which a lamination sheet S already separated is absent in the sheet laminator200.FIG.16is different fromFIGS.11and15in that the sheet detectors (conveyance sensors C1to C5) do not detect already-separated portions of the lamination sheet S on the conveyance path of the laminator body (in other words, there is no separated sheet). Here, it is assumed that an inner sheet P is fed newly (as a first sheet) from the sheet tray102when the mixing mode is executed. In such a case, when the sheet type is an inner sheet (sheet medium) by the determination sensors127, the sheet laminator200ejects the inner sheet P as it is (seeFIG.17). Accordingly, even if an inner sheet P is fed by mistake before the lamination sheet S (two-ply sheet) is separated, the processing is not interrupted, thus preventing occurrence of downtime. FIG.18is a flowchart illustrating a series of steps of lamination processing in the mixing mode. A description is given below of the series of steps with reference toFIG.22. In step S101, the main controller500of the sheet laminator200determines the type of a sheet fed from the sheet tray102with the determination sensors127. If the sheet type is a lamination sheet (two-ply sheet S1) (YES in step S101), the process proceeds to step S102. In step S102, the main controller500of the sheet laminator200determines, with the conveyance sensors C1to C5, whether a lamination sheet S that has already been separated is present on the conveyance path of the laminator body. When the lamination sheet S is present (YES in step S102), in step S103, the sheet laminator200ejects the separated sheet (Example 2; seeFIG.15). Then, the process proceeds to step S104. When there is no lamination sheet S on the conveyance path of the laminator body in step S102(NO in step S102), the process also proceeds to step S104. In step S104, the sheet laminator200winds the fed lamination sheet S1around the winding roller109(seeFIGS.5and6). In step S105, the sheet laminator200separates the entire two sheets of the lamination sheet S1from each other (seeFIG.9). After the completion of step S105, the sheet laminator200is in a state in which the already-separated sheet S1is present in the laminator body. Then, the process returns to step S101again. In step S101, when the sheet type is a sheet medium (inner sheet P) (NO in step S101), the process proceeds to step S106. In step S106, the main controller500of the sheet laminator200determines, with the conveyance sensors C1to C5, whether a lamination sheet S that has already been separated is present on the conveyance path of the laminator body. When the lamination sheet S (or the lamination sheet S1) is present (YES in step S102), in step S107, the main controller500of the sheet laminator200performs the inserting operation and the ejecting operation of the inner sheet P (Example 1; seeFIGS.12to14). Thus, a series of steps of sheet processing (lamination processing) is completed. When the main controller500of the sheet laminator200determines in step S106that no lamination sheet S (or a lamination sheet S2) is present on the conveyance path of the laminator body (NO in step S106), the process proceeds to step S108. The sheet laminator200ejects the inner sheet P as it is (Example 3; seeFIG.17). After completion of step S108, the sheet laminator200is in a state in which there is no lamination sheet S1that has already been separated in the laminator body. Then, the process returns to step S101again to wait for feeding again. As described above, in the sheet laminator200according to the present embodiment, the main controller500changes the lamination processing (sheet processing) according to the determination result of the sheet determination device and the detection result of the sheet detector when the mixing mode is executed. Accordingly, both types of sheets, in other words, lamination sheets S and inner sheets P can be mixed on the sheet tray102, and the number of types of insertable inner sheets can be increased. In addition, the need for increasing the size of the sheet laminator can be obviated. A description is given below of an advantageous configuration of the sheet laminator200. When the sheet laminator200determines that a first conveyed sheet and a second conveyed sheet are of the same sheet type in the mixed mode, it is desirable to change the lamination processing (sheet processing). For example, when both the first sheet and the second sheet are two-ply sheets (S1and S2), the main controller500stops the conveyance of both two-ply sheets (S1and S2) as error processing. Such a configuration can prevent the two-ply sheets from being jammed in the sheet laminator200. When both the first sheet and the second sheet are two-ply sheets (S1and S2), the first sheet S1is separated while the second sheet S2is reversely conveyed and returned to the sheet tray102. Such a configuration can prevent the two-ply sheets from being jammed and facilitate the subsequent processing. A second embodiment is described below. A sheet laminator according to a second embodiment has a feature in which an operation panel10serving as a notification device indicates the type of sheets loaded on a sheet tray102to the user and guides the user to perform a correct operation. FIG.19is an example of a screen displayed on the operation panel to prompt loading of a lamination film on the sheet tray.FIG.20is an example of a screen displayed on the operation panel to prompt loading of an inner sheet on the sheet tray. In the mixing mode, a screen as illustrated inFIG.19orFIG.20is displayed on the operation panel10to prompt the user to load a lamination film (two-ply sheet) or an inner sheet (sheet medium). This mode is referred to as a manual lamination mode in that the mode prompts the user to perform work. When the user loads sheets as instructed on the screen on the sheet tray102and touches (presses) an area displayed as “OK”, the sheet laminator200starts a series of steps of lamination processing. However, when the user touches (or presses) an area displayed as “OK” without loading the sheet as instructed on the screen onto the sheet tray102, an error screen as illustrated inFIG.21is displayed on the operation panel10to prompt the user to confirm. The type of the loaded sheets is determined by the determination sensors127(seeFIGS.2and10) serving as the sheet determination device described above. A dedicated sensor may be separately provided. FIG.22is a flowchart illustrating a series of steps of lamination processing in the mixing mode as the third mode and the manual lamination mode. A description is given below of the series of steps with reference toFIG.22. In step S201, the main controller500of the sheet laminator200determines whether a lamination sheet S that has already been separated is present on the conveyance path of the laminator body. When the lamination sheet S is present (YES in step S201), in step S202, the main controller500of the sheet laminator200displays, on the operation panel10, a screen for prompting loading of inner sheets on the sheet tray102(seeFIG.19). In step S203, the main controller500waits for the user to load an inner sheet P on the sheet tray102and instruct the start of the lamination processing. In step S204, the main controller500of the sheet laminator200determines whether the sheet type is a lamination sheet (two-ply sheet S). When the sheet is a lamination sheet (YES in step S204), the process proceeds to step S205. The main controller500of the sheet laminator200displays an error screen for prompting sheet removal on the operation panel10(seeFIG.21). In step S206, the user removes the lamination sheet. On the other hand, in step S204, when the sheet type is an inner sheet (NO in step S204), the process proceeds to step S207. The sheet laminator200performs the inserting operation of the inner sheet. After the operation is completed, the process proceeds to step S208, and the sheet is ejected. In the previous step S201, if there is no sheet S that has already been separated on the conveyance path of the laminator body, in step S209, the main controller500of the sheet laminator200displays on the operation panel10a screen for prompting loading of a lamination sheet on the sheet tray102(seeFIG.20). In step S210, the main controller500waits for the user to load a lamination sheet S on the sheet tray102and instruct the start of the lamination processing. In step S211, the main controller500of the sheet laminator200determines whether the sheet type is a lamination sheet (two-ply sheet S). When the sheet is a lamination sheet (YES in step S211), the process proceeds to step S212. The sheet laminator200performs separating operation. Then, the process returns to step S201. By contrast, in step S211, when the sheet type is an inner sheet (NO in step S211), the process proceeds to step S213. The main controller500of the sheet laminator200displays an error screen for prompting sheet removal on the operation panel10(refer toFIG.21). In step S214, the main controller500waits for the user to remove the lamination sheet. As described above, in the sheet laminator200according to the present embodiment, the user can load a lamination sheet or an inner sheet as the manual lamination mode when the mixing mode is executed. In such a case, since a message is displayed on the operation panel10, the user can be guided to the correct operation. A third embodiment is described below. FIG.23is a schematic view illustrating an overall configuration of a sheet laminator according to an embodiment of the present disclosure. In a sheet laminator200baccording to the present embodiment, the sheet tray102is provided with a size sensor C6that is a size detector to detect the size of the sheet being conveyed (or the length of the conveyed sheet in the conveyance direction). In other words, the sheet laminator200bcan detect the conveyance direction length Ls of a lamination sheet S and the conveyance direction length Lp of an inner sheet P using the size sensor C6. In the sheet laminator200baccording to the present embodiment, a size comparator of a main controller500that controls the entire operation of the sheet laminator200bcan compare the conveyance direction length Ls of the lamination sheet S and the conveyance direction length Lp of the inner sheet P. The main controller500is configured by a computer including, for example, a central processing unit (CPU), a read-only memory (ROM), a random access memory (RAM), and an input/output (I/O). The size comparator is software implemented in the computer. In the mixed mode, when the separated lamination sheet S is present on the conveyance path of the laminator body and the detected conveyance direction length Lp of the inner sheet P falls within the conveyance direction length Ls of the lamination sheet S (Ls>Lp), the sheet laminator200bperforms the inserting operation of the inner sheet P. However, in a case where the inner sheet P does not fall within the lamination sheet S (Ls>Lp), the main controller500stops the conveyance of the inner sheet P at that time and performs error processing. As illustrated inFIG.24, when a plurality of inner sheets are fed and the sum (P1+P2) of the conveyance direction lengths of inner sheets Lp1and Lp2falls within the conveyance direction length Ls of the lamination sheet S (Ls>Lp1+Lp2), the sheet laminator200inserts the inner sheets P1and P2. By contrast, if the inner sheets P1and P2do not fall within the lamination sheet S (Ls>Lp1+Lp2), the main controller500stops the conveyance of the inner sheets P1and P2at that time and performs error processing. In a case where only the inner sheet P1has a size that falls within the lamination sheet S (Ls>Lp1), only the inner sheet P1may be inserted into the lamination sheet S, and the main controller500may stop the conveyance of the inner sheet P2and perform error processing. An inner sheet(s) (inner sheet P2or both inner sheets P1and P2) may be reversely conveyed and returned to the sheet tray102. In such a case, the user only needs to acquire an inner sheet(s) (inner sheet P2or both inner sheets P1and P2) from the sheet tray102, thus facilitating subsequent processing. As described above, the sheet laminator200baccording to the present embodiment detects the conveyance direction length of a conveyed sheet by the size sensor C6, and changes the lamination processing (sheet processing) according to the comparison result of the size comparator. Accordingly, a plurality of inner sheets P can be appropriately inserted into the lamination sheet S. As the size detector, the conveyance sensor C1can be used to detect the size of the sheet at the detection timing. Alternatively, an encoder of a motor that rotates the conveyance roller pair107may be used. Further, the size sensor C6, the conveyance sensor C1, and the encoder may be used in combination. Next, the first mode according to an embodiment of the present disclosure is described with reference toFIGS.1and12to14. The first mode is a mode in which, in the image forming system400, a sheet medium (e.g., an inner sheet P) on which an image has been formed by the image forming apparatus300is sandwiched between separated sheets of a two-ply sheet (e.g., an lamination sheet S) by the sheet processing apparatus or the sheet laminator200, and lamination processing is performed by a heat presser (e.g., the heat pressing rollers120) An inner sheet P is stored in at least one of the plurality of feeding units5of the image forming apparatus300inFIG.1. When the first mode is executed, first, the inner sheet P is fed, printing is performed by the image forming unit4of the image forming apparatus300, and an image is fixed by the heat fixing unit3. Thereafter, the inner sheet P passes through the conveyance path in the image forming apparatus300and is conveyed to the relay conveyance path126of the sheet laminator200. Thereafter, as illustrated inFIG.12, the inner sheet P is conveyed toward the inside of the lamination sheet S separated, and as illustrated inFIGS.13and14, the inner sheet P is merged with the lamination sheet S and sandwiched between the separated sheets of the lamination sheet S. The lamination sheet S sandwiching the inner sheet P is laminated by heating and pressing of the heat pressing rollers120and is then ejected to the ejection tray104. Here, an operation device for the user to select the first mode, the second mode, and the third mode is described with reference toFIGS.25to27. As illustrated inFIG.25, the sheet laminator200or the image forming apparatus300includes a rotary switch150. The user rotates the rotary switch150to select the first mode, the second mode, or the third mode. Instead of the rotary switch150, three buttons corresponding to the respective modes may be provided. The switch or buttons allow the user to easily switch the mode among the first mode, the second mode, and the third mode. As illustrated inFIG.26, instead of or in addition to the rotary switch150, the operation panel10is installed in the sheet laminator200or the image forming apparatus300. The user touches the operation panel10to select the first mode, the second mode, or the third mode. Switching on the operation panel10allows the user to easily switch the mode among the first mode, the second mode, and the third mode. The main controller500of the sheet laminator200controls, for example, the heat pressing rollers120and the image forming apparatus300to perform the first mode, the second mode, or the third mode in accordance with the selection on the operation panel10. The controller that performs the control of the first mode, the second mode, and the third mode is not limited to the main controller500of the sheet laminator200and may be any other controller of the image forming system400. For example, a controller of the image forming apparatus300may perform the control of the first mode, the second mode, or the third mode in accordance with the selection on the operation panel10. As illustrated inFIG.27, instead of or in addition to the rotary switch150and the operation panel10, a microphone160as an audio input mechanism is connected to the sheet laminator200or the image forming apparatus300. When the user inputs voice to the microphone160, the voice is transmitted to the main controller500of, for example, the sheet laminator200, and each mode can be selected. Switching by voice input allows the user to easily switch the first mode, the second mode, or the third mode. Next, the second mode according to an embodiment of the present disclosure is described with reference toFIGS.28to33. The second mode is a mode in which the image forming system400performs lamination processing on a sheet set (hereinafter also referred to as an inner-sheet set sheet PS) in which a user sandwiches a sheet medium (e.g., an inner sheet P) between separates sheets of a two-ply sheet (e.g., the lamination sheet S). Accordingly, the user can select a mode in which the inner-sheet set sheet PS is fed in an off-line manner. In the sheet laminator200, an operation in a case where the inner-sheet set sheet PS is fed in the second mode is described below. First, a description is given of an embodiment for setting an operation content according to the type, size, and the like of a sheet fed in the second mode in the sheet laminator200. FIGS.28A,28B, and28Care diagrams illustrating the operation panel10as an operation device for the user to perform sheet feed setting. The operation panel10illustrated inFIG.28Ahas, as adjustment items of “sheet feed setting”, film-sheet thickness (in this example, “thick” is selected), inner-sheet thickness (in this example, “plain sheet” is selected), film-sheet size (in this example, “A4” is selected), lamination temperature (in this example, “high” temperature is selected), and lamination speed (in this example, “low” speed is selected). The operation panel10illustrated inFIG.28Ballows the user to set the details of the sheet feed setting and finely adjust values such as film-sheet thickness (μm), inner-sheet thickness (basis weight), film-sheet size (vertical), film-sheet size (horizontal), lamination temperature (° C.), and lamination speed (mm/s) in unit of steps. In the operation panel10ofFIG.28C, in the second mode, the user can set the thickness of the inner-sheet set sheet PS on the operation panel10. In this example, as illustrated inFIG.28A, the sheet thickness is not divided into the inner-sheet thickness and the film-sheet thickness, and only the adjustment item of “sheet-set thickness” is provided (in this example, “thick” is selected). In other words, the user can roughly select the thickness of the entire inner-sheet set sheet PS. According to the embodiment illustrated inFIGS.28A to28C, in the second mode, the user can set the thickness of the inner-sheet set sheet PS on the operation panel10. Accordingly, not only the setting of the film-sheet thickness but also the inner-sheet set sheet considering the inner-sheet thickness can be dealt with, and the proper lamination temperature setting can be performed. According to the embodiment illustrated inFIGS.28A to28C, in the second mode, the user can set the temperature of the lamination processing using the operation panel10. Thus, the temperature setting can be easily performed with the operation panel10. According to the embodiment illustrated inFIGS.28A to28C, in the second mode, the user can set the processing speed of the lamination processing using the operation panel10. Thus, the speed setting can be easily performed with the operation panel10. FIGS.29A and29Bare diagrams illustrating another operation device for the user to perform the sheet feed setting. In this example, the sheet laminator200or the image forming apparatus300includes a rotation knob151(FIG.29A) or a switch, and a slide knob152(FIG.29B) instead of the operation panel. The user can adjust the adjustment items using the rotation knob151and the slide knob152. In this example, the rotation knob151selects the lamination speed (“low speed”, “middle speed”, and “high speed”). However, a rotation knob is also provided to select other adjustment items such as the thickness of the inner-sheet set sheet PS. In this example, the slide knob152selects the lamination temperature (“low temperature”, “middle temperature”, and “high temperature”). However, a slide knob is also provided to select other adjustment items such as the thickness of the inner-sheet set sheet PS. Alternatively, a microphone160as an operation device illustrated inFIG.27may be connected to the sheet laminator200or the image forming apparatus300, and may be set by voice input. According to the embodiment ofFIG.29B, in the second mode, the user can set the temperature of the lamination processing with the knob. Thus, the temperature setting can be easily performed with the knob. According to the embodiment ofFIG.29A, in the second mode, the user can set the processing speed of the lamination processing with the knob. Thus, the speed setting can be easily performed with the knob. Next, the operation of the sheet laminator200in the second mode is described below. As illustrated inFIG.30, the sheet laminator200feeds an inner-sheet set sheet PS set on the sheet tray102. Here, the speed at which the inner-sheet set sheet PS is fed and conveyed is a speed determined in advance based on a combination of items of “sheet feed setting”. After the inner-sheet set sheet PS is conveyed into the sheet laminator200, as illustrated inFIG.31, the inner-sheet set sheet PS is conveyed as it is without being separated by a separation mechanism including, for example, the separation claws116, and as illustrated inFIG.32, lamination processing is performed by the heat pressing rollers120. At this time, the speed and temperature of the lamination processing with the heat pressing rollers120follow the “sheet feed setting”. In the manual off-line mode of the inner-sheet set sheet PS, the inner-sheet set sheet PS only passes through the separation mechanism. During this period, since it is not necessary to eject the inner sheet P, the operation of the image forming apparatus300is stopped. Thus, the image forming apparatus does not operate as an image forming apparatus main in the off-line mode, thereby contributing to energy saving. Next, a description is given of an embodiment of a process for newly feeding an inner-sheet set sheet PS when there is a separated lamination sheet S in the sheet laminator200in the second mode. As illustrated inFIG.33, the lamination sheet S already present in the sheet laminator200at the time of feeding a new inner-sheet set sheet PS is ejected as it is by the rotation of the exit roller pair113. Such a configuration can obviate the need for the user to remove an excess lamination sheet S in the sheet laminator200, thereby eliminating downtime associated with the removal operation. Whether the lamination sheet S already exists in the sheet laminator may be determined by combining any two or more of the conveyance sensors C1to C5in the sheet laminator200. As described above, the image forming system400according to the above-described embodiments of the present disclosure has a first mode in which a printed inner sheet P are fed in-line from the image forming apparatus300, set between separated sheets of a two-ply sheet (lamination sheet S), and laminated by the heat pressing rollers120, a third mode in which an inner sheet P is fed off-line from the sheet tray102and laminated by the heat pressing rollers120, and a second mode in which an inner-sheet set sheet PS is fed off-line from the sheet tray102and laminated by the heat pressing rollers120. The image forming system400can switch the mode among the first mode, the second mode, and the third mode. In the second mode, even if the inner sheet P has a shape or a type that cannot be fed from the sheet tray, the user can off-line feed the inner sheet P set as the two-ply sheet S. Accordingly, since the image forming system400can function as a laminator that executes only the lamination processing, it is not necessary to prepare a dedicated laminator. Although the sheet laminator has been mainly described above as an embodiment, embodiments of the present disclosure are not limited to the sheet laminator. A similar configuration can be applied to a sheet processing apparatus in which the heat pressing rollers120as a heat presser and the ejection roller121disposed downstream from the heat pressing rollers120are removed from the sheet laminator200. The sheet processing apparatus can perform a separating operation and an inserting operation of an inner sheet as sheet processing. The image forming apparatus300illustrated inFIG.1may include a sheet processing apparatus instead of the sheet laminator. Further, an image forming system according to an embodiment of the present disclosure may include an image forming apparatus300and one of a sheet processing apparatus or a sheet laminator200detachably attached to the image forming apparatus300. An image forming system according to another embodiment of the present disclosure may further include, for example, at least one of a sheet feeder (a stacker) or a case binding device. The image forming apparatus300uses an electrophotographic method as a method of forming an image, but is not limited thereto, and may use an image forming method such as an inkjet method or a stencil printing method. In some embodiments, the operation panel10may be provided on the image forming apparatus300instead of the exterior of the sheet laminator200. Although the present disclosure has been described in detail with reference to several embodiments, such embodiments are merely examples, and various modifications may be made without departing from the scope of the present disclosure. For example, some embodiments and advantageous configurations may be combined with each other. The above-described embodiments are illustrative and do not limit the present disclosure. Thus, numerous additional modifications and variations are possible in light of the above teachings. For example, elements and features of different illustrative embodiments may be combined with each other and substituted for each other within the scope of the present disclosure. Any one of the above-described operations may be performed in various other ways, for example, in an order different from the one described above. Each of the functions of the described embodiments may be implemented by one or more processing circuits or circuitry. Processing circuitry includes a programmed processor, as a processor includes circuitry. A processing circuit also includes devices such as an application specific integrated circuit (ASIC), digital signal processor (DSP), field programmable gate array (FPGA), and conventional circuit components arranged to perform the recited functions. | 52,028 |
11858288 | DETAILED DESCRIPTION The following detailed description of example implementations refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements. The following description uses a spectrometer as an example. However, the techniques, principles, procedures, and methods described herein may be used with any sensor, including but not limited to other optical sensors and spectral sensors. In some cases, a document, such as paper currency, may include one or more optical security features, such as a watermark or a pattern printed with color shifting ink, on a region of the document. A person may inspect, or may use a validation device, to analyze the document to determine that the one or more optical security features are present in the security article. Based on identifying the one or more optical security features, the person, or the validation device, may determine that the document is genuine. For example, a person may view a watermark in a dollar bill and may conclude that the dollar bill is not counterfeit. However, as advanced printing technology becomes more widely available (e.g., beyond government organizations or security-providing companies), an optical security feature may be able to be reproduced (or a facsimile optical feature that appears to be similar to the optical feature may be produced), which enables counterfeiting of the document and increases a likelihood that the counterfeit document is deemed legitimate. Further, in some cases, a document, such as a transaction card, may include an integrated circuitry (IC) chip that includes information associated with the document. A person may use a chip reader transaction device that reads the IC chip (e.g., by applying current to the IC chip and capturing one or more electronic measurements associated with the IC chip) to determine authentication information included in the IC chip, which the chip reader transaction devices uses to validate the IC chip and the document. However, the interaction between the IC chip and the chip reader transaction device is subject to interception vulnerabilities (e.g., by card skimmer devices), which enables the IC chip to be reproduced in a counterfeit document and/or for authentication information included in the IC chip to be used in future fraudulent transactions. Some implementations described herein provide a security article that includes an optical component with a plurality of optical channels. An optical channel, of the plurality of optical channels, may be configured to pass a first portion of a first set of light beams (that are associated with a first wavelength range) when the first set of light beams falls incident on at least one of a first surface or a second surface of the optical channel, reflect a second portion of the first set of light beams when the first set of light beams falls incident on the first surface of the optical channel, and reflect at least a portion of a second set of light beams (that are associated with a second wavelength range) when the second set of light beams falls incident on the second surface of the optical channel. In this way, the optical channel may have one or more optical characteristics, such as a reflection characteristic associated with the first side of the optical channel, a transmission characteristic associated with the optical channel, and/or a reflection characteristic associated with a second side of the optical channel. Accordingly, the optical component may be configured to include a plurality of optical channels with particular sets of optical characteristics that can be used to uniquely identify the optical component and/or the security article in which the optical component is included. Some implementations described herein provide a security article reader system that may read the optical component of the security article. The security article reader system may include a first light emission device configured to emit a first set of light beams toward a first surface of the optical component of the security article (e.g., when the security article is placed within an interrogation area of the security article reader system) and a second light emission device configured to emit a second set of light beams toward a second surface of the optical component of the security article (e.g., when the security article is placed within the interrogation area of the security article reader system). The security article reader system may include a plurality of sensor elements configured to generate sensor data associated with the plurality of optical channels included within the optical component of the security article (e.g., when at least some of the first set of light beams or at least some of the second set of light beams are received by the plurality of sensor elements after being transmitted or being reflected by the plurality of optical channels). The security article reader system may include one or more or more processors that are configured to determine, based on the sensor data, one or more respective optical characteristics of the plurality of optical channels and thereby determine identification information associated with the optical component. The one or more processors then may validate (or invalidate) the optical component and/or security article based on the identification information. In this way, some implementations allow for an optical component that can represent unique information based on the optical characteristics of the plurality of optical channels included in the optical component. The representation of the information by the optical component has an increased complexity as compared to a digital bit representation by a conventional IC chip, making duplication of a counterfeit optical component difficult. Further, using optical characteristics to represent information reduces a likelihood that a card skimmer device (or any other type of man-in-the-middle device) is able to read or replicate the information during a legitimate transaction without altering or obscuring the optical characteristics that are to be read by a security article reader system. In this way, a facsimile optical component is harder to produce, which reduces a likelihood of counterfeiting of the security article that includes the optical component. Accordingly, use of technical resources, such as computing resources (e.g., processing resources, memory resources, communication resources, and/or power resources, among other examples) to investigate counterfeiting, scan potentially counterfeit security articles, identify counterfeit security articles, and/or analyze security articles, among other examples may be reduced. FIGS.1A-1Bare diagrams of example configurations of an optical channel100described herein. The optical channel100may be included in an optical component (e.g., optical component202described below in relation toFIGS.2A-2Cand/or optical component404described below in relation toFIGS.4A-4D). As shown inFIGS.1A-1B, the optical channel100may include a first mirror102, a spacer104, a second mirror106, and/or an absorber layer108. As shown inFIG.1A, the first mirror102and/or the second mirror106may each include a dielectric mirror. For example, the first mirror102and/or the second mirror106may each include a set of alternating dielectric layers, such as an alternating set of hydrogenated silicon layers and silicon dioxide layers. Alternatively, as shown inFIG.1B, the first mirror102and/or the second mirror106may each include a metallic mirror, such as a silver mirror. As further shown inFIGS.1A-1B, the spacer104be disposed between the first mirror102and the second mirror106(e.g., the spacer104may disposed on the first mirror102and the second mirror106may be disposed on the spacer104). In some implementations, the spacer104may comprise one or more spacer layers (e.g., as described in more detail herein in relation toFIGS.2B-2C). In some implementations, a thickness of the spacer104may be configured to provide a particular distance between the first mirror102and the second mirror106to cause the optical channel100to pass light associated with a particular wavelength range (e.g., to pass light that has a wavelength that is greater than or equal to a lower bound of the particular wavelength range and that is less than an upper bound of the particular wavelength range). As further shown inFIGS.1A-1B, the absorber layer108may be disposed on the second mirror106(e.g., a surface of the second mirror106that is opposite the surface of the second mirror106that is disposed on the spacer104). For example, as shown inFIGS.1A-1B, the absorber layer108may be disposed on a top surface of the second mirror106. Accordingly, a surface (e.g., a top surface) of the optical channel100may include a surface (e.g., a top surface) of the absorber layer108. The absorber layer108may include a material comprising germanium, silicon, amorphous silicon, silicon-germanium, a metallic oxide, a telluride, a sulfide, an arsenide, a phosphide, and/or an antimonide, among other examples. In some implementations, a thickness of the absorber layer108may be configured to cause a portion of light that falls incident on the absorber layer108to be absorbed by the absorber layer108and another portion of the light to pass through the absorber layer108. Additionally, or alternatively, the thickness of the absorber layer108may be configured to cause the optical channel100to have a Fano resonance characteristic. For example, when light that is associated with a particular wavelength range falls incident on the surface (e.g., the top surface) of the optical channel100, the absorber layer108may have a particular thickness to cause the optical channel100to pass a first portion of the light (e.g. through the optical channel100from the top surface of the optical channel100to a bottom surface of the optical channel100) and to reflect a second portion of the light (e.g., at the top surface of the of the optical channel100). In a specific example, when visible light (e.g., red-green-blue (RGB) light) falls incident on the surface (e.g., the top surface) of the optical channel100, the absorber layer108may have a particular thickness to cause the optical channel100to pass a first portion of green light included in the visible light (e.g. through the optical channel100from the top surface of the optical channel100to the bottom surface of the optical channel100) and to reflect a second portion of the green light included in the visible light (e.g., at the top surface of the of the optical channel100). In some implementations, another surface of the optical channel100(e.g., that does not include a surface of the absorber layer108) may reflect light associated with a one or more different wavelength ranges (e.g., that do not overlap with the particular wavelength range described above). For example, when broadband light that is associated with the particular wavelength range and the one or more different wavelength ranges falls incident on the other surface (e.g., the bottom surface) of the optical channel100, the optical channel100may pass at least a portion of light associated with the particular wavelength range that is included in the broadband light (e.g. through the optical channel100from the bottom surface of the optical channel100to the top surface of the optical channel100) and may reflect at least a portion of light associated with the one or more different wavelength ranges (e.g., at the bottom surface of the optical channel100). In a specific example, when visible light falls incident on the other surface (e.g., the bottom surface) of the optical channel100, the optical channel100may pass at least a portion of green light included in the visible light (e.g. through the optical channel100from the bottom surface of the optical channel100to the top surface of the optical channel100) and may reflect at least a portion of purple light (e.g., a mixture of red light and blue light) included in the visible light (e.g., at the bottom surface of the of the optical channel100). As indicated above,FIGS.1A-1Bare provided as examples. Other examples may differ from what is described with regard toFIGS.1A-1B. FIGS.2A-2Care diagrams of an overview of an example implementation200described herein. As shown inFIG.2A, example implementation200may include an optical component202that includes a plurality of optical channels204(e.g., arranged in a two dimensional array).FIG.2Ashows a top-down view of the optical component202. In some implementations, the optical component202may be included in a security article (e.g., security article402described herein in relation toFIGS.4A-4D). In some implementations, as further described herein, each optical channel204has a same or similar configuration as the optical channel100described herein in relation toFIGS.1A-1B. In some implementations, some or all of the plurality of optical channels204may have a Fano resonance characteristic (e.g., as described herein). Further, the number of optical channels204, of the plurality of optical channels204, that have a Fano resonance characteristic may be greater than or equal to a threshold number of optical channels. The threshold number may be greater than or equal to, for example, 5, 10, 16, 32, 64, or 128. FIG.2Bshows an example cross-sectional, side view of the optical component202along the line A-A shown inFIG.2A. As shown inFIG.2B, a set of optical channels204(shown as optical channels204-1through204-8) may be arranged in a row (or column) adjacent to each other. Each optical channel204, of the set of optical channels204, may include a substrate206(e.g., a glass substrate, or other light transmissive material, on which other layers described herein are grown, deposited, or otherwise formed), a first mirror208(e.g., that is the same as, or similar to, the first mirror102described herein in relation toFIGS.1A-1B), a set of spacer layers210(e.g., that is the same as, or similar to, the spacer104described herein in relation toFIGS.1A-1B), a second mirror212(e.g., that is the same as, or similar to, the second mirror106described herein in relation toFIGS.1A-1B), and/or an absorber layer214(e.g., that is the same as, or similar to, the absorber layer108described herein in relation toFIGS.1A-1B). As further shown inFIG.2B, the first mirror208may be disposed on the substrate206, the set of spacer layers210may be disposed on the first mirror208, the second mirror212may be disposed on the set of spacer layers210, and/or the absorber layer214may be disposed on the second mirror212. Accordingly a surface of the absorber layer214(e.g., a top surface of the absorber layer214as shown inFIG.2B) may be included in a surface of the optical channel204(e.g., a top surface of the optical channel204as shown inFIG.2B). The surface of the optical channel204(e.g., the top surface of the optical channel204) may be included in a surface of the optical component202(e.g., a top surface of the optical component202). In some implementations, each optical channel204, of the set of optical channels204, may include a different number of spacer layers210. Accordingly, a thickness of the set of spacer layers210for each optical channel204may be different, which may cause each optical channel204to be configured to pass light associated with a particular wavelength range (e.g., to pass light that has a wavelength that is greater than or equal to a lower bound of the particular wavelength range and that is less than an upper bound of the particular wavelength range). For example, as shown inFIG.2B, the optical channel204-1includes a set of spacer layers210that includes eight spacer layers210, which causes the optical channel204-1to pass light associated with a first wavelength range; the optical channel204-2includes a set of spacer layers210that includes seven spacer layers210, which causes the optical channel204-2to pass light associated with a second wavelength range; the optical channel204-3includes a set of spacer layers210that includes six spacer layers210that causes the optical channel204-3to pass light associated with a third wavelength range; and so on. In some implementations, a thickness of an absorber layer214of an optical channel204, of the set of optical channels204, may match (e.g., may be the same as, within a thickness tolerance, such as 2 nanometers) a thickness of an absorber layer214of at least one other optical channel204of the set of optical channels204. For example a thickness of the absorber layer214of the optical channel204-1may match a thickness of the absorber layer214of the optical channel204-2. In some implementations, a thickness of an absorber layer214of an optical channel204may be associated with a particular wavelength range of light that the optical channel204is configured to pass. Accordingly, each absorber layer214of the set of optical channels204may have a different thickness than that of other optical channels204of the set of optical channels204. For example, a difference between a thickness of an absorber layer214of the optical channel204-3and a thickness of an absorber layer214of the optical channel204-4may satisfy (e.g., may be greater than) a thickness difference threshold, such as 2 nanometers. In some implementations, each optical channel204, of the set of optical channels204, may have a Fano resonance characteristic (e.g., due to the absorber layer214being disposed on the second mirror212and/or a surface of the absorber layer214being included in a surface of the optical channel204). For example, each optical channel204, of the set of optical channels204, may be configured to pass first light beams associated with a particular wavelength range when the first light beams fall incident on a first surface or a second surface (e.g., a top surface or a bottom surface) of the optical channel204, to reflect second light beams associated with the particular wavelength range when the second light beams fall incident on the first surface (e.g., the top surface) of the optical channel204, and/or to reflect third light beams associated with a different wavelength range when the third light beams fall incident on the second surface (e.g., the bottom surface) of the optical channel204. In an additional example, the optical channel204-1may be configured to receive (e.g., on a top surface and/or a bottom surface of the optical channel204-1) broadband light that includes a first set of light beams associated with a first wavelength range and a second set of light beams associated with a second wavelength range. The optical channel204-1may be configured to pass a first portion of the first set of light beams (e.g., through the optical channel204-1) when the first set of light beams falls incident on at least one of the top surface or the bottom surface of the optical channel204-1, to reflect a second portion of the first set of light beams (e.g., at the top surface of the optical channel204-1) when the first set of light beams falls incident on the top surface of the optical channel204-1, and/or to reflect at least a portion of the second set of light beams (e.g., at the bottom surface of the optical channel204-1) when the second set of light beams falls incident on the bottom surface of the optical channel204-1. Additionally, or alternatively, the optical channel204-1may be configured to prevent the second set of light beams from passing through the optical channel204-1(e.g., may be configured to block the second set of light beams) when the second set of light beams falls incident on at least one of the top surface or the bottom surface of the optical channel204-1. As another example, the optical channel204-2may be configured to receive (e.g., on a top surface and/or a bottom surface of the optical channel204-2) broadband light that includes a third set of light beams associated with a third wavelength range and a fourth set of light beams associated with a fourth wavelength range. The optical channel204-2may be configured to pass a first portion of the third set of light beams (e.g., through the optical channel204-2) when the third set of light beams falls incident on at least one of the top surface or the bottom surface of the optical channel204-2, to reflect a second portion of the third set of light beams (e.g., at the top surface of the optical channel204-2) when the third set of light beams falls incident on the top surface of the optical channel204-2, and/or to reflect at least a portion of the fourth set of light beams (e.g., at the bottom surface of the optical channel204-2) when the fourth set of light beams falls incident on the bottom surface of the optical channel204-2. Additionally, or alternatively, the optical channel204-2may be configured to prevent the fourth set of light beams from passing through the optical channel204-2(e.g., may be configured to block the fourth set of light beams) when the fourth set of light beams falls incident on at least one of the top surface or the bottom surface of the optical channel204-2. FIG.2Cshows another example cross-sectional, side view of the optical component202along the line A-A shown inFIG.2A. As shown inFIG.2C, a set of optical channels204(shown as optical channels204-1through204-8) may be arranged in a row (or column) adjacent to each other. Each optical channel204, of the set of optical channels204, may include a first mirror208, a set of spacer layers210, a second mirror212, and/or an absorber layer214. As further shown inFIG.2C, the set of optical channels204may include a first subset of optical channels204(e.g., that includes optical channels204-1,204-2,204-4,204-5, and204-7), a second subset of optical channels204(e.g., that includes optical channels204-3and204-6), and/or a third subset of optical channels204(e.g., that includes optical channel204-8). For an optical channel204of the first subset of optical channels204(e.g., that includes optical channels204-1,204-2,204-4,204-5, and204-7), the set of spacer layers210may be disposed on the first mirror208, the second mirror212may be disposed on the set of spacer layers210, and/or the absorber layer214(e.g., absorber layer214-1,214-2,214-4,214-5, or214-7) may be disposed on the second mirror212(e.g., in a similar manner as that described above in relation toFIG.2B). Accordingly a surface of the absorber layer214(e.g., a top surface of the absorber layer214as shown inFIG.2C) may be included in a first surface of the optical channel204(e.g., a top surface of the optical channel204as shown inFIG.2C) and the first surface of the optical channel204(e.g., the top surface of the optical channel204) may be included in a first surface of the optical component202(e.g., a top surface of the optical component202). In this way, each optical channel204, of the first subset of optical channels204, may have a Fano resonance characteristic (e.g., due to the absorber layer214being disposed on the second mirror212and/or the surface of the absorber layer214being included in the first surface of the optical channel204). For example, each optical channel204, of the first subset of optical channels204, may be configured to pass first light beams associated with a particular wavelength range when the first light beams fall incident on the first surface or the second surface (e.g., a top surface or a bottom surface) of the optical channel204, to reflect second light beams associated with the particular wavelength range when the second light beams fall incident on the first surface (e.g., the top surface) of the optical channel204, and/or to reflect third light beams associated with a different wavelength range when the third light beams fall incident on the second surface (e.g., the bottom surface) of the optical channel204. For an optical channel204of the second subset of optical channels204(e.g., that includes optical channels204-3and204-6), the first mirror208may be disposed on the absorber layer214(e.g., absorber layer214-3or214-6), the set of spacer layers210may be disposed on the first mirror208, and/or the second mirror212may be disposed on the set of spacer layers210. In this way, the second subset of optical channels204may have a different orientation (e.g., an opposite orientation) than that of the first subset of optical channels204. Accordingly a surface of the absorber layer214(e.g., a bottom surface of the absorber layer214as shown inFIG.2C) may be included in a first surface of the optical channel204(e.g., a bottom surface of the optical channel204as shown inFIG.2C) and the first surface of the optical channel204(e.g., the bottom surface of the optical channel204) may be included in a second surface of the optical component202(e.g., the bottom surface of the optical component202). In this way, each optical channel204, of the second subset of optical channels204, may have a Fano resonance characteristic (e.g., due to the absorber layer214being disposed on the first mirror208and/or the surface of the absorber layer214being included in the first surface of the optical channel204). For example, each optical channel204, of the second subset of optical channels204, may be configured to pass first light beams associated with a particular wavelength range when the first light beams fall incident on the first surface or the second surface (e.g., a bottom surface or a top surface) of the optical channel204, to reflect second light beams associated with the particular wavelength range when the second light beams fall incident on the first surface (e.g., the bottom surface) of the optical channel204, and/or to reflect third light beams associated with a different wavelength range when the third light beams fall incident on the second surface (e.g., the top surface) of the optical channel204. For an optical channel204, of the third subset of optical channels204(e.g., that includes optical channel204-8), the set of spacer layers210may be disposed on the first mirror208, and/or the second mirror212may be disposed on the set of spacer layers210and the optical channel204may not include an absorber layer214. In this way, each optical channel204, of the third subset of optical channels204, may not have a Fano resonance characteristic (e.g., due to an absence of an absorber layer214). For example, each optical channel204, of the third subset of optical channels204, may be configured to pass first light beams associated with a particular wavelength range when the first light beams fall incident on a first surface or a second surface (e.g., a top surface or a bottom surface) of the optical channel204, to reflect second light beams associated with a different range when the second light beams fall incident on the first surface (e.g., the top surface) of the optical channel204, and/or to reflect third light beams associated with the different wavelength range when the third light beams fall incident on the second surface (e.g., the bottom surface) of the optical channel204. As indicated above,FIGS.2A-2Care provided as examples. Other examples may differ from what is described with regard toFIGS.2A-2C. FIGS.3A-3Bare diagrams of an overview of an example implementation related to an optical channel300(e.g., that corresponds to an optical channel100described herein in relation toFIGS.1A-1Band/or the optical channel204described herein in relation toFIGS.2A-2C). As shown inFIGS.3A-3B, the optical channel300may include a substrate302(e.g., that is the same as, or similar to, the substrate206described herein in relation toFIG.2B), a first mirror304(e.g., that is the same as, or similar to, the first mirror102described herein in relation toFIGS.1A-1Band/or the first mirror208described herein in relation toFIGS.2B-2C), a set of spacer layers306(e.g., that is the same as, or similar to, the spacer104described herein in relation toFIGS.1A-1Band/or the set of spacer layers210described herein in relation toFIGS.2B-2C), a second mirror308(e.g., that is the same as, or similar to, the second mirror106described herein in relation toFIGS.1A-1Band/or the second mirror212described herein in relation toFIGS.2B-2C), and/or an absorber layer310(e.g., that is the same as, or similar to, the absorber layer108described herein in relation toFIGS.1A-1Band/or the absorber layer214described herein in relation toFIGS.2B-2C). As shown inFIG.3A, a set of broadband light beams312may fall incident on a first surface (e.g., a top surface) of the optical channel300. The set of broadband light beams312may include a first set of light beams314that are associated with a first wavelength range and a second set of light beams316that are associated with a second wavelength range. The optical channel100may be configured to pass light associated with the first wavelength range. Accordingly, the optical channel100may pass a first portion of the first set of light beams314-1through the optical channel300from the first surface (e.g., the top surface) to a second surface (e.g., a bottom surface) of the optical channel300. Further, the optical channel300may have a Fano resonance characteristic (e.g., due to the absorber layer310being disposed on the second mirror308and/or a surface of the absorber layer310being included in the first surface of the optical channel300). Accordingly, the optical channel300may reflect (e.g., at the first surface of the optical channel300) a second portion of the first set of light beams314-2. As shown inFIG.3B, the set of broadband light beams312may fall incident on the second surface (e.g., the bottom surface) of the optical channel300. Accordingly, because the optical channel100may be configured to pass light associated with the first wavelength range, the optical channel100may pass the first portion of the first set of light beams314-1through the optical channel300from the second surface (e.g., the bottom surface) to the first surface (e.g., the top surface) of the optical channel300. Further, because the absorber layer310is disposed on the second mirror308and not on the first mirror304and/or the absorber layer310is included in the first surface (e.g., the top surface) of the optical channel300and not in the second surface (e.g., the bottom surface) of the optical channel300, the optical channel300may not exhibit the Fano resonance characteristic for light beams that fall incident on the second surface (e.g., the bottom surface) of the optical channel300. Accordingly, the optical channel300may reflect (e.g., at the second surface of the optical channel300) at least a portion of the second set of light beams316. As indicated above,FIGS.3A-3Bare provided as examples. Other examples may differ from what is described with regard toFIGS.3A-3B. FIGS.4A-4Dare diagrams of an overview of an example implementation400described herein. As shown inFIG.4A, example implementation400may include a security article402that includes an optical component404(e.g., that is the same as or similar to the optical component202described herein in relation toFIGS.2A-2C), which may include a plurality of optical channels406(e.g., that correspond to the optical channel100, the optical channel204, and/or the optical channel300described herein in relation toFIGS.1A-1B,2A-2C, and3A-3B). In some implementations, the security article402may include currency, a bank note, a government issued identification card, a private organization identification card, or a transaction card, among other examples. As shown in a top portion ofFIG.4A(e.g., that depicts the security article402as an identification card), the optical component404may be located within a region of the security article402and each optical channel406, of the plurality of optical channels406included in the optical component404, may be located within a respective subregion of the region of the security article402. As shown in a bottom portion ofFIG.1A(e.g., that depicts a cross-sectional, side view of the security article402along the line B-B shown in the top portion ofFIG.4A), a set of optical channels406may be arranged adjacent to each other in a row (or column) (e.g., in a similar manner as the set of optical channels204described herein in relationFIGS.2B-2C). As further shown inFIG.4A, a first surface (e.g., a top surface) of an optical channel406may be included in a first surface (e.g., a top surface) of the optical component404, which may be included in a first surface (e.g., a top surface) of the security article402. Additionally, or alternatively, a second surface (e.g., a bottom surface) of an optical channel406may be included in a second surface (e.g., a bottom surface) of the optical component404, which may be included in a second surface (e.g., a bottom surface) of the security article402. FIGS.4B-4Dshow a security article reader system408that is configured to receive the security article402and to read the security article402to determine information related to the security article402. For example, the security article reader system408may include an interrogation area (e.g., an internal portion of the security article reader system408) in which the security article402may be placed to allow the security article reader system408to read the security article402(e.g., by optically interrogating the optical component404, as further described herein). As shown inFIGS.4B-4C, the security article reader system408may include a first light emission device410, a second light emission device412, and/or a plurality of sensor elements414(e.g., shown as a first set of sensor elements414-1and a second set of sensor elements414-2). The first light emission device410and/or the second light emission device412may each include, for example, a halogen light, an incandescent light, a compact fluorescent (CFL) light, a laser, a light emitting diode (LED), a florescent light, a neon light, and/or arrays of any of the preceding light emission devices. The first light emission device410and/or the second light emission device412may each be configured to provide light associated with a wavelength particular range (e.g., that is associated with a visible light range, an infrared light range, and/or an ultraviolet light range, among other examples). For example, at least one of the first light emission device410and/or the second light emission device412may provide light in a range of 700 nanometers to 1100 nanometers, which may enable sensing (e.g., by the plurality of sensor elements414) based on light in the near-infrared (NIR) range. As another example, at least one of the first light emission device410and/or the second light emission device412may provide light in a broad range, such as a range of 300 nanometers to 2000 nanometers, which may enable sensing (e.g., by the plurality of sensor elements414) based on broad spectrum light. The plurality of sensor elements414may provide information related to light that falls incident on the plurality of sensor elements414. For example, an individual sensor element414, of the plurality of sensor elements414, may provide an indication of intensity of light that is incident on the sensor element414(e.g., active/inactive or a more granular indication of intensity). As another example, the sensor element414may provide an indication of a wavelength or wavelength range of light that is incident on the sensor element414(e.g., red light, blue light, green light, ultraviolet light, and/or infrared light, among other examples). The plurality of sensor elements414may be configured to collect respective information from individual sensor elements414, of the plurality of sensor elements414, to generate sensor data. In some implementations, one or more optical filters (not shown inFIGS.4B-4C) may be disposed over the plurality of sensor elements414(e.g., a first individual optical filter may be disposed over the first set of sensor elements414-1and a second individual optical filter may be disposed over the second set of sensor elements414-2). An optical filter, of the one or more optical filters, may include a spectral filter, a multispectral filter, an optical interference filter, a bandpass filter, a blocking filter, a long-wave pass filter, a short-wave pass filter, a dichroic filter, a linear variable filter (LVF), a circular variable filter (CVF), a Fabry-Perot filter (e.g., a Fabry-Perot cavity filter), a Bayer filter, a plasmonic filter, a photonic crystal filter, a nanostructure and/or metamaterial filter, an absorbent filter (e.g., comprising organic dyes, polymers, glasses, and/or the like), and/or the like. In some implementations, the first light emission device410may be configured to emit a set of light beams416toward the first surface (e.g., the top surface) of the security article402when the security article402is placed within the interrogation area of the security article reader system408. The set of light beams416may include light beams associated with a broadband wavelength range (e.g., visible light, ultraviolet light, and/or infrared light) or, in some implementations, may include light beams associated with one or more particular wavelength ranges. For example, the set of light beams416may include a first set of light beams418that are associated with a first wavelength range and/or other sets of light beams associated with other wavelength ranges. As shown inFIG.4B, the first light emission device410may be configured to emit the set of light beams416toward the first surface of the optical component404that is included in the security article402. As further shown inFIG.4B, at least some of the set of light beams416may be transmitted to a first surface of an optical channel406-1(e.g., that corresponds to the optical channel100, the optical channel204, and/or the optical channel300described herein in relation toFIGS.1A-1B,2A-2C, and3A-3B), of the plurality of optical channels406. The optical channel406-1may be configured to pass light associated with a first wavelength range (e.g., that is included in the broadband wavelength range associated with the set of light beams416). Accordingly, the optical channel406-1may pass a first portion of the first set of light beams418-1(e.g., that is associated with the first wavelength range) through the optical channel406-1from the first surface (e.g., the top surface) to a second surface (e.g., a bottom surface) of the optical channel406-1. Further, the optical channel406-1may have a Fano resonance characteristic. Accordingly, the optical channel406-1may reflect (e.g., at the first surface of the optical channel406-1) a second portion of the first set of light beams418-2. As further shown inFIG.4B, the first portion of the first set of light beams418-1may transmit (after passing through the optical channel406-1) toward the first set of sensor elements414-1and/or the second portion of the first set of light beams418-2may transmit (after being reflected by the first surface of the optical channel406-1) toward the second set of sensor elements414-2. Accordingly, at least some of the first set of sensor elements414-1may receive and determine information related to the first portion of the first set of light beams418-1(e.g., an intensity of the first portion of the first set of light beams418-1) and/or at least some of the second set of sensor elements414-2may receive and determine information related to the second portion of the first set of light beams418-2(e.g., an intensity of the second portion of the first set of light beams418-2). In some implementations, the plurality of sensor elements414may be configured to generate sensor data that indicates the information related to the first portion of the first set of light beams418-1and/or the information related to the second portion of the first set of light beams418-2. In some implementations, the second light emission device412may be configured to emit a set of light beams420toward the second surface (e.g., the bottom surface) of the security article402when the security article402is placed within the interrogation area of the security article reader system408. The set of light beams420may include light beams associated with a broadband wavelength range (e.g., visible light, ultraviolet light, and/or infrared light) or, in some implementations, may include light beams associated with one or more particular wavelength ranges. For example, the set of light beams420may include a second set of light beams422that are associated with the first wavelength range (e.g., describe above in relation to the first set of light beams418), a third set of light beams424that are associated with a second wavelength range, and/or other sets of light beams associated with other wavelength ranges. As shown inFIG.4C, the second light emission device412may be configured to emit the set of light beams420toward the second surface of the optical component404that is included in the security article402. As further shown inFIG.4C, at least some of the set of light beams420may be transmitted to a second surface of the optical channel406-1of the plurality of optical channels406. As described above, the optical channel406-1may be configured to pass light associated with the first wavelength range (e.g., that is included in the broadband wavelength range associated with the set of light beams420). Accordingly, the optical channel406-1may pass a first portion of the second set of light beams422-1(e.g., that is associated with the first wavelength range) through the optical channel406-1from the second surface (e.g., the bottom surface) to the first surface (e.g., the top surface) of the optical channel406-1. Further, the optical channel406-1may not exhibit the Fano resonance characteristic for light beams that fall incident on the second surface (e.g., the bottom surface) of the optical channel406-1. Accordingly, the optical channel406-1may reflect (e.g., at the second surface of the optical channel406-1) at least a first portion of the third set of light beams424-1(e.g., that is associated with the second wavelength range). As further shown inFIG.4C, the first portion of the second set of light beams422-1may transmit (after passing through the optical channel406-1) toward the second set of sensor elements414-2and/or the first portion of the third set of light beams424-1may transmit (after being reflected by the second surface of the optical channel406-1) toward the first set of sensor elements414-1. Accordingly, at least some of the first set of sensor elements414-1may receive and determine information related to the first portion of the third set of light beams424-1(e.g., an intensity of the first portion of the third set of light beams424-1) and/or at least some of the second set of sensor elements414-2may receive and determine information related to the first portion of the second set of light beams422-1(e.g., an intensity of the first portion of the second set of light beams422-1). In some implementations, the plurality of sensor elements414may be configured to generate sensor data that indicates the information related to the first portion of the second set of light beams422-1and/or the information related to the second portion of the second set of light beams422-2. In some implementations, the first light emission device410may be configured to emit the set of light beams416(e.g., toward the first surface of the security article402and/or the first surface of the optical component404of the security article402) during a first time period. In some implementations, the second light emission device412may be configured to emit the set of light beams420(e.g., toward the second surface of the security article402and/or the second surface of the optical component404of the security article402) during a second time period. The second time period may not be coextensive with the first time period. That is, the first light emission device410and the second light emission device412may sequentially emit the set of light beams416and the set of light beams420, such that the optical channel406-1does not pass or reflect any portion of the set of light beams416when passing or reflecting one or more portions of the set of light beams420(or vice versa). In this way, the plurality of sensor elements414may generate more accurate sensor data related to the set of light beams416and/or the set of light beams420than would be generated otherwise (e.g., because the set of light beams416and/or the set of light beams420are not affected by interference or other optical issues that would result from the set of light beams416and/or the set of light beams420being emitted at a same time). As shown inFIG.4D, the plurality of sensor elements414may be associated with one or more processors426(e.g., that are included in the security article reader system408). The one or more processors426may control the security article reader system408and/or other components of the security article reader system408. For example, the one or more processors426may cause the first light emission device410to emit the set of light beams416(e.g., toward the first surface of the optical component404during the first time period) and/or may cause the second light emission device412to emit the set of light beams420(e.g., toward the second surface of the optical component404during the second time period). Further, the one or more processors426may cause the plurality of sensor elements414to generate the sensor data (e.g., during the first time period and/or the second time period). As further shown inFIG.4D, and as shown by reference number428, the plurality of sensor elements414may provide the sensor data to the one or more processors426. In this way, the one or more processors426may obtain and/or identify the sensor data. The sensor data may indicate, for each optical channel406, of the plurality of optical channels406, information relating to how the optical channel406interacted with the set of light beams416and/or the set of light beams420. For example, for the optical channel406-1, the sensor data may indicate the information related to the first portion of the first set of light beams418-1(e.g., that was passed by the optical channel406-1), the information related to the second portion of the first set of light beams418-2(e.g., that was reflected by the first surface of the optical channel406-1), the information related to the first portion of the second set of light beams422-1(e.g., that was passed by the optical channel406-1), and/or the information related to the first portion of the third set of light beams424-1(e.g., that was reflected by the second surface of the optical channel406-1), as described herein in relation toFIGS.4B-4C. As further shown inFIG.4D, and by reference number430, the one or more processors426may process the sensor data to determine one or more respective optical characteristics of the plurality of optical channels406. For example, for the optical channel406-1, the one or more processors426may identify a first portion of the sensor data (e.g., that includes the information related to the first portion of the first set of light beams418-1) and/or a second portion of the sensor data (e.g., that includes the information related to the first portion of the second set of light beams422-1) and may determine, based on the first portion of the sensor data and/or the second portion of the sensor data, a transmission characteristic associated with the optical channel406-1(e.g., a transmission performance of the optical channel406-1). As another example, for the optical channel406-1, the one or more processors426may identify a third portion of the sensor data (e.g., that includes the information related to the second portion of the first set of light beams418-2), and may determine, based on the third portion of the sensor data, a reflection characteristic associated with the first side of the optical channel406-1(e.g., a reflection performance of the first side of the optical channel406-1). In an additional example, for the optical channel406-1, the one or more processors426may identify a fourth portion of the sensor data (e.g., that includes the information related to the first portion of the third set of light beams424-1) and may determine, based on the fourth portion of the sensor data, a reflection characteristic associated with the second side of the optical channel406-1(e.g., a reflection performance of the second side of the optical channel406-1). As further shown inFIG.4D, and by reference number432, the one or more processors426may determine, based on the one or more respective optical characteristics of the plurality of optical channels406, identification information associated with the optical component404. In some implementations, the one or more processors426may identify a set of optical characteristics associated with an optical channel406and determine, based on the set of optical characteristics and/or a location of the optical channel406within the optical component404, a value associated with the optical channel. For example, for the optical channel406-1, the one or more processors426may identify and process a transmission characteristic associated with the optical channel406-1, a first reflection characteristic associated with the first side of the optical channel406-1, and/or a second reflection characteristic associated with a second side of the optical channel406-1to determine a 3-bit value (e.g., where a first bit corresponds to the transmission characteristic, a second bit corresponds to the first reflection characteristic, and a third bit corresponds to the second reflection characteristic, and each bit indicates whether its corresponding optical characteristic is present and/or satisfies an optical characteristic threshold). Additionally, or alternatively, the one or more processors426may add one or more bits to the 3-bit value to generate an n-bit value (e.g., where n>3, and the one or more bits indicate a location of the optical channel406-1within the optical component404). In this way, the one or more processors426may determine respective n-bit values of the plurality of optical channels406. The one or more processors426may process at least some of the respective n-bit values of the plurality of optical channels406to determine the identification information associated with the optical component404. For example, the one or more processors426may concatenate a plurality of the n-bit values to generate an m-bit value (e.g., where m>n, and m is a multiple of n) that identifies the optical component404. The identification information associated with the optical component404may include an identifier (e.g., a universally unique identifier (UUID)), a text string, a number string, and/or an alphanumeric string, among other examples, and the identifier may correspond to printed, displayed, and/or other information that is otherwise included in the secure article402. In some implementations, the one or more processors426may determine (e.g., based on the identification information associated with the optical component404) whether the security article402is valid. For example, the one or more processors426may search a data structure (e.g., that is included in the security article reader system408or accessible to the security article reader system408) that includes entries associated with valid security articles for an entry associated with the identification information. The one or more processors426may determine that the security article402is valid when the one or more processors426find an entry or may determine that the security article402is not valid when the one or more processors426do not find an entry. In some implementations, the one or more processors426may cause (e.g., based on determining whether the security article402is valid) information indicating whether the security article is valid to be displayed on a display associated with the security article reader system408(e.g., to indicate that the security article402can be or cannot be used for a transaction, that a holder of the security article402can or cannot access a restricted area, and/or that a locked resource is to be unlocked or to remain locked, among other examples). In some implementations, the one or more processors426may cause (e.g., based on determining whether the security article402is valid) granting or denying access to a resource (e.g., a prescription drug, a hazardous material, and/or a restricted area, among other examples). For example, when the one or more processors426determined that the security article402is valid, the one or more processors426may send a signal to a device or component associated with the resource to cause the device or component to release the resource or otherwise allow a holder of the security article402access to the resource. As another example, when the one or more processors426determined that the security article402is not valid, the one or more processors426may send a signal to a device or component associated with the resource to cause the device or component to lock the resource (or to maintain a lock on the resource) or otherwise prevent a holder of the security article402from accessing the resource. As indicated above,FIGS.4A-4Dare provided as examples. Other examples may differ from what is described with regard toFIGS.4A-4D. FIG.5is a diagram of example components of a device500, which may correspond to the security article reader system408. In some implementations, the security article reader system408may include one or more devices500and/or one or more components of device500. As shown inFIG.5, device500may include a bus510, a processor520, a memory530, a storage component540, an input component550, an output component560, and a communication component570. Bus510includes a component that enables wired and/or wireless communication among the components of device500. Processor520includes a central processing unit, a graphics processing unit, a microprocessor, a controller, a microcontroller, a digital signal processor, a field-programmable gate array, an application-specific integrated circuit, and/or another type of processing component. Processor520is implemented in hardware, firmware, or a combination of hardware and software. In some implementations, processor520includes one or more processors capable of being programmed to perform a function. Memory530includes a random access memory, a read only memory, and/or another type of memory (e.g., a flash memory, a magnetic memory, and/or an optical memory). Storage component540stores information and/or software related to the operation of device500. For example, storage component540may include a hard disk drive, a magnetic disk drive, an optical disk drive, a solid state disk drive, a compact disc, a digital versatile disc, and/or another type of non-transitory computer-readable medium. Input component550enables device500to receive input, such as user input and/or sensed inputs. For example, input component550may include a touch screen, a keyboard, a keypad, a mouse, a button, a microphone, a switch, a sensor, a global positioning system component, an accelerometer, a gyroscope, and/or an actuator. Output component560enables device500to provide output, such as via a display, a speaker, and/or one or more light-emitting diodes. Communication component570enables device500to communicate with other devices, such as via a wired connection and/or a wireless connection. For example, communication component570may include a receiver, a transmitter, a transceiver, a modem, a network interface card, and/or an antenna. Device500may perform one or more processes described herein. For example, a non-transitory computer-readable medium (e.g., memory530and/or storage component540) may store a set of instructions (e.g., one or more instructions, code, software code, and/or program code) for execution by processor520. Processor520may execute the set of instructions to perform one or more processes described herein. In some implementations, execution of the set of instructions, by one or more processors520, causes the one or more processors520and/or the device500to perform one or more processes described herein. In some implementations, hardwired circuitry may be used instead of or in combination with the instructions to perform one or more processes described herein. Thus, implementations described herein are not limited to any specific combination of hardware circuitry and software. The number and arrangement of components shown inFIG.5are provided as an example. Device500may include additional components, fewer components, different components, or differently arranged components than those shown inFIG.5. Additionally, or alternatively, a set of components (e.g., one or more components) of device500may perform one or more functions described as being performed by another set of components of device500. FIG.6is a flowchart of an example process600associated with an optical component of a security article. In some implementations, one or more process blocks ofFIG.6may be performed by a security article reader system (e.g., security article reader system408). In some implementations, one or more process blocks ofFIG.6may be performed by another device or a group of devices separate from or including the security article reader system. Additionally, or alternatively, one or more process blocks ofFIG.6may be performed by one or more components of device500, such as processor520, memory530, storage component540, input component550, output component560, and/or communication component570. As shown inFIG.6, process600may include identifying sensor data associated with a plurality of optical channels included within an optical component of a security article (block610). For example, the security article reader system may identify sensor data associated with a plurality of optical channels included within an optical component of a security article, as described above. As further shown inFIG.6, process600may include determining, based on the sensor data, one or more respective optical characteristics of the plurality of optical channels (block620). For example, the security article reader system may determine, based on the sensor data, one or more respective optical characteristics of the plurality of optical channels, as described above. As further shown inFIG.6, process600may include determining, based on the one or more respective optical characteristics of the plurality of optical channels, identification information associated with the optical component (block630). For example, the security article reader system may determine, based on the one or more respective optical characteristics of the plurality of optical channels, identification information associated with the optical component, as described above. As further shown inFIG.6, process600may include causing one or more actions to be performed based on the identification information associated with the optical component (block640). For example, the security article reader system may cause one or more actions to be performed based on the identification information associated with the optical component, as described above. Process600may include additional implementations, such as any single implementation or any combination of implementations described below and/or in connection with one or more other processes described elsewhere herein. In a first implementation, process600includes causing a first light emission device of the security article reader system to emit a first set of light beams toward a first surface of the optical component during a first time period, causing a second light emission device of the security article reader system to emit a second set of light beams toward a second surface of the optical component during a second time period, wherein the first time period and the second time period are not coextensive, and causing a plurality of sensor elements of the security article reader system to generate the sensor data during the first time period and the second time period. In a second implementation, alone or in combination with the first implementation, determining the one or more respective optical characteristics of the plurality of optical channels comprises identifying, for an optical channel, of the plurality of optical channels, at least one of a first portion of the sensor data that is associated with a first subset of light beams of a first set of light beams that is reflected by a first side of the optical channel, a second portion of the sensor data that is associated with a second subset of light beams of the first set of light beams that is passed by the optical channel, a third portion of the sensor data that is associated with a first subset of light beams of a second set of light beams that is passed by the optical channel, or a fourth portion of the sensor data that is associated with a second subset of light beams of the second set of light beams hat is reflected by a second side of the optical channel, and determining, based at least one of the first portion of the sensor data, the second portion of the sensor data, the third portion of the sensor data, or the fourth portion of the sensor data, one or more optical characteristics of the optical channel. In a third implementation, alone or in combination with one or more of the first and second implementations, the one or more respective optical characteristics of the plurality of optical channels includes, for an optical channel, of the plurality of optical channels, at least one of a reflection characteristic associated with a first side of the optical channel, a transmission characteristic associated with the optical channel, or a reflection characteristic associated with a second side of the optical channel. In a fourth implementation, alone or in combination with one or more of the first through third implementations, determining the identification information associated with the optical component comprises identifying, based on the one or more respective optical characteristics of the plurality of optical channels, a first set of optical characteristics associated with a first optical channel, of the plurality of optical channels, and a second set of optical characteristics associated with a second optical channel, of the plurality of optical channels, determining, based on the first set of optical characteristics and/or a location of the first optical channel, a first value associated with the first optical channel, determining, based on the second set of optical characteristics and/or a second location of the second optical channel, a second value associated with the second optical channel, and determining, based on the first value and the second value, the identification information associated with the optical component. In a fifth implementation, alone or in combination with one or more of the first through fourth implementations, causing the one or more actions to be performed comprises determining, based on the identification information associated with the optical component, whether the security article is valid, and granting or denying access to a resource based on determining whether the security article is valid. In a sixth implementation, alone or in combination with one or more of the first through fifth implementations, determining the one or more respective optical characteristics of the plurality of optical channels comprises determining, based on the sensor data, a reflection characteristic associated with a first side of an optical channel of the plurality of optical channels; determining, based on the sensor data, a transmission characteristic associated with the optical channel; and determining, based on the sensor data, a reflection characteristic associated with a second side of the optical channel. In a seventh implementation, alone or in combination with one or more of the first through sixth implementations, causing the one or more actions to be performed comprises determining, based on the identification information associated with the optical component, whether the security article is valid, and causing information indicating whether the security article is valid to be displayed on a display associated with the security article reader system. AlthoughFIG.6shows example blocks of process600, in some implementations, process600may include additional blocks, fewer blocks, different blocks, or differently arranged blocks than those depicted inFIG.6. Additionally, or alternatively, two or more of the blocks of process600may be performed in parallel. The foregoing disclosure provides illustration and description, but is not intended to be exhaustive or to limit the implementations to the precise forms disclosed. Modifications and variations may be made in light of the above disclosure or may be acquired from practice of the implementations. As used herein, satisfying a threshold may, depending on the context, refer to a value being greater than the threshold, greater than or equal to the threshold, less than the threshold, less than or equal to the threshold, equal to the threshold, not equal to the threshold, or the like. Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the disclosure of various implementations. In fact, many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification. Although each dependent claim listed below may directly depend on only one claim, the disclosure of various implementations includes each dependent claim in combination with every other claim in the claim set. As used herein, a phrase referring to “at least one of” a list of items refers to any combination of those items, including single members. As an example, “at least one of: a, b, or c” is intended to cover a, b, c, a-b, a-c, b-c, and a-b-c, as well as any combination with multiple of the same item. No element, act, or instruction used herein should be construed as critical or essential unless explicitly described as such. Also, as used herein, the articles “a” and “an” are intended to include one or more items, and may be used interchangeably with “one or more.” Further, as used herein, the article “the” is intended to include one or more items referenced in connection with the article “the” and may be used interchangeably with “the one or more.” Furthermore, as used herein, the term “set” is intended to include one or more items (e.g., related items, unrelated items, or a combination of related and unrelated items), and may be used interchangeably with “one or more.” Where only one item is intended, the phrase “only one” or similar language is used. Also, as used herein, the terms “has,” “have,” “having,” or the like are intended to be open-ended terms. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Also, as used herein, the term “or” is intended to be inclusive when used in a series and may be used interchangeably with “and/or,” unless explicitly stated otherwise (e.g., if used in combination with “either” or “only one of”). Further, spatially relative terms, such as “below,” “lower,” “bottom,” “above,” “upper,” “top,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the apparatus, device, and/or element in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly. | 68,123 |
11858289 | MODE(S) FOR CARRYING OUT THE INVENTION Embodiments of an applicator according to the present invention will be described referring to the drawings. The applicator to be described in the following embodiments is formed as a cosmetic article applied to the eyeliner. FIG.1shows the applicator of a first embodiment, specifically,FIG.1Ais a longitudinal sectional view,FIG.1Bis a sectional view taken along line A-A ofFIG.1A, andFIG.1Cis a sectional view taken along line B-B ofFIG.1A. An applicator1of the embodiment includes a cylindrical shaft (main body)3having a cavity. The main body3includes a storage chamber5for storing a liquid100, and an application body (brush)7for applying the liquid100, which are formed therein. The main body3is divided into the storage chamber5side and the application body7side by a partition10press fitted and fixed to the inside of the main body3. The main body3may be formed to have a circular cross section, or a non-circular (polygonal and the like) cross section. The application body7is held by a holder8which is press fitted to the leading end side of the main body3, and integrated therewith. The application body7has its leading end side protruding from a leading edge3aof the main body3, and its proximal side facing the partition10. In the embodiment, the proximal side of the application body7faces the partition10while having a rib11integrated with the holder8or the partition10intervening therebetween. The application body7is held with the rib11while having a gap S formed between the application body and the partition10. In this case, the application body7may be held in direct contact with the partition10. In other words, the application body7may be structured to be in contact (tight contact) with the partition10for sealing. Alternatively, the application body7and the partition10may be formed to be in partial contact with each other. The partition10has a through hole (constituting the flow passage)10ain its center part. Preferably, the application body7has its axial core aligned (may be substantially aligned) with the axial center of the flow passage10a. The rib11is formed around a circumference of the flow passage10aso as to be communicated with an air passage8aas described below. For example, the rib11may be annularly formed to enclose the flow passage10a, and has a notch partially formed to communicate the gap S with the flow passage10a. In this way, the shape and arrangement of the rib11are not limited so long as the air inflow to the inside of the flow passage10ais allowed. Even in the case where the application body7and the partition10are in tight contact with each other (including partial tight contact), air can be securely ventilated. The air passage8amay be arbitrarily formed so long as it is structured to allow inflow of the atmosphere to the flow passage10a(gap S). In this embodiment, the air passage is formed around an outer circumference of the holder8. The air passage8amay be formed into an arbitrary shape and arrangement so long as communication with the atmosphere is allowed by forming the air passages8aat multiple positions (in the structure ofFIG.1, they are formed at two positions on the outer circumference of the holder8at an angular interval of approximately 180°), forming those passages into an arc-like arrangement on the outer circumference of the holder8, or the like. AsFIG.1shows, the holder8has a small-diameter portion8bto which the application body7is fixed so that an annular gap8cbetween the application body7and the inner surface of the holder8serves as the air passage. A cap13for protecting the application body7protruding from the leading edge3ais detachably attached to the leading end side of the main body3. A cap-like tail plug12is press fitted and fixed to the rear end side. The cap13may be detachably attached to the main body3, or to the holder8for holding the application body7. In the embodiment, it is detachably attached to the main body3. Upon attachment of the cap13to the main body3, the air passage8ais brought into the closed state. The tail plug12may be press fitted and fixed to a rear end opening of the main body3or detachably attached. The tail plug performs the sealing function by filling the main body3with the liquid100from the rear end opening. If the liquid is filled from the leading end side, the tail plug12does not have to be provided. An air communication pipe15in abutment on the partition10for closing the flow passage10ais disposed in the storage chamber5. The air communication pipe15extends axially in the storage chamber5while being urged against the partition10constantly by an urging unit to be described later. A circumferential wall15aof the air communication pipe15has its internal diameter made larger than a diameter of the flow passage10a. Upon abutment of the air communication pipe15on the partition10, the flow passage10ais closed by the circumferential wall15a. An arbitrary process may be implemented for closing the flow passage10aso long as the closing operation is performed using the displaceable air communication pipe15. For example, the closing operation may be performed by fitting the outer circumferential surface of the circumferential wall15aof the air communication pipe15with the inner circumferential surface of a recess part10cof the partition10, which will be described later (fitting to the degree that hardly disturbs displacement of the air communication pipe15). Alternatively, the flow passage10amay be closed through abutment of a leading edge15cof the air communication pipe15on the partition10, or the use of the circumferential wall15aor/and the leading edge15c. The cross section of the air communication pipe15may be formed into the polygonal shape besides the circular shape in no restrictive manner. It may also be formed to have a partially solid part. For example, the part at the rear end side may be solid to impart the weight-added part. The structure of the air communication pipe15(thickness, length, material, or the like) may be appropriately determined in accordance with property of the liquid to be filled (viscosity, usage, or the like). The air communication pipe15may be arbitrarily formed so long as it performs the function for communication of the storage chamber5that closes the flow passage10awith the atmosphere via the air passage8a. In the embodiment, the air communication pipe15is structured to allow communication with the atmosphere via the flow passage10aformed in the center part of the partition10. For this reason, the air communication pipe15has an air port open to the storage chamber. The air port of the embodiment is formed as a through hole (opening)15A formed in the circumferential wall15aof the air communication pipe15at the tail plug side (hereinafter referred to as air port15A). The air communication pipe15may be structured to communicate with the atmosphere through the passage other than the flow passage10asuch as by forming an air hole other than the flow passage in the partition. The air communication pipe15is urged by an urging unit20so that the leading edge15cis brought into abutment on the partition10. The urging unit20of the embodiment is formed as a spring member20A that intervenes between the main body (tail plug) and the air communication pipe. In this case, the spring member20A is formed as a coil spring, and held by abutting one end on the inner surface of the tail plug12, and the other end on a stirring member22to be press fitted to the air communication pipe15. The stirring member22performs the function of stirring the liquid100stored in the storage chamber5when vibrating (shaking) the main body3, and includes a protrusion22athat protrudes radially with respect to the air communication pipe15. The stirring member22may be structured to serve as a specific weight (mass) so that the spring member20A is easily compressed upon shaking of the main body3. The urging unit20may be arbitrarily structured to perform a function for constantly abutting the air communication pipe15on the partition10to close the flow passage10a, and to separate the air communication pipe15from the partition10upon shaking of the main body3to guide the liquid in the storage chamber to the flow passage10avia the outer circumferential surface of the air communication pipe15. In other words, the urging unit is not limited to the coil spring disposed between the above-described main body3(tail plug12) and the air communication pipe15. For example, it may be constituted by the disc spring, or the tension spring without being limited to the arrangement position. It may be formed by adding a specific load applied to the air communication pipe15so that the urging unit abuts on the partition10by its own weight. The air communication pipe15is axially displaceable in the storage chamber5so that the flow passage10ais closed with the circumferential wall15a. Preferably, the air communication pipe15is disposed in the storage chamber while being in a radially restricted state for securing the stable closed state. In the embodiment, the partition10is provided with a regulating part for regulating the air communication pipe15to be aligned (or nearly aligned) with the axial center of the main body3. The regulating part may be formed by slightly increasing the thickness of the partition10in the axial direction, and forming a recess part (regulating part)10cin the thickened section, which accommodates a tip end of the air communication pipe15. The recess part10cmay be arbitrarily formed so long as the air communication pipe15is axially movable with the play to a certain degree. Specifically, the micro-gap may be formed between the outer circumferential surface of the air communication pipe15and the inner circumferential surface of the recess part10cso that the liquid can be held therebetween in the state where the air communication pipe15is urged against the partition10side. Even if the fitted state between the outer circumferential surface of the air communication pipe15and the inner circumferential surface of the recess part10chardly holds the liquid, such state is permissible so long as the liquid can be guided to the inside of the flow passage10aupon displacement of the air communication pipe15to separate from the partition. Preferably, the axial length of the recess part10cis longer than a stroke (to be adjusted by the urging force of the urging unit) W of the air communication pipe15so that the air communication pipe15can be stably regulated (inFIG.1, the respective lengths are substantially the same). The partition10of the embodiment includes a flow rate adjuster for adjusting the flow rate of the liquid to be supplied from the storage chamber5to the flow passage10a. The flow rate adjuster is disposed in consideration of viscosity and type of the liquid stored in the storage chamber, appropriate quantity of the liquid to be supplied upon shaking of the main body, or the like. For example, an axially extending annular wall10dthat is fitted with the inner surface of the main body3is formed on the outer circumference of the partition10, to which ribs (flow rate adjusters)10eextending toward the circumferential wall15aof the air communication pipe15are attached. AsFIG.1Bshows, the ribs10eare formed along the longitudinal direction of the annular wall10dat, for example, four points at an angular interval of approximately 90°. Each of the ribs10eis formed adapted to the internal diameter of the recess part10cconstituting the above-described regulating part. It is possible to form the recess part10c, the annular wall10d, and the ribs10eintegrally with the partition10. In this case, the supply quantity of the liquid to the flow passage10amay be adjusted by variously changing each thickness, the number, each axial length, and each protruding height of the ribs10e. In the above-described structure, like the recess part10c, the ribs10eextendingly formed on the annular wall10dallow movement of the air communication pipe15to be stably regulated. Referring toFIG.1, the above-structured applicator1in the normal state allows the spring member20A to bring the air communication pipe15into abutment on the partition10. Abutment of the leading edge15cof the circumferential wall15aon the partition10closes the flow passage10aformed in the partition10. When shaking the main body3in this state, the spring member20A is compressed by the weight of the stirring member22so that the air communication pipe15is separated from the partition10. At this time, the liquid in the storage chamber5(liquid between the flow rate adjusters10e) flows into the flow passage10afrom the recess part10c, and directly moves to the application body7as shown inFIG.2. The storage chamber5is communicated with the atmosphere via the air passage8aformed in the holder8, the flow passage10a, and the air port15A of the air communication pipe15. Upon separation of the air communication pipe15from the partition10, the liquid immediately flows into the flow passage10aof the partition10, and moves toward the application body7. In this case, despite the high-viscous liquid, the internal pressure of the storage chamber5is in substantially the same state as that of the atmosphere (upon detachment of the cap13, the internal pressure of the storage chamber immediately becomes the same as the atmospheric pressure). When the air communication pipe15is separated from the partition10, the liquid immediately moves toward the flow passage10aby the gravity of the liquid, the water load, and shaking operation so that the application body7secures the stable liquid outflowing state (smooth liquid application state). As described above, the storage chamber5is communicated with the atmosphere so that the liquid outflowing state is improved (good response to liquid supply). Accordingly, there is no need of shaking the main body3frequently. This allows the application body7to apply the liquid sufficiently by shaking less frequently. The use of low-viscous liquid secures sufficient outflow quantity only by shaking the main body once or twice. As described above, formation of the flow rate adjusters10eallows adjustment of the outflow quantity from the flow passage10a. The air communication pipe15is urged against the partition10under the urging force of the spring member20A. When shaking of the main body3is stopped, the air communication pipe15closes the flow passage10ato prevent outflow of the liquid from the storage chamber to the application body. The unnecessary liquid outflow from the flow passage10aof the partition10is avoided to prevent the application body side from being brought into the liquid-rich state. In the embodiment, the protrusion22aof the stirring member22performs the stirring function. Even if the stored liquid is likely to cause compositional separation, the liquid can be mixed by shaking. In the structure as described above, it is preferable to provide the air port15A of the air communication pipe15at the position that is free from entry of the liquid to be filled in the storage chamber5upon change in the posture of the main body3. In the embodiment, asFIG.1shows, in the case where the application body7is directed either downward or upward (not shown), the air port15A is set to be positioned above the surface of the liquid100stored in the storage chamber5. Although not shown, in the case where the main body3is laterally placed, the air port is set so that the liquid surface is below the circumferential wall15aof the air communication pipe15. As a result, the liquid100in the storage chamber5does not infiltrate into the air port15A irrespective of the posture of the main body3. This may prevent the liquid outflow to the application body side through the air port15A even if the internal pressure of the storage chamber5is increased. In the case of small diameters of both the air communication pipe15and the air port15A, high viscosity of the liquid to be stored, or the like, quantity of the outflowing liquid to the inside of the air communication pipe15becomes very small. The liquid outflowing to the inside of the air communication pipe15is allowed to directly flow into the application body7via the flow passage10a. Accordingly, it is possible to change the position where the air port15A is formed in accordance with the liquid to be stored the diameter of the air communication pipe15, or the like. FIG.3is a longitudinal sectional view of the applicator according to a second embodiment of the present invention. In the embodiment to be described herein, the similar components to those shown inFIG.1will be designated with the same reference codes, and explanations thereof, thus will be omitted. In the embodiment, a flow passage10a′ formed in the partition10has its diameter gradually increased toward the tail plug side. An opening diameter of the flow passage10a′ is substantially the same as the internal diameter of the air communication pipe15so that the liquid can easily flow to the flow passage10a′. This structure secures large inflow quantity of the liquid to the flow passage10a′ upon separation of the air communication pipe15from the partition10. Storage of the high-viscous liquid may improve the liquid discharge sensitivity. FIG.4is a longitudinal sectional view of the applicator according to a third embodiment of the present invention. In this embodiment, an opening (air port) open to the storage chamber is formed in the stirring member22press fitted to a rear end opening15B instead of forming the air port in the circumferential wall15aof the air communication pipe15. In other words, an air port22bis formed in a rear end of the stirring member22press fitted to the opening15B of the air communication pipe15. A through hole22cis also formed in the stirring member22while penetrating therethrough in the axial direction. Air in the air communication pipe15is discharged to the inside of the storage chamber5via the through hole22cand the air port22bof the stirring member22. It is possible to variously change the structure and position of the air port for discharging air in the air communication pipe15into the storage chamber5, and further the air discharging path or the like. In the structure as described above, it is preferable to form the air port22bto prevent inflow of the liquid filled in the storage chamber5upon change in the posture of the main body3. As the drawing shows, a reservoir chamber30may be provided to the application body side seen from the partition10for storing the liquid outflowing from the flow passage10a. The reservoir chamber30as shown in the drawing is provided by forming a recess part7ain the application body7. Otherwise, the reservoir chamber may be formed between the partition10and the application body7having its length shortened. Even if a large quantity of liquid outflows from the flow passage10aas a result of excessive shaking of the main body3, the reservoir chamber30allows storage of the surplus liquid. This allows continuous application, and also immediate application upon detachment of the cap13without shaking the main body3. To form the reservoir chamber30, an occluding body for occluding the liquid may be disposed in the reservoir chamber. The occluding body is made of a material with weaker capillary force than the application body7so that the liquid outflowing from the flow passage10acan be temporarily occluded. Upon consumption of the liquid through application by the application body7, the occluded liquid can be consumed. This makes it possible to suppress the application body7from being brought into the liquid-rich state. FIG.5is a longitudinal sectional view of the applicator according to a fourth embodiment of the present invention. In the embodiment, the liquid outflowing from the flow passage10aof the partition10is not directly supplied to the application body7. Instead, the reservoir chamber30is formed between the partition10and the application body7, at which a relay member35is disposed for liquid transfer so that the liquid is guided to the application body7via the relay member35. The material for forming the relay member35is not specifically limited so long as the relay member35performs the function for transferring the liquid to the application body7. If the liquid outflows excessively from the flow passage10a, the surplus liquid is stored in the reservoir chamber30. Upon consumption of the liquid for application by the application body side, the stored liquid may be transferred to the application body via the relay member35(the liquid can be supplied to the application body without requiring frequent shaking of the main body). Alternatively, in addition to the liquid transfer function, the temporary liquid storage function may be imparted to the relay member35. For example, it may be formed as a porous bar-like member by bundling many fibers parallel to the axial direction in the compressional state. The resultant structure serves to transfer the inflowing liquid from the flow passage10ato the application body7under the capillary force. If there is no inflowing liquid from the flow passage10a, the liquid can be stored. In the structure provided with the reservoir chamber30, the capillary force of the fibrous relay member is capable of transferring the liquid stored in the reservoir chamber to the application body side. The relay member35may be arbitrarily formed so long as it is structured to sensitively transfer the liquid outflowing from the flow passage10a, or the liquid stored in the reservoir chamber30to the application body7. The porosity of the member is appropriately selected in accordance with viscosity of the liquid stored in the storage chamber. For example, in the case of the low-viscous liquid, it is preferable to employ the member with low porosity. In the case of the high-viscous liquid, it is preferable to employ the member with high porosity. A storage part S1may be formed around the relay member35to store the liquid overflowing out of the relay member35. The storage part S1can be formed as the gap between the inner surface of a main body8A of the holder8and the outer surface of the relay member. The storage part S1allows the region provided with the relay member35to be filled with the liquid to protect the application body7from being dried. In other words, the application body7can be kept in a wet state so that the application can be performed immediately after detachment of the cap13. This also allows the application body to continuously perform application without requiring frequent shaking of the main body3. The relay member35is not limited to the fibrous structure. For example, the molded article such as a plastic product can be used to hold the liquid under the capillary force along the axial direction. FIG.6is a longitudinal sectional view of the applicator according to a fifth embodiment of the present invention. In the embodiment, the reservoir chamber as described above is not formed. Instead, the relay member35is held with the holder8. The main body8A of the holder8has a cylindrical shape, and extends in the axial direction, in which the integrally formed application body7and the relay member35are held. Openings8d,8eeach having a polygonal cross section are formed at top and bottom ends of the main body8A of the holder8, respectively. The relay member35having a circular cross section is inserted through the openings, and held therein. The gap (storage part) S1is formed between the relay member35and the main body8A, in which the liquid outflowing from the flow passage10ais held (serving as a liquid sump). The structure stabilizes the holding state of the relay member35, and facilitates stable formation of the gap S1around the relay member. FIG.7is a longitudinal sectional view of the applicator according to a sixth embodiment of the present invention. In this embodiment, an axially movable mass40for stirring the liquid is disposed in the storage chamber5. The mass40has an axially penetrating through hole40ain the center for accommodating insertion of the air communication pipe15. The mass40can be brought into abutment on the protrusion22aof the stirring member22. As the mass40can be brought into abutment on the protrusion22aof the stirring member22by shaking the main body3, the air communication pipe15is made easily movable against the urging force of the spring member20A. The mass40axially displaces in the storage chamber to perform the liquid stirring function. This makes it possible to stir the pigment-based liquid efficiently. FIG.8is a longitudinal sectional view of the applicator according to a seventh embodiment of the present invention. In this embodiment, an axially extending rod-like member50is disposed in the air communication pipe15. The rod-like member50is provided with a specific weight and, when the main body3is shaken, abuts on an inner surface22eof the stirring member22to make the air communication pipe15easily movable against the urging force of the urging unit. As the liquid resistance does not act on such member, it can drop earlier than the air communication pipe15. This makes it possible to guide the liquid in the storage chamber5(liquid in the flow rate adjuster10e) to the flow passage10a. In other words, movement of the rod-like member50within the air communication pipe effectively prevents the liquid from being clogged and dried around the flow passage. The rod-like member50may be brought into abutment on the relay member35(application body7) via the flow passage10aof the partition10. The structure as described above allows the rod-like member50to perform the function of the relay member, and the liquid to be smoothly supplied to the application body. FIG.9is a longitudinal sectional view of the applicator according to an eighth embodiment of the present invention. In this embodiment, a rear end of the rod-like member50as shown inFIG.8is fitted with the stirring member22to integrally operate the air communication pipe15and the rod-like member50in association with each other. A tip end side of the rod-like member50is brought into contact with the application body7under the urging force of the spring member20A via the flow passage10a, the reservoir chamber30and the recess part7aformed in the application body7. This structure allows the liquid accumulated in the reservoir chamber30and the recess part7a, or the like to be efficiently supplied to the application body7. The rod-like member50is in contact with the application body7constantly under the urging force of the spring member20A. The use of the liquid holding material for forming the rod-like member50protects the application body7from being dried. FIG.10is a longitudinal sectional view of the applicator according to a ninth embodiment of the present invention. In this embodiment, a partition13ais formed in the cap13to have a storage chamber13btherein so that the storage chamber13bis filled with a solvent13A. The solvent13A in the storage chamber can be brought into contact with the application body7via a through hole13cformed in the partition13ato protect the application body7from being dried. FIG.11shows the applicator according to a tenth embodiment of the present invention.FIG.11Ais a longitudinal sectional view, andFIG.11Bis a sectional view taken along line C-C ofFIG.11A. In this embodiment, a relay member10fis inserted and fixed to the inside of the flow passage10aof the partition10for adjusting the outflow quantity of the liquid flowing to the application body side. The relay member10fof the embodiment has one end entering the air communication pipe15while having a given space therefrom, and the other end in contact with the application body7. The relay member10fdisposed in the flow passage10aallows adjustment of the outflow quantity (outflow rate) of the liquid flowing to the application body7side when the air communication pipe15is separated from the partition10upon shaking, or the like. The relay member10fmay be formed as a bundled fiber body. The flow passage10aof the partition10has a polygonal cross section for accommodating insertion of the relay member10fhaving a circular cross section so that the relay member10fis positioned and fixed. The gap between the inner surface of the flow passage and the outer surface of the relay member10fmay be formed as the adjustment flow passage10a″. The structure allows the liquid to flow in the relay member10f, and allows the gap to serve as an air replacement part (air passage) to supply the liquid to the application body7by adjusting the outflow quantity. In this case, the outer circumference of the relay member10fmay come in contact with the inner surface of the flow passage10aof the partition at two or more points. The flow passage10amay be appropriately modified to have an elliptical cross section, for example. FIG.11C to11Eillustrate modified examples of the relay member as shown inFIG.11A. The relay member may be formed as a plastic molded product such as polyacetal (POM) besides the bundled fiber body. Each of the plastic relay members10fa,10fb,10fcas shown in the drawings is fitted with the inside of the flow passage10aof the partition10, and provided with the adjustment flow passage10a″ including a higher capillary force section and a lower capillary force section along the axial direction. In other words, air flows to the lower capillary force section, and the liquid flows to the higher capillary force section so that the outflow quantity (outflow rate) of the liquid supplied to the application body7is adjusted. As described above, the relation between the inner surface of the flow passage10aof the partition10and the relay member is not specifically limited. The relation may be implemented by forming the air passage inside the relay member, or forming the gap in the outer surface region. The relay member does not have to constantly hold the liquid therein. The liquid required by the application body7may be of arbitrary type so long as it can be supplied to the relay member and the application body through a tip end of the storage chamber5, which is opened by shaking. Each length of the relay members10f,10fa,10fb,10fcmay extend over an entire axial length of the flow passage10aof the partition10, or extend partially in the axial direction. Alternatively, one end of each of the relay members may extend to the rear end of the inside of the air communication pipe15, and the other end may extend to the inside of the application body7. Furthermore, the other end of each of the relay members may be just in contact with the application body7, or may be separated from the application body7. The structure for inserting the relay member into the air communication pipe15is not limited so long as such member is not fitted with the air communication pipe15to prevent an air port15A from being blocked. FIG.12shows a modified example of the above-described first embodiment.FIG.12Ais a longitudinal sectional view, andFIG.12Bis a sectional view taken along line D-D ofFIG.12A. In the structure as shown inFIG.1, the leading edge15cof the air communication pipe15is directly brought into abutment on the partition10to seal the flow passage10a. A seal material16may be provided to intervene between the leading edge15cand the partition10as an auxiliary member for imparting sealability. Preferably, the seal material16is made of a flexible material. For example, such material as silicon, rubber, and cotton may be used for forming a plate-like shape. A communication hole16awith the diameter larger than that of the flow passage10ais formed in the center of the seal material16. The seal material is disposed between the air communication pipe15and the partition10to improve tight contactness when the air communication pipe15is pressed by the urging unit, resulting in improved sealability. The embodiments of the present invention have been described. The present invention is not limited to those embodiments, but may be variously modified. The present invention is characterized in that the air communication pipe15is urged against the partition to close the flow passage10atherein, air is communicated with the inside of the storage chamber5via the air communication pipe15, and the air communication pipe15is separated from the partition to allow the liquid in the storage chamber to outflow from the flow passage10aby shaking the main body3. It is possible to appropriately modify structures of the application body7and the partition10, and the path through which air passes to reach the air communication pipe15from outside. It is also possible to appropriately modify the size (capacity) of the storage chamber5, the thickness, length, the stroke of the air communication pipe15, or the like in accordance with usage of the applicator (viscosity of the liquid to be stored, and the capacity). The embodiments may be implemented by replacing the component of one embodiment with that of the other embodiment, or combining the components. In the embodiments, the cosmetic tool such as the eyeliner has been described as an exemplified case. However, the present invention is applicable to various applicators such as the writing tool. Accordingly, the shape and the axial length of the main body, and structure of the application body may be appropriately modified. | 33,453 |
11858290 | DETAILED DESCRIPTION OF THE INVENTION The following describes the embodiments of the present invention with specific embodiments. The person skilled in the art may easily understand other advantages and effects of the present invention from the content disclosed in this specification. Although the description of the present invention will be introduced together with the preferable embodiment, it does not represent that the features of the present invention are limited to the embodiment. On the contrary, the purpose of combining the embodiment to introduce the invention is to cover the choices or improvements based on the claims of the present invention or which may extend over it. In order to provide deep understanding of the present invention, the following description will contain many specific details. The present invention may not use to implement these details. Besides, in order not to confuse or bedim the key point of the present invention, some specific details will be omitted in the description. Besides, “up”, “down”, “front”, “back” used in the following description, are defined by the space position based on the fume hood used by the experimenters in the laboratory, while it should not be understood as the limitation to the present invention. In the present invention, “down”, “front” refers to an end of an applicating head, “up”, “back” refers to an end of a reservoir. The normal condition or the not specifically noted condition mentioned in the present invention usually refers to the room temperature and standard atmospheric pressure, and the abnormal condition refers to the outside temperature or in which pressure deviates from the normal condition. Capillary pressure P in the present invention is defined as the pressure produced when in the normal condition, an end of a porous body (liquid sealing tube or buffer) of sufficient length (generally required 2-15 cm) is just in contact with the horizontal liquid surface and after positioned upright for 30 minutes; the liquid rises to the height of h, P=ρgh, in which the p is the density of the liquid, g is the gravitational acceleration, and h is the rising height of the liquid. The test method of the rising height of the liquid h in the present invention is defined as follows:1) Put a porous body with a length of H into a liquid to absorb the fluid until saturation, then test its saturated absorption weight of W0,2) With the same porous body and the same liquid, one end of the porous body is just in contact with the liquid surface and positioned vertically for 30 minutes, test its absorption weight of W,3) Calculate the value of h is as: h=(W/W0)×H As shown inFIG.1atoFIG.6b, according to the liquid applicator of the present invention, comprising: an applicating head1, a buffer2in communication with the outside air, a gas-liquid exchanger3, and a reservoir4supplying a liquid to the gas-liquid exchanger3, the gas-liquid exchanger3has a wick31, liquid sealing tube32covering on the outer peripheral wall of the wick31, and a gas-liquid channel30disposed between the wick31and the liquid sealing tube32; the buffer2covers on the outer peripheral wall of the liquid sealing tube32, and capillary pressure of the liquid sealing tube32is greater than capillary pressure of the buffer2by 30% or more. A Gas-Liquid Exchanger According to the liquid applicator of the present invention, the gas-liquid exchanger3has a wick31, a liquid sealing tube32covering on the outer peripheral wall of the wick31, and a gas-liquid channel30disposed between the wick31and the liquid sealing tube32. A Wick The wick31of the present invention can be made of bonded fiber, such as bonded polyester fiber, acrylic fiber, or the like. In addition, a groove is provided on the outer peripheral wall of the wick31, the gas-liquid channel30is formed by the groove and the inner peripheral wall of the liquid sealing tube32. That is, one or more grooves which is provided on the outer peripheral wall of the wick31and extended from one end to the other end are used as the gas-liquid channel30. When providing only one groove, the groove serves as a gas-conduction channel for conducting the air to the reservoir4, and the wick31servers as a liquid-conduction channel for transferring the liquid from the reservoir4to the applicating head1. When providing multiple grooves, a part of the grooves can also serve as a liquid-conduction channel for transferring the liquid from the reservoir4to the applicating head1. The wick31of the present invention may also be made of plastics of which the surface can be wetted by the liquid, such as polyformaldehyde, nylon, etc., two or more grooves provided on the surface of the plastic wick31, wherein at least one groove serves as a gas-conduction channel for conducting the air to the reservoir4, the rest of r grooves serve as a liquid-conduction channel for transferring the liquid from the reservoir4to the applicating head1. A Liquid Sealing Tube The liquid sealing tube32of the present invention is made of porous material, such as filtration membrane or fiber. The wall thickness of the liquid sealing tube32is 0.1-5 mm, for example 0.1 mm, 0.5 mm, 1 mm, 2 mm, 5 mm. The thinner wall of the liquid sealing tube32can be made of a filtration membrane, and the thicker wall of the liquid sealing tube32can be made of homogenous fiber or bonded bicomponent fiber. The thinner wall of the liquid sealing tube32has a smaller capacity, which is beneficial to utilize more fully and release the liquid, as well as to reduce the residual amount; and the thicker wall of the liquid sealing tube32has a larger capacity, which is beneficial to retain more liquid in the gas-liquid exchanger3, so that it also has good liquid release performance even when the applicating head1is used upwards. The liquid sealing tube32covers on the outer peripheral wall of the wick31. The liquid sealing tube32may partially or completely covers on the outer peripheral wall of the wick31. The covering area can be reasonably selected according to the needs of the design. After the liquid sealing tube32absorbs a certain amount of liquid so that the air cannot pass through the liquid sealing tube32radially, thereby isolating the wick31from the gas-liquid channel30and the buffer2, in this case, the reservoir4exchanges air with the outside only by the gas-liquid channel30, but not from the buffer2through the liquid sealing tube32. The gas-liquid channel30is formed between the inner wall of the liquid sealing tube32after absorbing the liquid and the wick31and the grooves provided on its surface, in addition, most of the space of the gas-liquid channel30is filled with liquid, so that the gas-liquid channel30is liquid-sealed into multiple small bubbles. When the liquid is discharged from the reservoir4through the gas-liquid exchanger3, the pressure difference between the reservoir4and the outside increases, which pushes the bubbles in the gas-liquid channel30to move to the reservoir4and enter in the reservoir4, so that the pressure difference between the reservoir4and the outside is reduced until balance, while the new liquid sealing segment and small bubbles are formed in the gas-liquid channel30. The capillary pressure of the liquid sealing tube32is greater than the capillary pressure of the buffer2by 30% or more, which makes it difficult for the buffer2to absorb liquid from the liquid sealing tube32in normal conditions. A Gas-Liquid Exchanger The gas-liquid exchanger3of the present invention includes the wick31and the liquid sealing tube32, in which the outer peripheral wall of the wick31is covered by the liquid sealing tube32completely or partially. The gas-liquid channel30is formed by the groove provided on the outer peripheral wall of the wick31of the gas-liquid exchanger3and the inner wall of the liquid sealing tube32, and is in communication with the outside air. According to the use requirements of the liquid applicator and the liquid properties therein, when the gas-liquid channel30serving as the gas-conduction channel, the maximum inscribed circle diameter of the cross-section of the gas-conduction channel is 0.1-0.8 mm. The gas-conduction channels with different maximum inscribed circle diameters have different capillary pressures to control the liquid sealing strength when conducting the air. The smaller the maximum inscribed circle diameter is, the smaller the gas-conduction amount is, which is suitable for the liquid applicator with smaller liquid output. The larger the maximum inscribed circle diameter is, the larger the gas-conduction amount is, which is suitable for the liquid applicator with larger liquid output. The fluid-conduction channel is also provided in the gas-liquid exchanger3. The wick31made of fibers per se can be served as the fluid-conduction channel, and the grooves provided on the surface of the wick31or the grooves with the inner wall of the liquid sealing tube32can also be formed into the fluid-conduction channel. When the liquid used in the liquid applicator contains larger particles, such as pearlescent ink or metal ink, the fluid-conduction channel which has grooves, is particularly important because the normal wick31without grooves will filter the whole or part of the particles in the liquid. A Buffer The buffer2covers on the outer peripheral wall of the liquid sealing tube32, and the capillary pressure of the liquid sealing tube32is greater than the capillary pressure of the buffer2by 30% or more. The buffer2can partially cover on the outer peripheral wall of the liquid sealing tube32, preferably completely cover on it. The buffer2of the present invention is made of porous material and is in communication with the outside air. The porous material made the buffer2can be sponge or fiber, the length and wall thickness of the buffer2can be set according to the internal space of the liquid applicator. The buffer2with proper capillary pressure according to the liquid used in the liquid applicator and the requirements for use. Capillary pressure of the liquid sealing tube32is greater than capillary pressure of the buffer2by 30% or more, and the buffer2barely absorbs liquid from the liquid sealing tube32in normal condition. The inner wall of the buffer2and the outer wall of the liquid sealing tube32are connected, if an abnormal condition occurs and the liquid content in the liquid sealing tube32is too high, the buffer2will absorbs excessive liquid from the liquid sealing tube32, which can prevent leakage of liquid from the applicating head1. When the abnormal condition disappears, the liquid in the buffer2is transferred back to the liquid sealing tube32and returned to the reservoir4through the liquid-conduction channel. In order to make the buffer2have the above properties, the density of the buffer2is 0.03-0.20 g/cm3. If the buffer2is made of fiber, the fiber denier is preferably 0.5-30 denier. An Applicating Head The applicating head1of the present invention may be connected to the wick31passing through the liquid sealing tube32, or it may be inserted into the gas-liquid exchanger3and connected to a part of the inner wall of the liquid sealing tube32. It can also be served as the applicating head1by extending the wick31. A Reservoir In the liquid applicator of the present invention, the reservoir4is a component for storing liquid. An upward or downward sleeve62can be provided on the bottom of the reservoir4. The sleeve62is inserted into the gas-liquid exchanger3, and in close contact with the inner wall of the liquid sealing tube32, or the liquid sealing tube32and the wick31is inserted into the sleeve62, which is beneficial to fix the gas-liquid exchanger3, and prevent the liquid from leaking out. A replaceable reservoir4can be used, which is beneficial to reuse components such as the housing6and reduce the waste of resources. The replaceable reservoir4can be connected to the liquid applicator in many ways, such as screwing, carding, and so on. The First Embodiment FIG.1ais a schematic structural view of the liquid applicator according to the first embodiment of the present invention, andFIG.1bis a cross-sectional view taken along the A-A section of Figure Ta. As shown inFIG.1aand Tb, the liquid applicator, according to the first embodiment, comprises an applicating head1, a buffer2in communication with the outside air, a gas-liquid exchanger3, and a liquid storage4supplying a liquid to the gas-liquid exchanger3. The gas-liquid exchanger3has a wick31, a liquid sealing tube32covering on the outer peripheral wall of the wick31and a gas-liquid channel30disposed between the wick31and liquid sealing tube32. The buffer2covers on the outer peripheral wall of the liquid sealing tube32, and capillary pressure of the liquid sealing tube32is greater than capillary pressure of the buffer2by 30% or more. According to the liquid applicator of the present embodiment, the outer peripheral wall of the wick31is completely covered by the the liquid sealing tube32, one end of the wick31extends out of the upper end of the liquid sealing tube32into the reservoir4, the other end passes through the lower end of it to connect with the applicating head1. In the present embodiment, the wick31is connected against the applicating head1. The liquid sealing tube32is filtration membrane or bonded fiber, and the buffer2is a sponge or bonded fiber. The outer peripheral wall of the liquid sealing tube32is covered by the buffer2. The liquid applicator, according to the present embodiment also comprises a housing6and a partition61, the reservoir4is integrated in the housing6, the partition61is also used as the bottom of the reservoir4. The partition61is provided with a through-hole for inserting the wick31. According to the liquid applicator of the present embodiment, the bottom of the reservoir4is provided with a downwardly extending sleeve62, the sleeve62and the through-hole provided on the partition61to insert the wick31are arranged coaxially and their inner diameter is equal. When assembling, the sleeve62can be inserted between the liquid sealing tube32and the wick31, and the outer peripheral wall of the sleeve62is tightly engaged with the inner wall of the liquid sealing tube32, so that it is easy to reliably assemble between the reservoir4and the gas-liquid exchanger3. The lower part of the housing6can be integrated with an applicating head seat10mounting the applicating head1. The applicating head seat10can also be molded individually and detachably mounted on the lower part of the housing6. The Second Embodiment FIG.2ais a schematic structural view of the liquid applicator according to the second embodiment of the present invention, andFIG.2bis a cross-sectional view taken along the B-B section ofFIG.2a. The structure of the present embodiment is similar to that of the first embodiment, and the same parts as the first embodiment will not be repeated in the description of this embodiment. As shown inFIGS.2aand2b, the liquid applicator according to the second embodiment comprises an applicating head1, a buffer2in communication with the outside air, a gas-liquid exchanger3, and a liquid storage4supplying a liquid to the gas-liquid exchanger3. The gas-liquid exchanger3includes a wick31, a liquid sealing tube32covering on the outer peripheral wall of the wick31, and a gas-liquid channel30disposed between the wick31and the liquid sealing tube32; the buffer2covers on the outer peripheral wall of the liquid sealing tube32, capillary pressure of the liquid sealing tube32is greater than capillary pressure of the buffer2by 30% or more. According to the liquid applicator of the present embodiment, the outer peripheral wall of the wick31is completely covered by the liquid sealing tube32, one end of the wick31extends out of the liquid sealing tube32into the reservoir4, the other end passes through it to insert into the applicating head1. Grooves are provided on the outer peripheral wall of the wick31and with the inner peripheral wall of the liquid sealing tube32to form a gas-liquid channel30. That is, on the outer peripheral wall of the wick31, one or more grooves are extended from one end to the other end to serve as a gas-liquid channel30. In this embodiment, the number of the grooves is set to 3. Preferably, the maximum inscribed circle diameter of the grooves is 0.5 mm. In this embodiment, preferably, the wick31is bonded fiber or plastic. Preferably, the liquid sealing tube32is bonded fiber, and the wall thickness of that is 0.5 mm. Preferably, the buffer2is a sponge or bonded fiber. The outer peripheral wall of the liquid sealing tube32is completely covered by the buffer2. The liquid applicator, according to the present embodiment, also comprises a housing6and a partition61, the reservoir4is integrated in the housing6, the partition61is also used as the bottom of the reservoir4. The partition61is provided with a through-hole for inserting the wick31. According to the liquid applicator of the present embodiment, the bottom of the reservoir4is provided with a downwardly extending sleeve62, the sleeve62, and the through-hole provided on the partition61to insert the wick31are arranged coaxially, and their inner diameter is equal. When assembling, the sleeve62can be inserted between the liquid sealing tube32and the wick31, and the outer peripheral wall of the sleeve62is tightly engaged with the inner wall of the liquid sealing tube32, so that it is easy to reliably assemble between the reservoir4and the gas-liquid exchanger3. According to the liquid applicator of the present embodiment, a protection body5is provided below the gas-liquid exchanger3, and its capillary pressure is not greater than the capillary pressure of the buffer2. In the present embodiment, the other end of the wick31passes through the liquid sealing tube32, then passes through the protection body5and inserts into the applicating head1successively. In extreme abnormal situations, such as carrying a liquid applicator from a low altitude to a high altitude or opening a liquid applicator on a high-flying plane, the liquid quickly exported from the reservoir4cannot be absorbed by the buffer2in time and lead to leakage due to the extreme air pressure difference between inside and outside of the reservoir4. In this case, the protection body5can absorb the liquid that spilled quickly from the gas-liquid exchanger3. After the abnormality is eliminated, the liquid temporarily stored in the protection body5is transferred to the applicating head1through the wick31or absorbed by the liquid sealing tube32. According to the liquid applicator of the present embodiment, it can be applied to an eyeliner. According to the liquid applicator of the present embodiment, since the number of grooves serving as the gas-liquid channel30is 3, at least one of which can be served as a liquid-conduction channel, the particles in the liquid eyeliner can be transported to the applicating head1through the groove or grooves without being filtered by the wick31. The Third Embodiment FIG.3ais a schematic structural view of the liquid applicator according to the third embodiment of the present invention, andFIG.3bis a cross-sectional view taken along the C-C section ofFIG.3a. The structure of the present embodiment is similar to that of the first embodiment, and the same parts as the first embodiment will not be repeated in the description of this embodiment. As shown inFIG.3aandFIG.3b, the liquid applicator according to the third embodiment comprises an applicating head1, a buffer2in communication with the outside air, a gas-liquid exchanger3, and a liquid storage4supplying a liquid to the gas-liquid exchanger3. The gas-liquid exchanger3includes a wick31, a liquid sealing tube32covering on the outer peripheral wall of the wick31, and a gas-liquid channel30disposed between the wick31and the liquid sealing tube32; the buffer2covers on the outer peripheral wall of the liquid sealing tube32, capillary pressure of the liquid sealing tube32is greater than capillary pressure of the buffer2by 30% or more. According to the liquid applicator of the present embodiment, the outer peripheral wall of the wick31is completely covered by the liquid sealing tube32, one end of the wick31extends out of the liquid sealing tube32into the reservoir4, the other end passes through it to insert into the applicating head1. Grooves are provided on the outer peripheral wall of the wick31and with the inner peripheral wall of the liquid sealing tube32to form a gas-liquid channel30. That is, on the outer peripheral wall of the wick31, one or more grooves are extended from one end to the other end to serve as a gas-liquid channel30. In this embodiment, the number of the grooves is set to 1. Preferably, the maximum inscribed circle diameter of the groove is 0.3 mm. In this embodiment, preferably, the wick31is bonded fiber. The liquid applicator, according to the present embodiment also comprises a housing6and a partition61, the reservoir4is integrated in the housing6, the partition61is also used as the bottom of the reservoir4. The partition61is provided with a through-hole for inserting the wick31. According to the liquid applicator of the present embodiment, the bottom of the reservoir4is provided with a downwardly extending sleeve62, the sleeve62and the through-hole provided on the partition61to insert the wick31are arranged coaxially and their inner diameter is equal. When assembling, the sleeve62can be inserted between the liquid sealing tube32and the wick31, and the outer peripheral wall of the sleeve62is tightly engaged with the inner wall of the liquid sealing tube32, so that it is easy to reliably assemble between the reservoir4and the gas-liquid exchanger3. Preferably, the liquid sealing tube32is bonded fiber and the wall thickness of that is 1 mm. Preferably, the liquid sealing tube32is abutted against below of the reservoir4, i.e., against the partition61. Preferably, the buffer2is a sponge or bonded fiber. The outer peripheral wall of the liquid sealing tube32is completely covered by the buffer2. Preferably, the buffer2and the liquid sealing tube32are integrally formed, the outer peripheral wall of the liquid sealing tube32and the inner peripheral wall of the buffer2are bonded. In the present embodiment, part of the wick31extending out of the housing6is formed into the applicating head1, i.e., the applicating head1and the wick31are integrally formed. The Fourth Embodiment FIG.4ais a schematic structural view of the liquid applicator according to the fourth embodiment of the present invention, andFIG.4bis a cross-sectional view taken along the D-D section ofFIG.4a. The structure of the present embodiment is similar to that of the first embodiment, and the same parts as the first embodiment will not be repeated in the description of this embodiment. As shown inFIG.4aandFIG.4b, the liquid applicator according to the fourth embodiment comprises an applicating head1, a buffer2in communication with the outside air, a gas-liquid exchanger3, and a liquid storage4supplying a liquid to the gas-liquid exchanger3. The gas-liquid exchanger3includes a wick31, a liquid sealing tube32covering on the outer peripheral wall of the wick31, and a gas-liquid channel30disposed between the wick31and the liquid sealing tube32; the buffer2covers on the outer peripheral wall of the liquid sealing tube32, capillary pressure of the liquid sealing tube32is greater than capillary pressure of the buffer2by 30% or more. According to the liquid applicator of the present embodiment, the liquid sealing tube32completely covers on the outer peripheral wall of the wick31. Grooves are provided on the outer peripheral wall of the wick31and with the inner peripheral wall of the liquid sealing tube32to form a gas-liquid channel30. That is, on the outer peripheral wall of the wick31, one or more grooves are extended from one end to the other end to serve as a gas-liquid channel30. In this embodiment, the number of the grooves is set to 3. Preferably, the maximum inscribed circle diameter of the grooves is 0.1 mm. Preferably, in this embodiment, the wick31is polyformaldehyde plastic. Preferably, the liquid sealing tube32is filtration membrane and the wall thickness of that is 0.1 mm. Preferably, the buffer2is a sponge or bonded fiber. The outer peripheral wall of the liquid sealing tube32is completely covered by the buffer2. The liquid applicator, according to the present embodiment, also comprises a housing6and a partition61, the reservoir4is integrated in the housing6, the partition61is also used as the bottom of the reservoir4. The partition61is provided with a through-hole for inserting the wick31. According to the liquid applicator of the present embodiment, the bottom of the reservoir4is provided with a sleeve62extending toward the inside of the reservoir4, the sleeve62and the through-hole provided on the partition61to insert the wick31are arranged coaxially and their inner diameter is equal. One end of the wick31is extended out of the buffer2together with the liquid sealing tube32, and inserted into the sleeve62of the reservoir4. The other end of the wick31is passed through the liquid sealing tube32and inserted into the applicating head1. The tip of the applicating head1is provided with a ball11. Preferably, the wick31abuts against the ball11. When assembling, one end of the wick31is inserted into the sleeve62of the reservoir4together with the liquid sealing tube32. The outer peripheral wall of the sleeve62is tightly engaged with the inner wall of the liquid sealing tube32, so that it is easy to reliably assemble between the reservoir4and the gas-liquid exchanger3. According to the liquid applicator of the present embodiment, it can be applied to a device with a small amount of fluid, such as a roller ball pen. The Fifth Embodiment FIG.5ais a schematic structural view of the liquid applicator according to the fifth embodiment of the present invention, andFIG.5bis a cross-sectional view taken along the E-E section ofFIG.5a. The structure of the present embodiment is similar to that of the first embodiment, and the same parts as the first embodiment will not be repeated in the description of this embodiment. As shown inFIGS.5aand5b, the liquid applicator according to the fifth embodiment comprises an applicating head1, a buffer2in communication with the outside air, a gas-liquid exchanger3and a liquid storage4supplying a liquid to the gas-liquid exchanger3. The gas-liquid exchanger3includes a wick31, a liquid sealing tube32covering on the outer peripheral wall of the wick31, and a gas-liquid channel30disposed between the wick31and the liquid sealing tube32; the buffer2covers on the outer peripheral wall of the liquid sealing tube32, capillary pressure of the liquid sealing tube32is greater than capillary pressure of the buffer2by 30% or more. According to the liquid applicator of the present embodiment, the outer peripheral wall of the wick31is completely covered by the liquid sealing tube32, one end of the wick31extends out of the liquid sealing tube32into the reservoir4, the other end passes through it to insert into the applicating head1. Grooves are provided on the outer peripheral wall of the wick31and with the inner peripheral wall of the liquid sealing tube32to form a gas-liquid channel30. That is, on the outer peripheral wall of the wick31, one or more grooves are extended from one end to the other end to serve as a gas-liquid channel30. In this embodiment, the number of the grooves is set to 5. Preferably, the maximum inscribed circle diameter of two of the grooves is 0.8 mm, and the other there is 0.5 mm. Preferably, the liquid sealing tube32is bonded fiber and the wall thickness of that is 5 mm. Preferably, the buffer2is bonded fiber. The outer peripheral wall of the liquid sealing tube32is completely covered by the buffer2. The liquid applicator according to the present embodiment also comprises a housing6and a partition61. The partition61is provided with a through-hole for inserting the wick31. The bottom of the partition61is provided with a downwardly extending lower sleeve621, the lower sleeve621and the through-hole provided on the partition61to insert the wick31are arranged coaxially and their inner diameter is equal. The top of partition61is provided with an upper sleeve622extending toward the inside of the reservoir4. The inner diameter of the upper sleeve622is slightly larger than the inner diameter of the through-hole provided on the partition61to insert the wick31. According to the liquid applicator of the present embodiment, the reservoir4is a replaceable reservoir4. An interface41is disposed on the reservoir4. When assembling, the interface41of the reservoir4is clamped with the upper sleeve622of the partition61to form a liquid seal. The lower sleeve621can be inserted between the liquid sealing tube32and the wick31, the outer peripheral wall of the lower sleeve621is tightly engaged with the inner wall of the liquid sealing tube32, so that it makes easy to reliably assemble between the reservoir4and the gas-liquid exchanger3and replace the reservoir4. According to the liquid applicator of the present embodiment, it can be served as a device with a large amount of fluid, such as ink brush. The Sixth Embodiment FIG.6ais a schematic structural view of the liquid applicator according to the sixth embodiment of the present invention, andFIG.6bis a cross-sectional view taken along the G-G section ofFIG.6a. The structure of the present embodiment is similar to that of the first embodiment, and the same parts as the first embodiment will not be repeated in the description of this embodiment. As shown inFIGS.6aand6b, the liquid applicator according to the sixth embodiment comprises an applicating head1, a buffer2in communication with the outside air, a gas-liquid exchanger3, and a liquid storage4supplying a liquid to the gas-liquid exchanger3. The gas-liquid exchanger3includes a wick31, a liquid sealing tube32covering on the outer peripheral wall of the wick31, and a gas-liquid channel30disposed between the wick31and the liquid sealing tube32; the buffer2covers on the outer peripheral wall of the liquid sealing tube32, capillary pressure of the liquid sealing tube32is greater than capillary pressure of the buffer2by 30% or more. According to the liquid applicator of the present embodiment, the outer peripheral wall of the wick31is partially covered by the the liquid sealing tube32, one end of the wick31extends out of the liquid sealing tube32into the reservoir4, the other end is located at inside the liquid sealing tube32and the distance between in and the bottom surface of the liquid sealing tube32is about a quarter of the axial height of the the liquid sealing tube32. Grooves are provided on the outer peripheral wall of the wick31and with the inner peripheral wall of the liquid sealing tube32to form a gas-liquid channel30. That is, on the outer peripheral wall of the wick31, one or more grooves are extended from one end to the other end to serve as a gas-liquid channel30. In this embodiment, the number of the grooves is set to 3. Preferably, the maximum inscribed circle diameter of the grooves is 0.2 mm. In this embodiment, preferably, the wick31is bonded fiber. Preferably, the liquid sealing tube32is bonded fiber and the wall thickness of that is 0.5 mm. Preferably, the buffer2is bonded fiber. The outer peripheral wall of the liquid sealing tube32is bonded to the inner peripheral wall of the buffer2. The liquid applicator, according to the present embodiment, also comprises a housing6and a partition61, the reservoir4is integrated in the housing6, the partition61is also used as the bottom of the reservoir4. The partition61is provided with a through-hole for inserting the wick31. According to the liquid applicator of the present embodiment, the bottom of the reservoir4is provided with a downwardly extending sleeve62, the sleeve62and the through-hole provided on the partition61to insert the wick31are arranged coaxially and their inner diameter is equal. When assembling, the sleeve62can be inserted between the liquid sealing tube32and the wick31, and the outer peripheral wall of the sleeve62is tightly engaged with the inner wall of the liquid sealing tube32, so that it is easy to reliably assemble between the reservoir4and the gas-liquid exchanger3. In the present embodiment, the applicating head1is inserted into the gas-liquid exchanger3and connected to a part of the inner wall of the liquid sealing tube32. The rear end of the applicating head1is integrally provided with an insertion part which is cylindrical, square, or conical, the insertion part is inserted into the liquid sealing tube32and abutted with or close to the wick31. Preferably, a groove is formed on the outer peripheral wall of the insertion part to form a gas-conduction channel. As shown inFIG.6b, according to the liquid applicator of the present embodiment, the housing6and the buffer2can be provided with an elliptical cross section, so that it can be applied to a device with medium laydown of fluid, such as highlighter marker. The examples are cited only to demonstrate and interpret the principles and efficacies of the present invention, and do not in any way limit the present invention. Any person familiar with the technology may modify or change the above examples without prejudice to the spirit and scope of the present invention. Thus, all the equivalent modifications and changes to the present invention made by any person with common knowledge in the field without breaking away from the spirits and technical ideas disclosed by the present invention shall fall within the scope of the claims of the present invention. The liquid applicator of the present invention generally refers to a device for writing and painting in office supplies, various types of liquid application devices used in cosmetics and other fields, etc. | 34,098 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.