System and method for applying primer to media in inkjet printers
An inkjet printer includes at least one printhead and a transfer member to apply primer onto media before the media is printed. The at least one printhead ejects drops of primer onto the transfer member and the transfer member forms a nip with a nip roller. Entry of media into the nip and entry of the primer image on the transfer member are synchronized to enable the primer image to be transferred to the media in the nip.
1 . A primer applicator for an inkjet printer configured to print ink images, the primer applicator comprising:
at least one printhead fluidly connected to a supply of primer;
a transfer member positioned opposite the at least one printhead;
a first actuator operatively connected to the transfer member, the actuator being configured to rotate the transfer member;
a nip roller configured to form a nip with the transfer member; and
a controller operatively connected to the at least one printhead and the first actuator, the controller being configured to:
operate the at least one printhead to form primer images on the transfer member, the primer images corresponding to the ink images; and
operate the first actuator to rotate the transfer member to transfer primer images from the transfer member onto media passing through the nip prior to the ink images being printed on the media.
2 . The primer applicator of claim 1 , the transfer member further comprising:
a transfer roller having a diameter greater than a diameter of the nip roller.
3 . The primer applicator of claim 2 , the transfer member further comprising:
a plurality of rollers, at least one of which is rotated by a second actuator; and
an endless belt mounted about the plurality of rollers, the endless belt being configured to rotate about the plurality of rollers.
4 . The primer applicator of claim 3 wherein the endless belt consists essentially of a polyimide, polyester, polyamide, polyurethane, EPDM rubber, poly ether ether ketone (PEEK), poly aryl ether ketone (PAEK), polyether sulfone, polycarbonate, polyetherimide, or composites of these materials.
5 . The primer applicator of claim 3 , the nip roller further comprising:
a stainless steel roller; and
a coating consisting essentially of silicone, viton, or polyurethane.
6 . The primer applicator of claim 5 further comprising:
a dryer having a plurality of heating elements, the dryer being positioned to direct heat toward the media after the primer images are transferred to the media.
7 . The primer applicator of claim 6 further comprising:
a primer remover configured to remove residual primer from the endless belt after the primer image has been transferred to the media.
8 . The primer applicator of claim 7 , the primer remover further comprising:
a blade that engages the endless belt.
9 . The primer applicator of claim 8 wherein the blade consists essentially of rubber.
10 . The primer applicator of claim 9 wherein the at least one printhead is a low resolution printhead configured to eject drops of a metal salt solution.
11 . An inkjet printer comprising:
at least one first printhead;
a media transport for moving a media sheet through a print zone opposite the at least one first printhead in a process direction; and
a primer applicator having:
at least one second printhead fluidly connected to a supply of primer;
a transfer member positioned opposite the at least one second printhead;
a first actuator operatively connected to the transfer member, the first actuator being configured to rotate the transfer member;
a nip roller configured to form a nip with the transfer member; and
a controller operatively connected to the at least one first printhead, the at least one second printhead and the first actuator, the controller being configured to:
operate the at least one second printhead to form primer images on the transfer member;
operate the first actuator to rotate the transfer member to transfer primer images from the transfer member onto media passing through the nip; and
operate the at least one first printhead to form ink images on the primer images on the media in the print zone.
12 . The inkjet printer of claim 11 , the transfer member further comprising:
a transfer roller having a diameter greater than a diameter of the nip roller.
13 . The inkjet printer of claim 12 , the transfer member further comprising:
a plurality of rollers, at least one of which is rotated by a second actuator; and
an endless belt mounted about the plurality of rollers, the endless belt being configured to rotate about the plurality of rollers.
14 . The inkjet printer of claim 13 wherein the endless belt consists essentially of a polyimide, polyester, polyamide, polyurethane, EPDM rubber, poly ether ether ketone (PEEK), poly aryl ether ketone (PAEK), polyether sulfone, polycarbonate, polyetherimide, or composites of these materials.
15 . The inkjet printer of claim 13 , the nip roller further comprising:
a stainless steel roller; and
a coating consisting essentially of silicone, viton, or polyurethane.
16 . The inkjet printer of claim 15 further comprising:
a dryer having a plurality of heating elements, the dryer being positioned to direct heat toward the media after the primer images are transferred to the media.
17 . The inkjet printer of claim 16 further comprising:
a primer remover configured to remove residual primer from the endless belt after the primer image has been transferred to the media.
18 . The inkjet printer of claim 17 , the primer remover further comprising:
a blade that engages the endless belt.
19 . The inkjet printer of claim 18 wherein the blade consists essentially of rubber.
20 . The inkjet printer of claim 19 wherein the at least one second printhead is a low resolution printhead configured to eject drops of a metal salt solution.
21 . A method for operating an inkjet printer comprising:
operating a media transport to move a plurality of media sheets through a print zone opposite at least one printhead in a process direction;
forming a primer image on a transfer member; and
transferring the primer image from the transfer member to the media before the media enters the print zone.
22 . The method of claim 21 , the forming of the primer image further comprising:
operating at least one other printhead to eject drops of the primer onto the transfer member.
23 . The method of claim 22 wherein the at least one other printhead has a resolution that is lower than a resolution of the at least one printhead, the at least one other printhead being configured to eject a metal salt solution.
24 . The method of claim 23 wherein the at least one other printhead has a resolution of 300 drops per inch.
25 . The method of claim 24 further comprising:
rotating the transfer member about a plurality of rollers.
26 . The method of claim 25 wherein the transfer member is an endless belt.
27 . The method of claim 24 further comprising:
operating an actuator to rotate the transfer member about a longitudinal axis.
28 . The method of claim 24 , the transferring of the primer image from the transfer member to the media further comprising:
forming a nip with the transfer member and a nip roller; and
directing the media through the nip.
29 . The method of claim 28 further comprising:
at least partially drying the primer image on the media before the media passes the at least one printhead.
30 . The method of claim 29 further comprising:
removing residual primer from the transfer member after the primer image is transferred from the transfer member to the media.