Diazo Developing Apparatus

Present invention relates to sheet developing equipment and more particularly to an apparatus for developing diazo sheet material.

The skyrocketing cost of silver has made diazo printing much more attractive in recent years and, accordingly, the market for reliable equipment to develop diazo sheet material, that is to say both coated paper sheets and plastic film, has increased rapidly in the last few years. In many prior devices, the sheets being developed contact machine parts as they pass through the machine. This can scratch the film which is, of course, undesirable. Another problem has been even and reliable exposure of the diazo sheets to developing material such as ammonia vapor. A further problem has been the high cost and unsatisfactory precision of the rolls used for carrying the sheets through the apparatus. A further problem has been the leakage of ammonia vapor from the devloping chamber at the location of the seal between the inlet and outlet rolls and the developing chamber and the uniform conduction of heat to the developing chamber as well as the prevention of heaters from moving or being displaced during operation. For example, in some prior equipment electrical resistance heater rods are used which are inadequately supported and the rods sometimes move slightly or droop during operation. In addition, heat is not conducted uniformly to different parts of the chamber. This can cause uneven heating, which is, of course, undesirable.

In view of these and other deficiencies of the prior art, this invention has as its major objective the provision of an improved diazo sheet developer with the following characteristics and advantages:

(a) Capacity for developing diazo sheets with either ammonia vapor or heat alone,

(b) the provision of dual purpose members engaged against inlet and outlet rollers to provide a vapor seal and, at the same time, yieldably bias rollers into engagement with one another,

(c) the provision of an ammonia development chamber composed of tanks having a C or channel-shaped cross-section with a reliable means for sealing their ends against the leakage of vapor,

(d) the provision of a low-cost construction and production method for rollers to be used in a diazo sheet developer wherein the rollers are strong, resistant to deflection or bending, and have resilient cylindrical surfaces with precise dimensions,

(e) a diazo sheet developer with a reliable provision for collecting and disposing of ammonia fumes that escape from the development chamber,

(f) provision for preventing the vapors from escaping around the ends of the drive and idler rollers,

(g) the provision of a fume removal device that effectively removes and disposes of any vapor escaping from either the pump or development chamber and,

(h) provision for securely supporting and retaining the electrical heating rods while at the same time distributing heat provided by the rods uniformly throughout the apparatus.

FIG. 1 is a perspective view of an apparatus embodying the invention.

FIG. 2 is a cross-sectional view taken on line 2--2 of FIG. 1.

FIG. 3 is a vertical cross-sectional view taken on line 3--3 of FIG. 2.

FIG. 4 is a partial vertical cross-sectional view taken on line 4--4 of FIG. 2.

FIG. 5 is a partial perspective view partly in section of the end of one of the rollers and its bushing.

FIG. 6 is a partial vertical sectional view taken on line 6--6 of FIG. 3.

FIG. 7 is a diagrammatic vertical and sectional view taken on line 7--7 of FIG. 2.

FIG. 8 is a perspective view of the tank and roller sealing gaskets.

FIG. 9 is a diagram illustrating the relationship between the development chamber and the outer plenum.

FIG. 10 is a perspective diagram of the ammonia distribution system.

FIG. 11 is a circuit diagram of the apparatus, and

FIG. 12 is a perspective view of the end of the top ammonia tank 50 and its sealing gasket 56.

The invention provides a diazo sheet developer that has a development chamber interposed between two pairs of aligned rollers, the first pair to feed sheet material into the development chamber and the second pair to withdraw the sheet such that the sheet passes directly through the apparatus in a straight line and as will be described in more detail below without touching any machine parts which could scratch it. The chamber is composed of upper and lower development tanks each of which preferably comprises a generally channel-shaped metal extrusion that is open on the side thereof facing the sheet as it passes through the machine, i.e. the center of the machine. In the preferred embodiment, the sheet material passes horizontally such that the upper tank opens downwardly while the lower tank is closed along its lower end and opens upwardly at its top facing the film. One or both of the tanks is heated and ammonia is preferably metered at a predetermined rate to produce ammonia vapor within the development tank.

In the preferred form of the invention, a pair of vertical plates are provided adjacent the ends of the tanks, and a gasket is compressed between the plates and the ends of the tanks for reliably sealing the tank ends. Resilient gaskets formed from compressible material are also compressed between the roll ends and the plate for sealing the ends of the rolls.

A preferred roller of a unique design is constructed from a metal roll over which an elastomeric hose is stretched, the exterior of which is ground down to provide an exposed surface of predetermined dimensions concentric with the center of the metal roll inside.

Outside the development chamber is a fume collection plenum communicating with a blower means and a vapor disposal means so that any vapor escaping from the development chamber is collected and disposed of without being able to escape into the atmosphere. The pump used for distributing ammonia is preferably enclosed within the vapor collection plenum as is the entire development chamber. The rollers are each sealed along their length by the provision of an elongated sealing strip engaged on the surface of the roller with some of the strips being engaged at a point normal to the roller on a side opposite the point of engagement between the rollers. In this way, the strips form a dual function. Besides sealing the roller edges against the escape of vapor, they also yieldably bias the rollers toward one another and eliminate the need for springs to provide this function.

With precision ground rollers on opposite sides of the development chamber, a straight-through feed is provided. There are no machine parts in the path of the sheet as it travels from the inlet to the outlet and, accordingly, the sheets will not touch anything that could scratch or otherwise damage them during the development process. In a preferred form of the invention, a timing belt is used for rotating the driven rollers and has been found highly effective in preventing bunching or damage to the film or other sheet material being processed. An automatic pump is provided with a variable displacement rate so that precise amounts of ammonia can be fed to the development chamber. In a preferred form of the invention, electrical resistance heaters are provided along the top and bottom of the development chamber and each is in the form of a rod captivated by a portion of the wall of the development chamber, e.g. by the provision of a groove having a C-shaped cross section extending the length of the top and bottom of the development chamber.

Referring now to the figures, and particularly FIGS. 1 through 3, the diazo copier is indicated generally by the numeral 10. It includes an exterior housing 12 having a top wall 14, bottom wall 16, rear wall 18, and front wall 20. The rear wall 18 includes an upper wall member 18a and a lower wall member 18b, between which is an outlet slot or aperture 18c. Similarly, the front wall 20 includes an upper wall portion 20a, a lower wall portion 20b separated by an inlet slot or aperture 20c, immediately below which is an entry tray 20f for supporting sheet material 19 (FIG. 3) just before it enters the apparatus. At opposite ends of the apparatus are end walls 21 and 23, wall 21 being provided with a multiplicity of parallel air entry louvers or slots 21a through which fresh air is drawn into the developer during operation as will be explained fully below.

The lower surface of the housing 12 comprises a flat rectangular base plate 22 to which is rigidly secured a pair of vertically disposed parallel laterally spaced apart side plates 24 and 26. Side plates 24 and 26 are also suitably secured to the top wall 14.

As best seen in FIG. 4, the side plates are provided with square openings 28 above which are located vertically elongated rectangular openings 30, and it is within these openings that the roller support bushings are mounted. The bottom two bushings 32 are fixed, while the upper bushings 32 are able to slide vertically within the vertically elongated openings. The bushings as seen in FIGS. 4 and 5 are provided with flattened diametrically opposed side walls 32a that just fit within the openings 28 and 30, respectively, the upper two being free to slide vertically as will be described below. Journal for rotation in the bushings 32 are a pair of idler pins 34 for the upper pair and a pair of drive pins 36 for the lower pair. The rollers that will be described below thus have a pair of aligned pins 34 or 36, as the case may be at each of its ends and each pin is, in turn, journaled for rotation in one of the bushings 32. The bushing can be formed, for example, from a suitable wear resistant low friction plastic resinous material and is preferably provided with a collar 32b that rests against the inside surface of one of the side plates 24 or 26.

As best seen in FIGS. 6 and 7, the drive pins 36 are provided with pulleys 36a and 36b over which is entrained a timing belt 38. The belt 38 is also entrained over a drive pulley 37a that is affixed to the shaft of the drive motor 37 (FIGS. 2 and 11). Belt tension is maintained by idler pulleys 38a and 38b (FIG. 7).

The lower rollers driven by the drive pins 36 are designated 40 and 42 and each is positioned with its uppermost edge in alignment between the inlet and outlet slots 20c and 18c, respectively. The upper idler rollers 44 and 46 are mounted immediately above rollers 42 and 40, respectively, to define a first pair of parallel mating inlet rollers 40 and 46 and a second pair of mating outlet or exit rollers 42 and 44. When the motor 37 is actuated during operation, the feed rollers 40 and 46 carry the sheets 19 from right to left in FIG. 3 through the apparatus from the inlet 20c, and the exit rollers 42 and 44 carry the sheets out of the apparatus through slot 18c. Since the mating surfaces of the roller pairs are in alignment, the apparatus provides a straight-through feed of the sheet material 19 and, as seen in FIG. 3, the sheets don't touch anything between the roller pairs and cannot be scratched or otherwise damaged during development. Motor 37 is supported in any suitable manner, as by means of the supporting plate 39, fastened at its lower end to the base plate 22.

Construction of the rollers, of which roller 46 is an example, will now be described with reference to FIGS. 5 and 6. Each of the rollers is composed of an inner roll member consisting of a metal tube 46b, over which is stretched a rubber hose 46a. The hose is slid over the tube 46b in this way. The tube 46b is closed at one end and the hose is started over the end of the tube. Compressed air is then forced into the hose causing it to expand and, as the hose expands, its diameter increases sufficiently so that it will slide easily onto the tube 46b. The source of compressed air is then removed and the resiliency of the material from which the hose is made causes it to contract tightly onto the tube 46b. Plugs 46c are then mounted in each end and the idler pin 34 or drive pin 36 is screw threaded into place in the plug. The roller is then centered on a grinder and a high speed abrasive grinding wheel is used to precision grind the surface of the rubber hose 46a to the predetermined diameter required. The dimensions of the rollers will accordingly be very precise and the surface will be concentric with the center of rotation. In addition, the surface has a very high coefficient of friction, enabling the rollers to grip the sheets securely as they rotate. The exterior layer 46a can be of any suitable resilient material such as synthetic rubber and particularly a closed cell foam rubber such as Hypalon. The rollers are ground to .+-.0.010 inches. The rubber tube is held in place by its own resiliency which, because it is stretched on the aluminum tube 46b, causes it to securely grip the outer surface thereof, the resulting friction holding it in place. While the center portion 46b of the roller can be formed from a variety of materials, aluminum tubing having a 1/16" wall and a 1" O.D. has been outstanding and results in a very lightweight roller that is yet resistant to deflection at the center which, if it were to occur, might allow vapor to escape from the developing chamber, and this advantage has permitted the use of relatively long rollers such as rollers 42" in length that exhibit a reliable seal along the length of each pair of rollers on the line where they are tangent to one another.

The development chamber in the center of the apparatus as seen in cross-section is composed of upper and lower portions comprising identical lower and upper ammonia tanks 49 and 50, respectively. The tanks 49 and 50 can conveniently be formed from generally channel-shaped aluminum extrusions, tank 49 being closed at the bottom and opening upwardly, while tank 50 at the top is closed at its upper aspect and opens downwardly. Each of the tanks is composed of three separate extrusions, a center or connecting extrusion 49a, 50a, having lateral flanges at its edges to which are connected generally Z-shaped extrusions 49b and 49c (tank 49) and 50b and 50c (tank 50). The Z-shaped extrusions are provided with flanges that mate with the corresponding flanges on the connecting extrusions and are secured to them by fasteners such as machine screws 52. It will be seen that the free ends of extrusions 49b and 50b define sheet inlet guides for material passing through the apparatus and the free ends of 49c and 50c define exit guides with the free edges thereof spaced further apart than the edges closest the outlet of the apparatus. This helps to guide paper or film that may be curled at its end toward the outlet 18c. In this way, the guide sections 49b, 50b, and 49c, 50c can be thought of as inlet guides and exit guides, respectively, for guiding sheet material through the apparatus. It should be noted, however, that once the sheet material reaches the nip between rollers 42 and 44, it will not touch any of the guides or other parts of the apparatus, thereby reducing the likelihood of becoming scratched.

Mounted above and below the tank are upper and lower insulation pads 53 and 55, respectively, which can be composed of fiberglass or other suitable heat insulating material for reducing heat transmission away from the development chamber, which, during operation, is maintained at elevated temperatures as will be described fully below.

The sealing means provided between the development chamber and the rollers will now be described by reference to FIGS. 3, 4, and 12. As shown in the figures, elongated ribbon-shaped sealing strips 54 extend between the tanks and the rollers. The strips 54 are secured at their inward edges between the mating extrusion flanges of the tanks 49 and 50 fastened together with screws 52. The free edges of the strips 54 are engaged upon the surface of the rollers with the surface of the rollers being free to slide against the contacting surfaces of the sealing strips. The resiliency or elasticity of the sealing strips holds their surfaces in tight engagement with the surfaces of the rollers thereby providing a reliable seal throughout their length. Suitable sealing strips 54 can be formed from two layers of 0.001" thick stainless steel ribbon. The upper strips 54 yieldably engage the upper surfaces of rollers 44 and 46 at a point substantially opposite their engagement with the lower rollers. In this way, the upper two sealing members yieldably bias the upper two rollers downwardly toward the lower roller thereby providing the dual function of maintaining the contacting roller pairs in engagement and allowing them to spring apart when a large object passes through while, at the same time, serving as a sealing strip for the development chamber to prevent the unwanted escape of ammonia vapor. During operation, as work pieces pass between the rollers, the upper rollers 44 and 46 are free to slide upwardly a short distance against the yieldable biasing effect of the upper strips 54 by virtue of the upward travel of the bushings 32 in their supporting slots 30, as shown with respect to roller 46 in FIG. 4 which, in the figure, is depicted by being displaced upwardly a small distance against the spring action of the sealing strip 54.

The end of each of the tanks 49 and 50 is sealed against the escape of gas by the provision of an elastic gasket 56 of generally rectangular shape sandwiched between each cut end of each tank and the side plates 24 and 26, respectively. The gaskets 56 are under compression, thereby preventing the escape of vapor. The tanks can be held in place in any convenient manner, as by means of screws 59 which extend through the side plates 24 and 26 into suitable screw holes provided in the tanks. The screws 59 are also shown in FIG. 3. Mounted between the side plates 24, 26 and the rollers 40-46 are roller sealing gaskets 58 formed from a suitable resilient flat sheet stock such as rubber. An excellent sealing material comprises synthetic rubber such as EPDM rubber having a layer of a low-friction material such as Teflon bonded to the inward surface thereof contacting the ends of the rollers 40-46 to provide a low friction sealing surface under compression against the ends of the rollers to reliably seal them against the escape of vapor. In this way, the rollers can rotate freely while the vapor seal is maintained by the resiliency of the sealing gaskets 58. The gaskets 58 are provided with openings 58c to accommodate the bushings 32.

At the top and bottom of the developing tanks are electrical resistance rod heaters 60 and 62 which are slid from the end during construction into a channel-shaped recesses 63 and 64 formed in the extrusions 50a and 49a, respectively. The channels 63 and 64 extend around more than 180.degree. of the periphery as seen in section, thereby captivating the heating rods 60 and 62 to reliably hold them in place at all points along their length. Accordingly, the heating rods 60 and 62 cannot move or sag from the desired location and, at the same time, are held in contact with the tanks at all times thereby reliably assuring uniform heat distribution throughout the tanks. In a typical situation, the heaters are sufficiently hot to maintain the interior of the chamber at about 180.degree. F. at the point where the film 19 is located. Each end of each heating rod is maintained in place by a fibrous insulating washer 60a and a snap ring 60b as shown in FIG. 12.

The distribution of ammonia vapor when used will now be described in connection with FIGS. 2, 10, and 11. As seen at the left in FIG. 2, there is provided a positive displacement electrically-operated pump 66 of any suitable known construction connected by means of a hose 67 to an outlet pipe 69 of an ammonia storage vessel V. In this way, the pump 66 withdraws the ammonia forcing it through supply hose 75 to a U-shaped distribution pipe having parallel legs 76 and 78, the former of which is provided with openings 80 of a small diameter along its length. The leg 76 of the distribution pipe extends through the ammonia tank 49, as best seen in FIGS. 3 and 10, and as the pump operates, small quantities of ammonia are expelled through the openings 80 and accumulate at the bottom of the tank 49 temporarily until vaporized by the heater 62. The warm ammonia vapor fills the chamber, thereby developing sheets 19. From leg 78 the excess ammonia is returned via hose 81 to the vessel V. Any excess ammonia is withdrawn from the bottom of the tank 49 through a drain fitting 82 via hose 84 to a collection vessel 86.

One suitable method for controlling the operation of pump 66 is through the use of a timer 68 which has a manual control knob as shown in FIGS. 1 and 2 that can be set to operate the pump intermittently at pre-selected intervals to thereby pump greater or lesser quantities of ammonia to the tank per unit of time.

The electrical circuit is shown in FIG. 11. As seen in the figure, current is supplied through conductors 90 and 92 to an on-off switch 80 in series with a circuit breaker 85. Heaters 60 and 62 are wired parallel with motors 37 and 72, and the timer 68 is wired across lines 90, 92 to supply current to the pump 66 for selected intervals of time. Numeral 83 represents a thermal safety switch and a thermostat, both of which are connected in series with the heaters. The thermostat maintains a set temperature and the thermal safety switch interrupts the current in case the tank temperature becomes excessive.

Refer now to FIG. 9 which illustrates clearly the inner development chamber 75 composed of the upper and lower development tanks 49 and 50 that with the rollers and their sealing strips defines a closed compartment enclosed within an outer compartment 73 that functions as a fume collection and removal plenum. The outer fume collection and removal plenum has a continuous stream of air passing through it so that any vapor leaking from the chamber 75 will be withdrawn and disposed of. As seen best in FIG. 2, incoming air passes into the outer fume collection and removal plenum 73 through louvers 21a. The incoming air then passes over the pump 66 and along all sides of the chamber 75 to a blower 70 which expels the air into any suitable disposal means such as a duct leading to the outside or into a replaceable ammonia neutralizing cartridge 71 available commercially which absorbs ammonia fumes. Thus, by providing an outer vapor collection and removal plenum surrounding the inner developing chamber and by placing the ammonia pump 66 within this plenum, any leaking ammonia from either the chamber 75 or the pump 66 is withdrawn and disposed of without entering the room where the device is used. In an alternative shown in dotted lines of FIG. 2, the blower 70 and cartridge 71 are replaced by cartridge 71a and centrally located blower 70a which draws air and vapor out of plenum 73 and exhausts it through cartridge 71a. In this case walls 24 and 26 seal the entire crossection of the housing 12 so that air and vapor is drawn in solely through slots or apertures 18c and 20c and louvers 21a are eliminated. Blower 70a is reversed in thermal development to cool the rollers by forcing air into the plenum 73 and out through slots or apertures 18c and 20c.

The invention has proved highly effective in operation, and the timing belt, in addition to being quiet in operation, advances the rollers uniformly and smoothly to provide even movement of the film which helps prevent damage to the film and promotes even development. Since there is no carrier or belt and since the film does not touch anything between the inlet and exit rollers, it will not be scratched during operation. Sealing strips 54 can be easily removed and replaced by removing screws 52.

When the apparatus is used for thermal development, i.e. by the action of heat alone, the heaters are turned up to a higher setting so that a temperature of approximately 230.degree. F. exists at the film plane and the chamber surface is about 300.degree.-330.degree. F.

The invention has proved successful operating solely as a thermal diazo developer with the ammonia removed and pump 66 is turned off. This success results from several factors. One of the most important is the application of heat to the sheet material almost entirely by hot air convection. As described above, the development chamber is provided with inlet and outlet slots which divide it into compartments located above and below the plane of the sheet material. One heating rod is in contact with each compartment viz. the channel-shaped aluminum extrusion, thereby heating it; and each compartment in turn heats the air therein such that heat transmission to the sheet material 19 is primarily by hot air convection. The inner and outer surfaces of the aluminum extrusions forming the compartments 49 and 50 are uncoated and are highly polished, accordingly, heat radiation therefrom is at a minimum. While not utterly essential, it is highly preferred that heaters be provided for both the upper and lower compartment for two reasons. First, sheet material can be passed through with the emulsion either up or down and development will take place equally well in both instances. Second, the application of heat from both the top and the bottom shortens the dwell time so that the machine capacity is increased.

Another important factor that contributes to the successful operation of the thermal development mode is the fact that the apparatus is constructed and the compartments are located so that the film passes straight through the apparatus without contacting any stationary parts which could scratch or damage the film. This is particularly important in thermal development since the film is very unstable at high temperatures. As seen in FIG. 3, for example, the film will not rub on anything when passing through the apparatus. It is important to use good engineering practice in selecting materials that will not be damaged by high heat and to provide sufficient room for thermal expansion of parts as they become hot as well as to allow for slippage between any parts that have a different coefficient of expansion or are heated to different temperatures. For example, to allow for expansion it is desirable to enable each sealing strip 54 to be free to slide longitudinally between the adjacent flanges of tanks 49 and 50 where it is supported along its edge. This can also be accomplished by tightening screws 52 only after the apparatus has come up to operating temperature.

It is apparent that many modifications and variations of this invention as set forth may be made without departing from the spirit and scope thereof. The specific embodiments described above are given by way of example only, and the invention is limited only by the terms of the appended claims.