Evolution Theory of Ink Jet Technologies

Transcription

1 Printing for Fabrication 2017 Evolution Theory of Ink Jet Technologies - Progress by Component or Architectural Knowledge Masahiko FUJII Marking Technology Laboratory Fuji Xerox Co., Ltd.

2 1 Involvement in Ink Jet Continuous Ink Jet Thermal Ink Jet Applications of Ink Jet Single Drop Detector M. Fujii, Optical Drop Sensor of Continuous Ink Jet Printer, 19th Imaging Technology Conference, dpi MEMS Printhead M. Fujii, New Thermal Ink Jet Printhead with Improved Energy Efficiency Using Silicon Reactive Ion Etching, The Journal of Imaging Science and Technology, Vol. 43, No. 4, 1999 Micro-Lens Array M. Fujii, Issues and Approaches Imposed on Ink Jet for The Progress of Printed Electronics, Transactions on The Japan Institute of Electronics Packaging Vol. 3, No. 1, D Printing High Quality 3D Printer 3D Data Handling Voxel-Based 3D Data Format FAV T. Takahashi & M. Fujii, Unrestricted 3D Structure Modeling and Seamless Data Flow to 3D Printers Using Voxel-based Data Format FAV (Fab-able Voxel), IS&T s NIP32, 2016

3 2 Macro-Trend of Ink Jet Printer Next Year (2018) : The 50th Anniversary of The First Ink Jet Printer Appearance And The 80th Anniversary of C. F. Carlson s Experiment for EP 1938 Mingograph (Siemens) Siphon Recorder (Kelvin) Pagewide Printhead R2R Fast Drying Ink Dryer 1984 ThinkJet (HP) Small Size 2005 True Press Jet 520 (Screen) 1996 High Image Quality 2011 High Image Quality & 2003 High Speed High Speed PM-700C (EPSON) Diluted Ink Photo Paper Small Drop 2017 JetPress 720 (Fuji Film) Defect Detection & Correction Impression Cylinder Under-Coating Latex Ink Dryer Videjet (A.B.Dick)

4 3 Definition of Ink Jet (My) Definition of Ink Jet : Dropletize liquid including colorants or functional materials, and Eject drops to recording target (media) on demand from image (pattern) signal, then Bring colorants or functional materials to (on) recording target (media). Defining technology is important to identify the invention, and to consider extensions or applications of the technology. Ink Jet is not a technology only to realize printers. M. Fujii, S. Sakai, A. Tomotake, H. Eguchi etc. (2008)

5 4 Marking Process of EP & Ink Jet Photoreceptor Charge Light Source Electrophotography Toner & Developer Latent Image Large Size High Cost Large Power Consumption Low Process Stability Paper Charge Exposure Development Transfer Fixing Cleaning Printhead Ink Jet Pagewide Printhead Simple Marking Process Ink Drops Swath Paper Serial Printer Small Size Ink Drops Low Cost Small Power Consumption High Process Stability Swath Line Printer

6 5 Possibility & Limitation of Ink Jet Ink Jet Marking Process is Simple. High Applicability to Various Applications Possibility Ink Jet Process Simplicity Marking Process is Achieved Only by Interactions between Ink And Media. Limitation Challenge Simplicity of process has both aspect of a possibility and a limitation. These two aspects led me my ink jet evolution theory.

7 6 Concentrating Functions Progress (CFP) Circumjacent Technologies Ink Supply Simple Process Key Components (Technologies) Printhead Printer s Prime Performances Image Quality Drop Volume Nozzle Resolution Ink Latitude Directionality Print Speed Firing Frequency Nozzle Number Robustness Maintenance System Ink (Functional Liquid) Penetrability Multi-Color Color Reproduction Penetrability Image Processing Dot Placement Paper (Media) Absorbability Circularity Gloss Control Absorption Speed Concentrating Functions Progress (CFP) Keeping merits come from process simplicity of Ink Jet Progress of system performance has brought by progress of each key components performance

8 7 Drop Volume & Image Quality Minimum Ink Drop Volume (pl) 10 2 Commercialized Home Printer 10 1 Drop Diameter (µm) 27 (Image Quality Quantified from Visual Aspect) Sensory Evaluation Score for Image Quality Ink Jet (Ink Jet Paper) Dry EP (Plain Paper) ( ) 1 Electrostatic Pull Ink Jet (AIST) 10-4 ( ) Year Ink Jet (Plain Paper) Year

9 7 Drop Volume & Image Quality Number Minimum of Ink Ink Color Drop Volume (pl) Commercialized Home Printer ( ) Electrostatic Pull Ink Jet (AIST) 10-4 ( ) Year 8 9 Drop Diameter (µm) (Image Quality Quantified from Visual Aspect) Sensory Evaluation Score for Image Quality Ink Jet (Ink Jet Paper) Dry EP (Plain Paper) Ink Jet (Plain Paper) Year

10 8 Speed Factor (Print Speed) Speed Factor = Frequency Nozzle Number Frequency * Nozzle Number Swath Multi-Path * Print Resolution * Print Direction - Maintenance - Others Firing Frequency (khz) Piezo ( ) Nozzle Number Nozzle Number 2 8 Swath (inch) Swath Thermal Year Year 2-4

11 8 Speed Factor (Print Speed) Print Speed Frequency * Nozzle Number Speed Factor = - Maintenance - Others Multi-Path * Resolution * Print Direction Firing Drop Number ( /sec) 2 30 Printing Speed 2 25 Until 2005 Tilt : = Moore s Low Year

12 9 End of CFP in Consumer Products Increase of key components performance has almost saturated, and progress of printer performances (image quality, print speed) have ticked over since If additional technology developments focusing on consumer market stop, no consumer will feel inconvenient. Shipment (M) SFP MFP Year Volume of Ink Jet printer Shipment in Japan I don t mean that all ink jet technology developments should be stopped.

13 10 New Progress Type Technologies progress of ink jet stop? NO! Concentrating Functions Progress (CFP) is still required in other market with different performance axis (required performance) [DF] NOT consumer s. CFP is only approaches in ink jet? Layer Thickness (µm) New type of technology progress has been necessary for new printer market with new hard issues. One of new markets is commercial printing, and new progress type is Sharing Functions Progress (SFP) Slot Die Coater Screen Gravure Offset High Viscosity Flexography Ink Jet Small Drop Size Reverse Offset Resolution (µm) S. Tokito, The 4th Workshop on Flexible Organic Electronics (2017)

14 11 Plane View of Ink Jet Market Image Quality Digital Fabrication Concentrating Functions Progress Home Concentrating Functions Progress Office Photo Finishing Pagewide Printhead Commercial Printing Sharing Functions Progress Low / Mid. High Transactional Light Production Serial Printhead : Technical Difficulties to Overcome Boundary Print Speed

15 Serious Issues in Commercial Printing Market Existing Market (Consumer, Office, Photo) Dot Commercial Printing Market Dot Permeable Media Non-Permeable Media (Coated Paper for Offset) Ink Jet Media Image Forming On Non-Permeable Media Offset Coated Paper No Multi-Pass Compatibility of High Speed & High Image Quality Challenge New Type of Technology Progress Not Saddle Printhead or Ink Line Printer : One Pass Process Sharing Functions Progress

16 13 Sharing Functions Progress (SFP) Printhead and Ink Progressed Adopt or combine another surrounding technologies. One Pass Image Quality for Commercial Printing Defect Detection Defect Compensation Impression Cylinder Image Forming On Non-Permeable Media Under-Coating Drying System Latex Ink No Under-Coating Under-Coating Before Compensation After Compensation Drying System Anti-Curl Agent Impression Cylinder Air Conditioner Pagewide Printhead Sharing Functions Progress Many ink jet Merits (small size, low cost, low energy Consumption) are lost. High Speed Printing with Cut Paper

17 14 Direction of Technology Progress Sharing Functions Progress (SFP) 2005? Commercial Printing Transfer Drying, Cooling Defect Detecting & Correction Under-Coating Pagewide Printhead Digital Fabrication Hydrophobic / Hydrophilic Control Concentrating Functions Progress (CFP) Imaging Process is Achieved Only by Interactions between Ink And Media. Drop Volume Firing Frequency Resolution Multi-Color Penetrability Color Reproduction Concentrating Functions Progress (CFP) Digital Fabrication Functional Ink Printhead Firing High Viscosity Media (Substrate) Reformulation

18 Innovation Portfolio by Henderson & Clark Changed Architecture Linkage between Core Concepts and Components Unchanged SFP Architectural Innovation Architectural Knowledge CFP Incremental Innovation Component Knowledge Radical Innovation Modular Innovation 15 R. Henderson & K. Clark, Architectural Innovation: The Reconfiguration Existing Product Technologies and the Failure of Established Firm (1990) Reinforced Core Component (Core Concept) Overturned

19 16 Technology Progress of Ink Jet Try And Error of Combinations Dominant Design 1980 Break Off Improvement of Components Concentrating 2005~ Functions Progress Try New Combinations Change Architecture Sharing Functions Progress Architectural Knowledge Component Knowledge Architectural Knowledge Again?! Continuous Ink Jet Charged Deflection Hertz Type Electrostatic Pull On Demand Ink Jet PIJ TIJ AIP ERF Electrostatic Pull Ink Jet Electrostatic Actuator Charged Deflection (Binary) Drop Volume Firing Frequency Nozzle Number Ink Penetrability PIJ, TIJ Stream, Ultra-Stream Vista JET JetRix Captive CIJ LILO

20 17 Approaches & Dominant Design Commercial Printing Market (Dry EP) (Liquid EP) Under- Coating Transfer IJ No Under- Coating Direct IJ Aqueous UV Various ink jet approaches to commercial printing exist, but the dominant design has NOT been established yet.

21 Contradiction of Progress in Commercial Printing Market Present Continuous On Demand Dominant Design Binary Deflection Thermal Ink Jet, Piezo Ink Jet Concentrating Functions Progress (CFP) Consumer Office Industry Digital Fabrication Stream, Ultra-Stream Captive CIJ Architectural Knowledge Component Knowledge Sharing Functions Progress (SFP) 18 Development Organization or Resource Allocation Based on Dominant Design Commercial Printing Architectural Knowledge Venture or start-ups assumes architectural progress essentially. Big Name

22 19 Contradiction of Progress in Commercial Printing Market Architectural Innovation should be brought by venture companies or start-ups essentially. On the other hand, Big companies have stored ink jet technologies and know-how required for commercial printing market. Here, we have contradiction of progress. No one can stop digitalization of commercial printing, what this contradiction brings?

23 20 Contrivances to Activate Ink Jet Technologies Progress For both SFP (Architectural Innovation) and CFP, (Incremental Innovation) Full-Blown ink jet technologies owned by ink jet company should be transfer or licensed to new challengers. (Don t enclose for the already stop-glowing market.) Engineers and Researchers network (Community) will help to share common information and create new applications and make innovations. Ink Jet Technical Networking (Community) in Japan

24 21 Architectural progress in Additive Manufacturing 1989 H. Kodama 1980 C. R. Deckard 1986 Material Extrusion S. S. Crump Vat Photopolymerization Additive Manufacturing Fusion Is Categorized into 7 Methods. Powder Bed Sheet These 7 Methods were Invented in 1980 s or 1990 s. Lamination About 30 years pasts, then M. Feygin 1989 Binder Jetting 1989 Material Jetting 1995 Directed Energy Deposition E. M. Sachs J. Sakai G. K. Lewis

25 21 Architectural progress in Additive Manufacturing - Target Shift of Additive Manufacturing 1989 H. Kodama C. R. Deckard 1980 Vat Photopolymerization Complex Manufacturing 1986 Powder Bed Material Latitude Fusion Productivity Cost 3D Production Material Extrusion Custom Manufacturing S. S. Crump Sheet Lamination 1987 M. Feygin Shift Material Binder Indirect Manufacturing Jetting Jetting E. M. Sachs Rapid Prototyping J. Sakai 1995 Directed Energy Deposition G. K. Lewis

26 21 Architectural progress in Additive Manufacturing H. Kodama C. R. Deckard Carbon Vat Photopolymerization CLIP Material 1986 Extrusion Powder Bed HP Fusion Multi Jet Fusion 2017 S. S. Crump XYZ Printing da Vinci Color 3D printer Sheet Lamination 1987 M. Feygin Material Binder Jetting Jetting E. M. Sachs Xaar & Loughborough University High Speed Sintering 1995 Directed Energy Deposition J. Sakai G. K. Lewis

27 22 Conclusion & Suggestion 2005 was one of important turning years for ink jet technology progress. Two type of ink jet technology progress exist. Concentrating Functions Progress (CFP) Sharing Functions Progress (SFP) CFP generates Incremental Innovation, SFP brings Architectural Innovation. CFP is still required for digital fabrication, SFP is necessary for commercial printing. In commercial printing market, a contradiction of progress has occurred, and dominant design has NOT been established yet. Full-blown ink jet technologies owned by ink jet companies should be transferred or licensed to new challengers to activate both CFP and SFP.

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