CN115397571A - Contact cleaning device - Google Patents

Abstract

The invention relates to a contact cleaning device for a sheet substrate (80) having a curved leading edge (82). The contact cleaning apparatus comprises: a resilient cleaning roller (24) and an air supply manifold (40) configured and arranged to direct air towards a contact zone on the resilient roller; and a conveyor (16) for conveying the sheet substrate to be cleaned towards the resilient cleaning roller, wherein the air supply manifold is configured and arranged to direct an air flow onto the leading edge of the curved sheet and/or onto the contact area of the resilient cleaning roller such that the sheet is flattened at the point of contact with the cleaning roller. Also disclosed is a contact cleaning apparatus for a sheet substrate having a curved leading edge, the contact cleaning apparatus comprising a flattening device. A flattening device is disposed proximate the first conveyor and is configured to operably engage the curved leading edge of the sheet substrate such that the curved leading edge of the sheet substrate is flattened at a point of contact with the resilient cleaning roller.

Description

Contact cleaning device

This application claims the benefit of british patent application No. GB2002942.7 filed on 3/1/2020 and the benefit of british patent application No. GB2101993.0 filed on 2/12/2021. British patent application No. GB2002942.7 and british patent application No. GB2101993.0 are expressly incorporated herein by reference in their entirety.

Technical Field

The present invention relates to a contact cleaning device for sheet substrates (sheeted substrates) having a curved leading edge. In particular, but not exclusively, the invention relates to a contact cleaning apparatus for a sheet substrate having a curved leading edge, wherein the apparatus comprises a flattening device operable to engage the curved leading edge of the sheet substrate. The present invention also relates to an air supply manifold that directs air onto the surface of the sheet substrate at the curved leading edge of the sheet, and/or onto the resilient cleaning roller before reaching the leading edge of the sheet substrate.

Background

Contact cleaning is used to clean the surface of a substrate or sheet. Once the substrates are cleaned, they are used in a variety of complex processes such as the manufacture of electronic devices, photovoltaic devices, and flat panel displays. Generally, a contact cleaning apparatus includes: a rubber or resilient cleaning roller for removing dirt particles from the substrate surface; and an adhesive roller for removing dirt particles from the cleaning roller.

In operation, the contact cleaning roller contacts at least the upper surface of the substrate, thereby removing debris by an adherent removal mechanism such as van der waals forces and adhesion forces. The inherent properties of the material used to form the contact cleaning roller attract debris and cause the debris to stick to the surface of the contact cleaning roller. The contact cleaning roller pulls the dirt particles away from the substrate surface in this manner due to attractive van der waals forces between the dirt particles and the roller. Accordingly, the existing contact cleaning roller can ensure efficiency in removing the smudge particles by maximizing contact with the surface of the substrate.

Contact cleaning devices for thin film sheet technology (such as copper foil) or thin film polymers require an elastomeric cleaning roller to be driven at high speeds and subsequently cleaned by an adhesive roller adjacent to the elastomeric cleaning roller. As used herein, such thin film sheet technology is referred to as a sheet substrate.

When the leading edge of a new thin sheet substrate reaches the resilient cleaning roller, the sheet substrate typically has a curved leading edge. The curved leading edge has the following risks: collide with the elastic cleaning roller to cause buckling of the sheet substrate, damaging a portion of the sheet substrate to render a portion of the sheet substrate unusable. Damage to the leading edge reduces process efficiency and risks causing malfunction or damage to the machine.

In other cases, the sheet substrate is wrapped around a resilient cleaning roller and the machine must be stopped in order to clean the sheet substrate on the roller before the machine can be restarted. Also, the efficiency of the cleaning process is significantly compromised.

In some cases, the sheet substrate is rigid due to its relative thickness or its inherent material properties. Additionally or alternatively, the sheet substrate has bends, for example in multiple directions, which stiffens the curved leading edge. In these ways, the curved leading edge of the sheet substrate will resist deformation, thereby increasing the risk of machine failure or damage.

It is an object of the present invention to alleviate some of the above disadvantages.

Disclosure of Invention

According to the present invention there is provided a contact cleaning apparatus according to the appended claims.

In a first aspect of the invention, a contact cleaning apparatus for a sheet substrate having a curved leading edge comprises:

a resilient cleaning roller and a first conveyor for conveying a sheet substrate to be cleaned towards the resilient cleaning roller, wherein the resilient cleaning roller comprises a contact zone arranged to receivingly engage a sheet substrate from the first conveyor, and

a flattening device disposed proximate to the first conveyor, wherein the flattening device is configured to operably engage the curved leading edge of the sheet substrate such that the curved leading edge of the sheet substrate is flattened at a point of contact with the resilient cleaning roller.

In certain embodiments, the flattening device includes a guide disposed opposite the first conveyor and configured to contactingly engage the curved leading edge of the sheet substrate such that the curved leading edge of the sheet substrate is flattened at the point of contact with the resilient cleaning roller.

In this way, the guide is arranged: the curved leading edge of the sheet substrate is abutted while the sheet substrate is conveyed toward the elastic cleaning roller. That is, the guide can flatten the curved leading edge by offsetting or deforming the curved leading edge before the curved leading edge is received in the contact region of the resilient cleaning roller. The outlet area of the guide is preferably arranged in close proximity to the resilient cleaning roller so that it operationally precedes the contact area only a short distance. However, the exit area of the guide may be located at any suitable position along the first conveyor.

Advantageously, the contact cleaning apparatus is capable of flattening a wide variety of sheet substrates. In particular, the inventors have found that the apparatus is effective for flattening curved leading edges of a stiff or otherwise deformation resistant sheet substrate. That is, the apparatus is capable of flattening a curved leading edge of a sheet substrate having a thickness of up to 6 millimeters or more.

In certain embodiments, the guide is disposed at an angle relative to the first conveyor, wherein the guide and the first conveyor are configured to provide for the passing of a curved leading edge as the curved leading edge approaches the contact region. In certain embodiments, the guide comprises a second conveyor, wherein the second conveyor is arranged at an angle relative to the first conveyor so as to provide said passing of the curved leading edge.

In these ways, the guide abuts the curved leading edge such that the leading edge is directed or passed towards the first conveyor. The second conveyor is arranged at any suitable angle relative to the first conveyor so as to provide suitable passage. In this manner, the angle can be selected based on the sheet substrate and the contact cleaning operating conditions. For example, the angle may be selected based on one or more of material properties of the sheet substrate, an operating speed of the contact cleaning apparatus, or a space within the apparatus in which the second conveyor is disposed.

In certain embodiments, the guide or second conveyor may be angled relative to the first conveyor at any suitable angle from substantially perpendicular to substantially parallel. That is, the angle of the guide or the second conveyor relative to the first conveyor may be selectively adjustable between perpendicular and parallel. In this way, the orientation of the guide (e.g., the second conveyor) may be adjusted to optimize processing of sheet substrates having curved leading edges with a range of deformation.

In certain embodiments, the second conveyor contactingly engages the first conveyor. In this way, the second conveyor passes the curved leading edge onto the first conveyor. In certain embodiments, the second conveyor may apply pressure to the curved leading edge. That is, the second conveyor may provide a nip effect with the first conveyor.

In certain embodiments, the second conveyor is driven. In this way, the second conveyor can actively engage the curved leading edge in order to guide it towards the resilient cleaning roller and provide a pass-through effect. In some embodiments, the second conveyor is driven due to a contacting engagement with the first conveyor. In some embodiments, the second conveyor is provided with an independent drive.

In certain embodiments, the flattening device comprises an air supply manifold, wherein the air supply manifold is operable to direct an air flow onto the curved leading edge and/or the contact region of the sheet substrate such that the curved leading edge of the sheet substrate is flattened at the contact point with the resilient cleaning roller. According to a further aspect of the invention, there is provided a contact cleaning apparatus for a sheet substrate having a curved leading edge. The contact cleaning apparatus includes a resilient cleaning roller and an air supply manifold configured and arranged to direct air onto a contact zone on the resilient cleaning roller. The contact cleaning apparatus further includes a conveyor for conveying the sheet substrate to be cleaned toward the elastic cleaning roller. The air supply manifold is operable to direct an air flow onto the curved leading edge and/or the contact region of the sheet substrate such that the curved leading edge of the sheet substrate is flattened at the point of contact with the resilient cleaning roller.

In certain embodiments, the contact zone comprises a boundary layer of air around the surface of the resilient cleaning roller. In certain embodiments, the contact zone extends at least partially around the resilient cleaning roller. Thus, when the air flow from the air supply manifold is directed to the contact zone, it forms an enhanced boundary layer.

When referred to herein, a "contact zone" is the portion of the contact cleaning apparatus where the leading edge of the sheet substrate engages the resilient cleaning roller. More specifically, it is a region: the region includes a location where the leading edge of the sheet substrate contacts the resilient cleaning roller or a boundary layer of air surrounding the resilient cleaning roller. As will be appreciated, this location may refer to one or more points or regions along the surface of the resilient cleaning roller or its air boundary layer depending on the cross-machine shape of the leading edge.

When referred to herein, a "boundary layer" is an air layer formed on the surface of an elastic cleaning roller.

As referred to herein, "flat" means that the leading edge of the sheet substrate is oriented to be properly received by the resilient cleaning roller for cleaning. That is, as the contact zone is approached, the sheet substrate leading edge is flat or substantially flat such that it is received by the resilient cleaning roller in a manner that provides effective cleaning.

When referred to herein, an "enhanced boundary layer" is a layer that temporarily increases in thickness as measured radially from the center of the resilient cleaning roller.

Thus, in use of the apparatus, the leading edge of the sheet substrate is deflected by the air flow into the contact region. In this manner, the leading edge of the sheet substrate is oriented to be received by the resilient cleaning roller for cleaning. The sheet substrate is flattened into the plane of the tail portion of the sheet substrate, thereby allowing the air flow and/or boundary layer to windingly convey the sheet substrate into the nip of the resilient rollers without damaging the sheet substrate or improperly engaging the resilient cleaning rollers (e.g., the sheet substrate is bonded to the rollers).

In certain embodiments, the enhanced boundary layer extends around the resilient cleaning roller until the nip. In this manner, the leading edge of the sheet substrate may be further biased by the enhanced boundary layer to flatten the sheet and enter the nip between the resilient cleaning rollers.

The air flow may be activated just before the leading edge reaches the elastomeric roller, so the boundary layer temporarily increases.

Thus, air is directed by the air supply manifold toward the contact area of the resilient cleaning roller.

In certain embodiments, the air supply manifold is operable to direct air directly onto the leading edge of the curved sheet so as to flatten the sheet as it approaches the resilient cleaning roller. Flattening of the sheet ensures that the sheet enters the contact zone rather than engaging another portion of the contact cleaning device, such as a process roller or another resilient cleaning roller. In this manner, flattening of the leading edge avoids buckling of the sheet substrate because it is not properly engaged with the resilient cleaning roller. Thus, the contact cleaning apparatus need not be stopped during the cleaning process. In addition, the apparatus does not require additional set-up time to ensure that the leading edge is properly engaged with or received by the resilient cleaning roller.

Alternatively or additionally, the air supply manifold may be operable to direct air onto the resilient cleaning roller. More specifically, the air supply manifold is operable to direct air onto the contact area of the resilient cleaning roller. In these embodiments, a reinforcing boundary layer is formed at the surface of the resilient cleaning roller. When the leading edge of the sheet substrate contacts the enhanced boundary layer, the bend at the leading edge is removed or substantially reduced, thereby flattening the sheet substrate in the contact zone.

In certain embodiments, the airflow from the air supply manifold is selectively activated. In this way, the air flow is provided only when the leading edge of the sheet substrate reaches the resilient cleaning roller. In this way, the air flow provides a temporary increase in the thickness of the boundary layer forming the enhanced boundary layer, thereby increasing the efficiency of the apparatus.

In certain embodiments, the air supply manifold is operable to direct air toward the contact zone at an adjustable angle relative to a reference plane extending vertically through the axis of rotation of the resilient cleaning roller. More specifically, the adjustable angle may be selected between being parallel to the reference plane and being perpendicular to the reference plane.

In certain embodiments, the angle is selected and adjustable and fixed relative to a reference plane extending vertically from the axis of rotation of the resilient cleaning roller prior to operation of the apparatus. Any angle can be selected within a range parallel to and perpendicular to a plane extending vertically from the rotational axis of the elastic cleaning roller. The angle is selected based on any one or more of: the speed of the conveyor; the material of the sheet substrate, and the like.

In certain embodiments, the air supply is directed tangentially onto the resilient cleaning roller in the contact zone.

In certain embodiments, the air supply manifold is operable to direct air toward the contact zone at an adjustable angle relative to the conveyor surface. More specifically, the adjustable angle may be selected between perpendicular to the conveyor surface and parallel to the conveyor surface.

In certain embodiments, the resilient cleaning rollers comprise pairs of resilient cleaning rollers. The pair of resilient cleaning rollers may be oppositely arranged to form a nip through which the sheet substrate is conveyed.

In certain embodiments, the contact cleaning apparatus includes a plurality of pairs of resilient cleaning rollers configured and arranged to provide one or more cleaning surfaces for the sheet substrate between each pair of rollers.

In certain embodiments, each resilient cleaning roller is cleaned by an adjacent adhesive roller.

In certain embodiments, the air supply manifold comprises a manifold comprising spaced apart apertures. More specifically, the manifold includes spaced apart air delivery apertures for outputting air from the manifold.

In certain embodiments, the manifold is tubular.

In certain embodiments, the manifold includes a plurality of spaced pin bores.

In certain embodiments, the manifold is formed from a metal or plastic material. Other suitable materials will be known to those skilled in the art.

In certain embodiments, the air supply manifold is operably coupled to an air supply source. The air supply source is operable to deliver air to the air supply manifold.

In certain embodiments, the contact cleaning apparatus includes a sensor configured and arranged to detect a leading edge of the sheet substrate.

In certain embodiments, the sensor is operably coupled to an air supply. In use of the apparatus, the sensor detects the leading edge of the sheet substrate and causes the air supply source to deliver air to the air supply manifold. The air supply manifold in turn directs air onto the leading edge of the sheet substrate and/or onto the contact region of the resilient cleaning roller.

In certain embodiments, the air supply directed at the curved leading edge of the sheet substrate straightens the sheet prior to the contact region of the resilient cleaning roller. Therefore, improper engagement of the sheet substrate with the elastic cleaning roller is prevented. Buckling of the sheet or winding of the sheet substrate around the elastic cleaning roller is also prevented. Further, air is used to facilitate transfer of the sheet substrate through the cleaning apparatus.

In certain embodiments, the air directed onto the resilient cleaning roller contact zone creates an enhanced boundary layer on the surface of the resilient cleaning roller. In this way, the air ensures that the sheet substrate is cleaned from contact by the resilient cleaning roller surface.

In certain embodiments, the air is supplied in pulses from an air supply manifold. More specifically, the pulse is generated when the sensor detects the leading edge of the sheet substrate adjacent to the elastic cleaning roller. Each air pulse flattens the leading surface as it approaches the contact zone.

In certain embodiments, the airflow through the airflow manifold is activated as a result of the sensor detecting that the curved leading edge of the sheet substrate is a predetermined distance from the contact region. Additionally or alternatively, the airflow through the airflow manifold is deactivated when the leading edge engages the contact region. In these ways, the airflow is used to flatten the curved leading edge only when the curved leading edge is proximate the contact zone. The airflow is provided only when the curved leading edge is within the operable range of the airflow manifold. Thus, the air flow provided by the air supply source is effectively utilized.

In certain embodiments, the conveyor is configured and arranged to convey the sheet substrate to the contact region.

In certain embodiments, the sheet substrate is a film. More specifically, the film is a thin film. Still more particularly, the film is a copper foil or a thin film polymer.

Drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 illustrates a schematic view of a contact cleaning apparatus in a first configuration, wherein the air supply to the airflow manifold is shut off;

FIG. 2 illustrates a schematic view of the contact cleaning apparatus of FIG. 1 in a second configuration;

FIG. 3 illustrates a schematic view of the contact cleaning apparatus of FIG. 1 in a third configuration;

FIG. 4 illustrates a schematic view of the contact cleaning apparatus of FIG. 1 in a fourth configuration;

FIG. 5 illustrates a schematic view of a contact cleaning apparatus according to an embodiment in a first configuration, in which the air supply of the airflow manifold is opened;

FIG. 6 illustrates a schematic view of the contact cleaning apparatus of FIG. 5 in a second configuration;

FIG. 7 illustrates a schematic view of the contact cleaning apparatus of FIG. 5 in a third configuration; and

FIG. 8 illustrates a schematic view of another example contact cleaning apparatus in accordance with aspects of the invention.

Detailed Description

Certain terminology is used in the following description for convenience only and is not limiting. The words "right," "left," "lower," "upper," "front," "rear," "upward," "downward," and "downward" refer to the directions referenced in the drawings and are described with respect to the directions of the described components when assembled and installed. The words "inner", "inwardly" and "outer", "outwardly" refer to directions toward and away from, respectively, a designated centerline or geometric center (e.g., central axis) of the described element, with the particular meaning being apparent from the context of the description.

Further, as used herein, the terms "connected," "attached," "coupled," and "mounted" are intended to include direct connections between two members without any other members interposed therebetween, as well as indirect connections between members in which one or more other members are interposed between the aforementioned members. The terminology includes the words above specifically mentioned, derivatives thereof and words of similar import.

Further, unless otherwise specified the use of ordinal adjectives such as "first," "second," "third," etc., merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Like reference numerals are used to describe like features throughout.

Referring first to FIG. 1, a contact cleaning apparatus 1 is shown. The contact cleaning apparatus includes a first pair of resilient cleaning rollers and a second pair of resilient cleaning rollers. The first pair of resilient cleaning rollers includes a first resilient cleaning roller 24 and a second resilient cleaning roller 26 mounted in the path of the conveyor 16. The conveyor 16 is driven by two conveyor rollers 12, 14 to convey the substrate 80 (i.e., sheet 80) along the conveyor 16. The first resilient cleaning roller 24 is elongated and generally cylindrical in shape and is mounted on a holder (not shown) with its rotational axis perpendicular to the plane of view about which the first resilient cleaning roller 24 is free to rotate. In this particular example, the first resilient cleaning roller 24 comprises a silicone elastomer layer, although other materials are also contemplated. The second elastic cleaning roller 26 is generally cylindrical in shape and includes a silicone elastomer layer. A second resilient cleaning roller 26 is mounted on a holder (not shown) with its rotational axis perpendicular to the plane of view and parallel to the rotational axis of the first resilient cleaning roller 24, about which the second resilient cleaning roller 26 is free to rotate. The first and second resilient cleaning rollers 24, 26 are mounted in contact with each other such that the first and second resilient cleaning rollers 24, 26 rotate about their respective axes of rotation in opposite directions. The first resilient cleaning roller 24 rotates counterclockwise and the second resilient cleaning roller 26 rotates clockwise.

The first and second resilient cleaning rollers 24, 26 are mounted to receive the substrate from the conveyor. Once the substrate has been received, both the first and second resilient cleaning rollers 24, 26 are arranged to contact the surface of the substrate 80. The first elastic cleaning roller 24 is arranged to contact the upper surface of the substrate 80. The second elastic cleaning roller 26 is arranged to contact the lower surface of the substrate 80. The base plate 80 has a curved end 82 closest to the roller.

The second pair of rollers includes a third resilient cleaning roller 34 and a fourth resilient cleaning roller 36 mounted in the path of the conveyor 16 downstream of the first pair of rollers. The third resilient cleaning roller 34 is elongated and generally cylindrical in shape and is mounted on a holder (not shown) with its rotational axis perpendicular to the plane of view about which the third resilient cleaning roller 34 is free to rotate. A fourth resilient cleaning roller 36 is mounted on a holder (not shown), the rotational axis of which is perpendicular to the plane of view and parallel to the rotational axis of the third resilient cleaning roller 34, about which rotational axis the fourth resilient cleaning roller 36 is free to rotate. The third and fourth elastic cleaning rollers 34 and 36 are installed to contact each other such that the third and fourth elastic cleaning rollers 34 and 36 rotate in opposite directions about their respective axes. The third resilient cleaning roller 34 rotates clockwise and the fourth resilient cleaning roller 36 rotates counterclockwise.

The third and fourth resilient cleaning rollers 34, 36 are mounted to receive the substrate from the first and second resilient cleaning rollers 24, 26. Once the substrate has been received, both the third and fourth resilient cleaning rollers 34, 34 are arranged to contact the surface of the substrate 80. The third elastic cleaning roller 34 is arranged to contact the upper surface of the substrate 80. The fourth elastic cleaning roller 36 is arranged to contact the lower surface of the substrate 80. The first pair of rollers 24, 36 and the second pair of rollers 34, 36 may each be provided with a nip through which the substrate 80 is to be conveyed.

A sheet substrate 80 to be cleaned is positioned on the surface of the conveyor 16, which conveys the sheet substrate 80 from left to right in fig. 1. The substrate 80 passes between the first and second pairs of resilient cleaning rollers in sequence. That is, the substrate 80 first passes between the first elastic cleaning roller 24 and the second elastic cleaning roller 26. The first elastic cleaning roller 24 rotates counterclockwise and the second elastic cleaning roller 26 rotates clockwise, thereby moving the substrate 80 to the right.

The first resilient cleaning roller 24 contacts the upper surface of the substrate 80, thereby removing debris from the upper surface. The inherent polarity of the material used to form the first resilient cleaning roller 24 draws debris from the upper surface of the substrate 80 and causes the debris to adhere to the surface of the first resilient cleaning roller 24. The relative attraction between the surface of the first resilient cleaning roller 24 and the debris is greater than the relative attraction between the debris and the surface of the substrate 80, allowing the debris to be removed.

The second elastic cleaning roller 26 rotates clockwise. The second resilient cleaning roller 26 contacts the lower surface of the substrate 80, removing debris therefrom. The inherent polarity of the material used to form the second resilient cleaning roller 26 picks up debris from the bottom surface of the substrate 80 and causes the debris to adhere to the surface of the second resilient cleaning roller 26. The relative attraction between the surface of the second resilient cleaning roller 26 and the debris is greater than the relative attraction between the debris and the surface of the substrate 80, allowing the debris to be removed.

The substrate 80 is then received by a second pair of resilient cleaning rollers. The substrate 80 passes between the third elastic cleaning roller 34 and the fourth elastic cleaning roller 36. The third elastic cleaning roller 34 rotates clockwise and the fourth elastic cleaning roller 36 rotates counterclockwise, thereby moving the substrate 80 rightward.

The third resilient cleaning roller 34 contacts the lower surface of the substrate 80, removing debris therefrom. The inherent polarity of the material used to form the third resilient cleaning roller 34 picks up debris from the lower surface of the substrate 80 and causes the debris to adhere to the surface of the third resilient cleaning roller 34. The relative attraction between the surface of the third resilient cleaning roller 34 and the debris is greater than the relative attraction between the debris and the surface of the substrate 80, allowing the debris to be removed.

The fourth elastic cleaning roller 36 rotates counterclockwise. The fourth resilient cleaning roller 36 contacts the upper surface of the substrate 80, removing debris therefrom. The inherent polarity of the material used to form the fourth resilient cleaning roller 36 draws debris from the upper surface of the substrate 80 and causes the debris to adhere to the surface of the fourth resilient cleaning roller 36. The relative attraction between the surface of the fourth contact scrub roller 36 and the debris is greater than the relative attraction between the debris and the surface of the substrate 80, allowing the debris to be removed. The second pair of contact cleaning rollers is implemented to remove any other debris not removed by the first pair of contact cleaning rollers.

A first adhesion roller 20 and a second adhesion roller 22 are also provided. The adhesive rollers 20, 22 are generally cylindrical in shape and comprise a body on the surface of which there is adhesive, the axis of rotation of the body being perpendicular to the plane of view and parallel to the axis of the elastic cleaning rollers 24, 26, 34, 36 about which the adhesive rollers 20, 22 are free to rotate. The first adhesive roll 20 includes a paper-made substrate and an adhesive on the substrate. The second adhesive roller 22 includes a paper base layer and an adhesive on the base layer.

The first adhesion roller 20 rotates against the first elastic cleaning roller 24 and the fourth elastic cleaning roller 36. As such, the respective surfaces of the first and fourth cleaning rollers 24 and 36 and the first adhesion roller 20 are sufficiently close that debris removed from the upper surface of the substrate 80 is transferred to the first adhesion roller 20. The adhesion between the debris on the first and fourth resilient cleaning rollers 24, 36 and the first adhesive roller 20 is greater than the adhesion that holds the debris to the surface of the first or fourth resilient cleaning rollers 24, 36, allowing the debris to be diverted.

The second adhesion roller 22 rotates against the second elastic cleaning roller 26 and the third elastic cleaning roller 34. As such, the respective surfaces of the second and third resilient cleaning rollers 26 and 34 and the second adhesion roller 22 are sufficiently close such that debris removed from the lower surface of the substrate 80 is transferred to the second adhesion roller 22. The adhesion between the debris on the second and third resilient cleaning rollers 26, 34 and the second adhesion roller 22 is greater than the adhesion holding the debris to the surfaces of the second and third resilient cleaning rollers 26, 34, allowing the debris to be diverted.

The contact cleaning apparatus 1 is further provided with an air supply manifold 40 fluidly coupled to an air supply source (not shown). The air supply manifold 40, shown in schematic cross-section, is provided in the form of a cylinder having holes therein. One of the holes 42 is shown in the depicted embodiment. A plurality of holes 42 in the form of pin holes may be provided, spaced apart along the longitudinal axis of the manifold 40.

An air supply (not shown) is configured to supply air into the air manifold so that the air may be exhausted through the holes 42. An air manifold 40 is mounted at a location upstream of the first pair of contact cleaning rollers 24, 26 to direct a flow of air onto the sheet substrate 80. More specifically, the air manifold 40 is designed to eject a stream of air onto the sheet substrate 80 before the sheet substrate 80 engages the contact area at the surface of the first and second resilient cleaning rollers 24, 26. This operation will be described in more detail with reference to fig. 5 to 7. Alternatively or additionally, the air supply manifold 40 is configured and arranged to inject an air stream onto the contact zone at the surface of the resilient rollers 24, 26.

Referring now to fig. 2 and 3, the substrate 80 is conveyed along the conveyor 16 toward the first pair of resilient cleaning rollers 24, 26. The curved leading edge 82 of the substrate 80 tends to face upward away from the conveyor 16 so that the substrate 80 is not flat.

In the example shown in fig. 2 and 3, the air supply manifold is deactivated and therefore does not provide any air. The resilient cleaning roller is typically driven to a very high speed to facilitate cleaning. As a result, and as shown in fig. 3, the curved leading edge 82 of the substrate 80 collides with the first resilient cleaning roller 24.

As shown in fig. 4, the substrate 80 is buckled against the first elastic cleaning roller 24 due to the high impact velocity. Without the air supply, the curved edge of the substrate 80 wraps around the first resilient cleaning roller 24. Therefore, the substrate 80 does not pass between the first elastic cleaning roller 24 and the second elastic cleaning roller 26 for cleaning, but the apparatus is clogged or malfunctions. The device 1 must then be repaired and serviced.

Referring now to fig. 5-7, the operation of the contact cleaning apparatus 101 using the aforementioned air manifold 140 will now be described. The contact cleaning apparatus 101 is substantially the same as the contact cleaning apparatus 1 in fig. 1 to 4. Referring first to fig. 5, sheet substrate 180 is conveyed along conveyor 116 driven by conveyor rollers 112, 114. The free leading edge 182 of the substrate 180 approaches the first pair of contact cleaning rollers 124, 126.

Referring now to fig. 6 and 7, air is discharged from the air outlet 142 of the air supply manifold 140 in a direction generally indicated by arrow 144. Thus, the air flow is directed towards the contact area of the first resilient cleaning roller 126. As the air flow approaches the contact zone, the air flow is directed onto the curved leading edge 182 of the substrate sheet 180. In this example, air is directed onto the curved leading edge 182 of the substrate 180 to flatten the substrate 180.

Additionally or alternatively, air may be discharged from the air outlet 142 onto the contact area between the first pair of resilient cleaning rollers 124, 126 and the curved leading edge 182 of the substrate 180. It is also contemplated that the air flow may be directed toward a location upstream of the contact zone. In this manner, as the curved leading edge 182 of the sheet substrate 180 is conveyed toward the contact region, the substrate 180 may be flattened out before the sheet substrate 180 is cleaned by the first and second pairs of resilient cleaning rollers 124, 126, 134, 136.

By directing air at the contact zone of the first pair of resilient rollers 124, 126, the boundary layer of air around the second resilient roller 126 is temporarily enhanced. In these examples, the enhanced boundary layer flattens the leading edge 182 of the sheet substrate 180 in the contact zone. Thus, the sheet substrate 180 is properly oriented to be received and cleaned by the first pair of resilient cleaning rollers.

The substrate 180 may be flattened out at any location upstream of the resilient cleaning rollers 124, 126, 134, 136.

In this particular embodiment, the air is supplied at an angle of 20 degrees relative to a reference plane extending vertically from the axis of rotation of the second resilient cleaning roller 126. The angle may be a fixed angle.

The angle of the air supply directed from the air outlets 142 of the air manifold 140 will depend on the speed at which the substrate 180 is transferred into the cleaning zone. The angle may be changed to any number of fixed angles between perpendicular to the reference plane and parallel to the reference plane. It is contemplated that the air may be supplied at different angles, such as at an angle between parallel to the reference plane and perpendicular to the reference plane.

In some examples, the angle of the air manifold outlet may vary relative to the surface of the reference plane.

In some examples, the air flow of the contact cleaning apparatus may be selectively activated. In this way, the air flow may only be active when the leading edge is close to the contact zone. Once the leading edge has engaged the contact zone, the air supply is no longer required to ensure correct operation of the apparatus. Thus, the air flow is deactivated when the remainder of the sheet substrate is conveyed through the contact zone.

In some examples, the contact cleaning apparatus is provided with a detection sensor (not shown). When a substrate on the conveyor approaches the contact zone, the detection sensor detects the leading edge of the substrate to activate the air flow. For example, when the leading edge of the substrate is detected by the sensor, the controller communicates with the air supply source to deliver air to the air supply manifold, which in turn delivers air through the outlet.

In some examples, the air flow may be discharged through an outlet of the manifold in a pulsed fashion. Alternatively, the pulsed air flow may be selectively activated, for example using a detection sensor to detect the leading edge of a substrate on the conveyor.

Referring now to FIG. 8, another example contact cleaning apparatus 201 for a sheet substrate having a curved leading edge is illustrated in accordance with aspects of the present invention. In the case where the features are the same as in the previous example, the reference numerals are the same except that the initial number is "2".

Thus, the example of fig. 8 shows a first pair of resilient cleaning rollers provided, including a first resilient cleaning roller 224 and a second resilient cleaning roller 226 mounted to receive the sheet substrate 280 from the first conveyor 216. A flattening device is disposed proximate the first conveyor 216 that is configured to operably engage the curved leading edge 282 of the sheet substrate 280 such that the curved leading edge 282 is flattened at the point of contact with the first pair of resilient cleaning rollers 224, 226.

In the example shown in fig. 8, the flattening device is a second conveyor 296. A second conveyor 296 is disposed adjacent to the first conveyor 216. The second conveyor 296 is configured to operably engage the curved leading edge 282 of the sheet substrate 280 such that the curved leading edge 282 is flattened at the point of contact with the second resilient cleaning roller 226.

The first pair of resilient cleaning rollers 224, 226 are substantially identical to the first pair of resilient cleaning rollers 24, 26 of the other examples described herein. Each of the first pair of resilient cleaning rollers 224, 226 is rotatably mounted on a holder (not shown) for receiving a substrate from the conveyor.

A second pair of resilient cleaning rollers 234, 236 is disposed downstream of the first pair of rollers. The second pair of rollers 234, 236 of the example shown in fig. 8 is substantially identical to the first pair of resilient cleaning rollers 34, 36 of the other examples described herein. Each of the second pair of rollers is rotatably mounted on a holder (not shown). The second pair of resilient cleaning rollers 234, 236 is arranged to receive the sheet substrate 280 from the first pair of resilient cleaning rollers 224, 226.

The first conveyor 216 is driven by the first conveyor roller 212 and the second conveyor roller 214. As such, the first conveyor 216 is adapted to convey the sheet substrate 280 thereon. The first conveyor roller 212 and the second conveyor roller 214 of the first conveyor 216 are arranged in opposite end regions of the first conveyor 216.

The second conveyor 296 is driven by first and second conveyor rollers 292, 294 arranged in opposite end regions of the second conveyor 296. The first conveyor roller 294 is positioned adjacent to both the first conveyor 216 and the first pair of resilient cleaning rollers 224, 226. The second conveyor roller 292 is positioned away from the first pair of resilient cleaning rollers 224, 226.

The first pair of resilient cleaning rollers 224, 226 and the second pair of rollers 234, 236 are each provided with a nip through which the substrate 280 is to be conveyed.

The contact cleaning apparatus 201 includes a first adhesion roller 220 and a second adhesion roller 222. The first and second adhesive rollers 220, 222 are mounted and arranged to transfer debris from the first and second pairs of resilient cleaning rollers 224, 226, 234, 236 in a manner similar to those other examples described herein.

In use, the first conveyor 216 is driven by its first and second conveyor rollers 212, 214. The first conveyor 216 is driven in the direction D2 so that the surface area supporting the sheet substrate 280 moves toward the first pair of resilient cleaning rollers 224, 226. As such, when the sheet substrate 280 is conveyed on the first conveyor 216, it moves in the direction D1 toward the first pair of resilient cleaning rollers 224, 226.

In use, the second conveyor 296 is driven by its first and second conveyor rollers 292, 294. The second conveyor 296 is driven in the direction D3 such that the surface of the second conveyor 296 that engages the curved leading edge 282 moves toward the first conveyor roller. In this manner, the surface engaging the curved leading edge 282 moves toward the first pair of resilient cleaning rollers.

The second conveyor 296 is disposed at an angle relative to the first conveyor 216. Due to the relative positioning of the second conveyor and the first conveyor, the second conveyor 296 is disposed in contacting engagement with the first conveyor 216 at a location adjacent the first pair of resilient cleaning rollers 224, 226. That is, the first conveyor 216 and the second conveyor 296 provide a nip through which the substrate 280 is to be conveyed.

The relative angular orientation of the first and second conveyors 216, 296 enables the first and second conveyors 216, 296 to guide the curved leading edge 282 as the curved leading edge 282 moves toward the first pair of cleaning rollers 224, 226. That is, as the gap between the first conveyor 216 and the second conveyor 296 decreases, the curved leading edge flattens as it approaches the nip of the first conveyor 216 and the second conveyor 296. Thus, the curved leading edge can be conveniently and easily flattened prior to being received by the resilient cleaning roller.

In some examples, the flattening device is any guide operable to engage and flatten the curved leading edge as the curved leading edge moves on the first conveyor. Suitable guides may include suitably angled, curved, or contoured surfaces such that the surfaces provide flattening of the curved leading edge as it moves on the first conveyor. Additionally or alternatively, the guide may comprise ridges, protrusions or ribs, optionally oriented in the direction of movement of the curved leading edge.

In some examples, the guides may be provided with a surface treatment or coating. In this way, the guide may provide a low friction guiding effect between the guide and the curved leading edge.

In some examples, the flattening device, such as the guide or the second conveyor, may be selectively adjustable. In this manner, the flattening apparatus may be positioned at different positions and angles relative to the first conveyor.

In the description and claims of this document, the words "comprise" and "contain" and variations of them mean "including but not limited to", and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. In the description and claims of this document, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, this document is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integral structures, characteristics, compounds, chemical moieties or groups described in connection with a particular aspect, embodiment or example of the invention are to be understood as applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this document (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any of the foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this document (including any accompanying claims, abstract or drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

It will be understood by those skilled in the art that the above embodiment(s) have been described by way of example only and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope of the invention as defined by the appended claims. Various modifications to the detailed design described above are possible.

Claims (19)

1. A contact cleaning apparatus for a sheet substrate having a curved leading edge, the contact cleaning apparatus comprising:

a resilient cleaning roller and a first conveyor for transporting the sheet substrate to be cleaned towards the resilient cleaning roller, wherein the resilient cleaning roller comprises a contact zone arranged to receivingly engage the sheet substrate from the first conveyor, and

a flattening device disposed proximate the first conveyor, wherein the flattening device is configured to operably engage the curved leading edge of the sheet substrate such that the curved leading edge of the sheet substrate is flattened at a point of contact with the resilient cleaning roller.

2. The contact cleaning apparatus of claim 1, wherein the flattening device comprises a guide disposed opposite the first conveyor and configured to contactingly engage the curved leading edge of the sheet substrate such that the curved leading edge of the sheet substrate is flattened at the point of contact with the resilient cleaning roller.

3. The contact cleaning apparatus of claim 2, wherein the guide is disposed at an angle relative to the first conveyor, and wherein the guide and the first conveyor are configured to provide penetration of the curved leading edge as the curved leading edge approaches the contact zone.

4. The contact cleaning apparatus of claim 3, wherein the angle of the guide relative to the first conveyor is selectively adjustable between perpendicular and parallel.

5. A contact cleaning device according to claim 3 or claim 4, wherein the guide comprises a second conveyor, and wherein the second conveyor is arranged at an angle relative to the first conveyor so as to provide said passing of the curved leading edge.

6. The contact cleaning apparatus of claim 5, wherein the second conveyor contactingly engages the first conveyor.

7. A contact cleaning device according to claim 5 or claim 6, wherein the second conveyor is driven.

8. The contact cleaning apparatus of claim 1, wherein the flattening device comprises an air supply manifold, wherein the air supply manifold is operable to direct an air flow onto the curved leading edge of the sheet substrate and/or the contact zone such that the curved leading edge of the sheet substrate is flattened at the contact point with the resilient cleaning roller.

9. A contact cleaning apparatus for a sheet substrate having a curved leading edge, the contact cleaning apparatus comprising:

a resilient cleaning roller and an air supply manifold configured and arranged to direct air onto a contact zone on the resilient cleaning roller;

and a conveyor for conveying the sheet substrate to be cleaned towards the resilient cleaning roller, wherein the air supply manifold is operable to direct an air flow onto the curved leading edge of the sheet substrate and/or onto the contact zone such that the curved leading edge of the sheet substrate is flattened at the point of contact with the resilient cleaning roller.

10. The contact cleaning apparatus of claim 8 or claim 9, wherein the resilient cleaning roller comprises an axis of rotation, and wherein the air supply manifold is operable to direct air at a curved leading edge of the sheet substrate and/or onto the contact region of the resilient cleaning roller at an adjustable angle relative to a reference plane extending vertically through the axis of rotation.

11. The contact cleaning apparatus of any one of claims 8 to 10, wherein the air supply manifold comprises a tubular manifold comprising spaced apart air delivery apertures.

12. The contact cleaning apparatus of any of claims 8 to 11, wherein the air flow is selectively activated.

13. The contact cleaning apparatus of claim 12, comprising a sensor arranged to operatively detect a leading edge of the sheet substrate prior to engagement with the contact zone, and wherein the sensor is operative to activate the air flow in response to detecting the leading edge.

14. The contact cleaning apparatus of any one of claims 10 to 13, wherein the adjustable angle of the air supply manifold is selectable between perpendicular to the reference plane and parallel to the reference plane.

15. The contact cleaning apparatus of claims 10-14, wherein the adjustable angle is selected and fixed relative to the reference plane prior to operation of the apparatus.

16. The contact cleaning apparatus according to any preceding claim, wherein the resilient cleaning rollers comprise a pair of resilient cleaning rollers arranged in opposition to form a nip through which the sheet substrate is conveyed.

17. The contact cleaning apparatus of any preceding claim, wherein the resilient cleaning roller comprises at least one pair of resilient cleaning rollers configured and arranged to provide a cleaning surface for the sheet substrate between each pair of rollers.

18. The contact cleaning apparatus of any preceding claim, wherein each resilient cleaning roller is cleaned by an adjacent adhesive roller.

19. A contact cleaning apparatus according to any preceding claim, wherein the contact zone extends at least partially around the resilient cleaning roller.

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