1. P1004: Open Source / Open Architecture
Low Energy Printing
P1004: Open Source / Open Architecture
Introductions

2. Printing Architecture
Input
(Energy)
Interface
Output
(Printed Paper)
Central Processing Unit
Paper Feed
Printer Head
Printer Driver
Data Stream
Xerography
Thermal Inkjet
Derek
Piezoelectric Inkjet
On-Demand
Continuous 2

3. Who? Team Members Stakeholders Faculty Guides Dean Culver
Shawn Hoskins
Derek Meinke
Tim Salter
Stakeholders
John Knapp, Research Fellow, Xerox Corp. – Marking Elements & Integration Lab
Rochester Institute of Technology
End user: Party that needs printing technology, but has very little electrical infrastructure to support it
Faculty Guides
Gerry Garavuso
Bill Nowak
Dr. Marcos Esterman
Shawn

4. What? Optimize Performance; Minimize Consumption Key Terminology
Identify areas of significant power consumption
Innovate and Substitute
Key Terminology
Xerography (Electrophotography)
Piezo Applications
Injet Printing
Challenges
What has already been done before?
Fuser Test Beds and Optimization
Electrophotographic Transfer Station
Dean

5. Where? Previous Locations of Research Current Technology Development
Past MSD projects stored on EDGE
Prototype and test fixtures at RIT
Current Technology Development
Continuing research at manufacturer locations and academic institutions
Research performed by company employees and students alike
Widespread knowledge base
Universities
Research facilities
Tim 5

6. When? Utilization Previous Projects Current Project
End product could be utilized immediately
Growing demand for technology in less developed countries with little infrastructure
Previous Projects
P09503: Electrophotographic Development and Transfer Station ( to )
P09505: Low-Energy Printing ( to )
Current Project
P10505: Concurrent Low-Energy Printing ( to )
Innovation & Creativity Festival
May 1, 2010
Shawn

7. Why? Importance of Technology Developement Impact on Current Society
Multidisciplinary involvement (ME, EE, IE)
New product design is the life blood of competing companies
Stakeholder interests: students, manufacturers customers
Impact on Current Society
Push towards low energy technology
RESOURCES
RIT
RIT neighbors graphic imaging companies
Involves multiple engineering departments
Opportunity to prepare students for career after graduation
Low-energy is a hot industry
Tim 7

8. How? Previous approaches to this concept include the following:
Extensive fuser research; measurement and PUGH analysis
Attributes of a successful project
Attributes of an unsuccessful project
“How to approach our project…”
Dean

9. Xerography (Electrophotography)
Dean

10. Xerography (cont.) Energy Demands (Standard Xerox 50 ppm Unit)
Illumination and Document Handling
Controls and Solonoids
Internal Losses
Electronics
User Interface
Mechanical Systems
Photoconductor and Image Transfer
Dean

11. Thermal Inkjet Printing
Print cartridge has 300 to 600 ink nozzles
Each nozzle is electrically heated
The ink is an aqueous solution
The heat causes the ink to boil, which forms a bubble inside the nozzle
The bubble propels the ink forward out of the nozzle toward the paper
The contraction of the bubble and the ink’s surface tension pulls more ink from the reservoir
Shawn

12. Piezoelectric Continuous Printing
Electrically Reactive Material
Deflection caused by voltage (and vise versa)
Pulse generation (similar to thermal inkjet) causing ink release
Ink droplets charged while exiting nozzle
Continuous stream with interval between droplets; wave effect
Application of Ink
Continuous discharge, unlike piezoelectric on-demand
Electrically charged ink is deflected by electrical field between plates
Charge intensity determines placements of ink droplets
Up to ~165,000 drops per SECOND!
Continuous Ink Discharge
Ink is deflected by plates onto media
Unused droplets are collected by gutter and recycled
Continuous discharge prevents clogging of ink nozzle
Tim 12

13. Piezoelectric Continuous Printing
Applications
Wide range of media materials
Ink deflection pattern compensates for different shapes
Often used to print expiration dates, bar codes, labels
Commercial/industrial applications; high-speed printing
Tim

14. The Piezoelectric Process
Tim

15. Piezoelectric Continuous Printing
Benefits
Prints on many types of materials
Allows for large distance between media and ink nozzle
Prints on materials of different textures and shapes
High speed
Low maintenance (low risk of clogging)
Disadvantages
High cost of print head
Large size, complexity
Limited print resolution
ENERGY: Only a small fraction of ink droplets are applied to media
Unused ink droplet ejection
Ink return pump
Tim

16. Piezoelectric On-Demand Printing
Piezoelectric materials deform under electric potentials
Process can be reversed
Uses up to 600 nozzles, similar to thermal inkjet
Piezoelectric material sits inside ink chamber
Material vibrates and deforms under electric potential
Ink becomes forced out of nozzle
Many different inks can be used
Epson currently holds patent on printing technology
Derek

17. Low Energy Printing Projects
Fusing System
Low-Power, Non-Thermal
Conclusion: Conventional Fusing System Optimized
P10505
In Progress
Conclusion: Collaboration Mutually Advantageous
Dean

18. Experimental Printing Test Fixture
P07501: Laser Fuser Test Bed
Continuously variable to simulate different conditions
Test reactions of toners
Effects of speed, pressure, and temperature
All aspects combined determine image quality
Issues and Resolutions
Unable to accurately measure applied toner temperature
Bring toner temperature to equilibrium before application
Accurate pressure profile curve concerns
Use linearly actuated cam to vary pressure
Whoever the hell did this 18

19. Experimental Printing Test Fixture
P08501: Roller Fuser Test Bed
Goal: Develop methods to improve current printing systems
Combine research and development from past project
Rollers resemble current in-use printers
Control Conditions
Vary pressure, temperature and speed of rollers
Test fusibility of toner under different conditions
Difficult to precisely control roller pressure
Suggest more refined linear actuators
This too 19

20. The MSD “State of the Art”
Fuser Optimized as of ’09
Electrophotography Attributes Not Yet Investigated
Typical Ink Application Systems (i.e. jet interruption) Not Yet Investigated
Dean
*P09505: Low Energy Printing (Xerox), Joshua Jones and Team