11

The Technology of The Technology of Color Laser Printers Color Laser Printers The Technology of The Technology of

Color Laser Printers Color Laser Printers

Mark Hibbard Washington County Community CollegeMark Hibbard Washington County Community CollegeRecharger Magazine World EXPORecharger Magazine World EXPO

27 September 200427 September 2004Session S19Session S19

22

OvervieOvervieww

Market Watch

Color for Free

Color Application

Current Printer Configurations (Networking)

Remanufacturing Options (still risk management)

Image Dynamics

Cartridge Components

Cartridge Complexity

33

Color Market Color Market

WatchWatch Color Market Color Market

WatchWatch Color-TimelineColor-Timeline

1993 QMS ($10k) 1993 QMS ($10k) 1996 QMS ($4K)1996 QMS ($4K) 1997 TEK ($2.2K) 1997 TEK ($2.2K) 1998 HP ($1.8K)1998 HP ($1.8K) 1999 QMS 1999 QMS ($1.2K) 2000(4550) 2002 (4600)($1.2K) 2000(4550) 2002 (4600)

( ~ $0.80( ~ $0.80 $0.6 $0.30 $0.20 $0.6 $0.30 $0.20 $0.12 $0.09 $0.12 $0.09

Business Imaging Pressure to “Go” ColorBusiness Imaging Pressure to “Go” Color

Communication with color NOT a Communication with color NOT a novelty novelty (WWW)(WWW)

Cost per page fallen rapidlyCost per page fallen rapidly Image quality Image quality Device independent document Device independent document

creationcreation Process speed increased Process speed increased Competition fierceCompetition fierce Corporate MIS Purchasing see Corporate MIS Purchasing see

valuevalue

44

North American Color Laser PlacementsNorth American Color Laser Placements North American Color Laser PlacementsNorth American Color Laser Placements Placements per Month

01000020000300004000050000600007000080000

1990

1994

1996

1998

1999

2000

2001

Year

Unit

s LaserHybrid

HP claims

~59% market share all laser printers

~70% Color Market

~62% Color Laser Market

55

The Ink Jet Crossroads

Cost per Page

$0.00

$0.20

$0.40

$0.60

$0.80

$1.00

1992

1996

1998

1999

2000

2001

Year

Uni

ts Color LPColor IJ

Paper media is the differential: photo printing

66

Imaging Decision MakersImaging Decision MakersImaging Decision MakersImaging Decision Makers

MIS Directors Connectivity / Flexibility

Purchasing Agent Comparison Shopping

Owner Operators Features

PC Resellers Cost / Features

Government Varied directives

Education Cost / Features

77

Color vs MonoColor vs Mono

Mono $ Color $

1993 $1,700.00 HP-LJ41996 $850.00 HP-LJ51997 $1,000.00 HP-LJ4000 $4,000 HP-LJC51998 $1,000.00 HP-LJ4000 $4,000 HP-LJC51999 $1,000.00 HP-LJ4000 $2,200 HP-LJ45002000 $1,100.00 HP-LJ4100 $1,900 HP-LJ45502001 $1,100.00 HP-LJ4300 $1,900 HP-LJ45502002 $1,000.00 HP-LJ4200 $1,790 HP-LJC4600

2003 $500.00 HP-LJ2300 $699 HP-LJC2500

2004 $399.00 HP-LJ1300 $500 HP-LJC2500

88

Mixed Graphic … NT/DesktopMixed Graphic … NT/Desktop

HP Printer Cost Comparison

$0

$500

$1,000

$1,500

$2,000

$2,500

$3,000

$3,500

$4,000

$4,500

1992 1994 1996 1998 2000 2002 2004 2006

Monochrome

Color

99

Color Imaging PrimerColor Imaging Primer Color Imaging PrimerColor Imaging Primer

Dots on a page - forget what you learned Subtractive color synthesis - White light contains all the wavelengths of the visible spectrum

Primary colors are used in computer monitors - RGB

Complementary colors are the control colors of printing technology. Single complementary colors reflect there own wavelength and absorb the rest of the spectra. M C Y

Two complementary colors in equal intensities will produce a primary color.

Magenta and Yellow =Red

Magenta and Cyan =Blue

Yellow and Cyan= Green

1010

Vary complementary intensities

(toner)

Produce “gamut” of color

Screen effect and the human eye !!!

Photo mechanical process tricks the eye Dot size, viewing distance, lighting Perceived image quality

Visual Color Image Characteristics

Color Reproduction …… memory color … gamut .. accuracy Tone Scale …. Rendering density , depth , texture Sharpness …. High definition detail Uniformity … Grain, banding, streaks

Psychometric Scale Is it real ? Or Roger Rabbit Subjective targets viewed at fixed distance and proper light Perceived image quality

1111

Pixel Pixel MagicMagicPixel Pixel MagicMagic

Dots within a cellDots within a cell Dithering - is the art of placing single pixels of CMY Dithering - is the art of placing single pixels of CMY

adjacent to one another to create the illusion of color. adjacent to one another to create the illusion of color. This is a “single level” process common to most This is a “single level” process common to most laser printers. laser printers.

Latest technology that HP uses on the 4500 places Latest technology that HP uses on the 4500 places dots on top of one another in varying amounts. This dots on top of one another in varying amounts. This is the multi level approach used in lithography. is the multi level approach used in lithography. ImageRET2400 is exclusive to HP.ImageRET2400 is exclusive to HP.

Level address ability is costly in memory and/or Level address ability is costly in memory and/or formatting time. formatting time.

o Toner development “dot gain” can alter color perceptionToner development “dot gain” can alter color perceptiono Humans can perceive shading gradients very wellHumans can perceive shading gradients very wello Core-Shell CP toners have better fusing, best color Core-Shell CP toners have better fusing, best color

images are perceived to be glossyimages are perceived to be glossy

1212

The Color WorldThe Color World

Color Systems and Real World– RGB monitors using 256 levels of

primary color can reproduce 16.77 million colors

– The print media world is severely limited. Since perfect dyes do not exist CMY usually creates a muddy brown color. So a “key” color of pure black is included.

– Gamut “Color Space”

Human Eye

Color Space

Color Monitor

Color SpaceRGB

CMYK Printer Color Space

1313

Real World Color PrintingReal World Color Printing

Materials - Paper, inks and toners are imperfect … producing imperfect colors

Developing dots - The dot needs to be uniform in size, shape and translucency. To correctly absorb or reflect the light.

Development (interlace/overlay) Transfer Fusing

Color formatting - Color picture information that is digitally represented in a WYSIWYG format is in RGB data form. The process of converting “bit by bit” the RGB data into CMY is not trivial. RIP systems are hot software projects in digital imaging.

1414

Color Color “complexity”“complexity”

Linear color developmentLinear color development This color process uses four This color process uses four

complete e-p systems that will complete e-p systems that will transfer color pigment onto the transfer color pigment onto the media in one-pass. Used in low media in one-pass. Used in low cost Optra 1200 to high cost cost Optra 1200 to high cost Xiekon printers. Where the 1200 Xiekon printers. Where the 1200 prints 4 ppm one side and the prints 4 ppm one side and the Xiekon prints 75 ppm both sides.Xiekon prints 75 ppm both sides.

Media lies on a transfer belt, each development station places toner onto the media. Each cartridge has a hopper, toner delivery mechanism, sweeper strips, cleaning blade, OPC, PCR and developer cylinder.

Fuser assembly

Black Yellow Cyan Magenta

Process Direction

1515

Color print engine Color print engine designdesign

Carousel development system To reduce the complexity of the printer a

carousel array that can rotate onto a single development zone is implemented within the Optra C.

Having four discrete toner vessels that can use a single contact development cylinder and single drum unit reduces the number of critical e-p components.

Transfer Cylinder

K

Y

M

C

Carousel

OPC Unit / Cleaning Blade

1616

Four pass color processingFour pass color processing

Direct transfer …. Intermediate Direct transfer …. Intermediate transfer - The four stage process transfer - The four stage process can develop the sequential color can develop the sequential color masks onto the OPC surface or masks onto the OPC surface or onto a transfer device in the onto a transfer device in the form of a belt or drum..form of a belt or drum..

Registration is super critical. Registration is super critical. Paper slippage upon transfer Paper slippage upon transfer cylinder is common. The laser cylinder is common. The laser “write process” occurs each “write process” occurs each pass as the carousel aligns the pass as the carousel aligns the staged color. The media is then staged color. The media is then separated from the transfer separated from the transfer cylinder and fused.cylinder and fused.

Rotational speed and toner Rotational speed and toner adhesion can effect color adhesion can effect color registration and definition. registration and definition.

Cleaning the OPC in the four Cleaning the OPC in the four pass process is critical. The OPC pass process is critical. The OPC and transfer systems will need and transfer systems will need robust cleaning components.robust cleaning components.

Color print engine Color print engine designdesign

1717

HP Color HP Color SystemsSystems

The installed base of 4500’s is Huge The installed base of 4500’s is Huge Durability- The hallmark of HP’s laser printer Durability- The hallmark of HP’s laser printer

series has been the excellent serviceability series has been the excellent serviceability and reliability. and reliability.

Four Pass to inline (One pass)Four Pass to inline (One pass)

DevelopmentDevelopment -- -- process speedprocess speed --- ---

Perceived qualityPerceived quality

DPI’s CM technologyhttp://www.dpisolutions.co.kr/

1818

Toners for Color SystemsToners for Color Systems

Color - non-magnetic tonersColor - non-magnetic toners The polyester binder resins are more The polyester binder resins are more

expensive than monochrome binders. expensive than monochrome binders. Color pigments that are “color correct” Color pigments that are “color correct”

expensive.expensive. Processing is expensive (getting cheaper)Processing is expensive (getting cheaper)

Direct Polymerization has arrivedDirect Polymerization has arrived Canon color toner is a DP toner with a PE Canon color toner is a DP toner with a PE

wax core. (CPT) wax core. (CPT) Several CP toner processes in IPSeveral CP toner processes in IP

Emulsion aggregate Emulsion aggregate (FujiXerox)(FujiXerox)

Chemical Milling (DPI)Chemical Milling (DPI) Suspension polymerization Suspension polymerization (Ricoh, Nippon)(Ricoh, Nippon)

1919

CPI Toner DevelopmentCPI Toner Development

Still a dynamic technologyStill a dynamic technology Only ~2% of all toner produced in 2000Only ~2% of all toner produced in 2000 Forecasted to represent ~10% by 2010Forecasted to represent ~10% by 2010 Many chemical companies have CPT Many chemical companies have CPT

manufacturing skills but have not manufacturing skills but have not participated in the business imaging marketparticipated in the business imaging market

Recognized suppliers, MCA, FX, Recognized suppliers, MCA, FX, Minolta/Konica, DIC, DPI, ICMI, Coates Minolta/Konica, DIC, DPI, ICMI, Coates Repro some others have vested interestRepro some others have vested interest

Cost and scale-up are barriers .. But being Cost and scale-up are barriers .. But being overcomeovercome

2020

Value added to image Value added to image performance !!performance !!

Smaller and more uniform PSSmaller and more uniform PS Lower grams per page without density Lower grams per page without density

sacrificesacrifice Better fusing (lower IBetter fusing (lower I22R)R) Better transparency … and better intra-Better transparency … and better intra-

color visual appearance color visual appearance Core-shell integrationCore-shell integration

2121

Image DynamicsImage Dynamics

• Complete charge control• Balance between opc sensitivity, development zone,

opc design, toner charge & process speed• Cleaning is paramount for color balance

125 v

400 v

Over-developed

Backgrounding

Smooth Color Gradient

2222

CPT replacements Traditional manufactureCPT replacements Traditional manufacture

TM’rd Color toner major issuesTM’rd Color toner major issues Fusing requirement is difficult to Fusing requirement is difficult to

match with pulverized clonematch with pulverized clone Particle size control is difficult with Particle size control is difficult with

classic manufacturingclassic manufacturing Post blending a additives for CC and Post blending a additives for CC and

fusing being used in some color toner fusing being used in some color toner systemssystems

Toner design gets much more Toner design gets much more complicated with increased PPMcomplicated with increased PPM

2323

Color Science …Color Science …

Seybold - 8Kenneth Elsman Kenneth Elsman -- Harlequin IncHarlequin Inc..

How do we measure color?How do we measure color?How do we measure color?

ll Flow chart of basic data collection for color Flow chart of basic data collection for color management.management.

Test TargetTest TargetSpectrophotometerSpectrophotometer

D50 IlluminationD50 Illumination22°° ObserverObserver

0/450/45°° geometrygeometry

XYZ

LAB

=

2424

Color Test Methods and StandardsColor Test Methods and Standards

Visual inspectionVisual inspection Image PerformanceImage Performance Cartridge line statisticsCartridge line statistics Print testingPrint testing Defect analysis …. Defect analysis ….

Corrective actionCorrective action ASTM ASTM ISO 13660ISO 13660

2525

Managing ColorManaging Color

What you see isn’t always what you getWhat you see isn’t always what you get Printers have different printing schemaPrinters have different printing schema Monitors have a Monitors have a widewide range of color range of color

variationvariation

Print output is VERY different Print output is VERY different

from screen outputfrom screen output

2626

Figure 7

Figure 3

2727

Figure 4

2828

Color InfluencesColor Influences

Light in the viewing roomLight in the viewing room Natural day lightNatural day light Florescent lightFlorescent light Ultraviolet lightUltraviolet light Amount of light or shadowAmount of light or shadow

2929

Figure 10

3030

Figure 11

“CMY” Subtractive colorants

3131

Color development

3232

Test patterns

3333

Integrated Test Targets

3434Color interference

3535

QEA Personal IAS -- Figure 12

3636

Setting up a Setting up a CellCell

Breakdown - Cleanliness will be Breakdown - Cleanliness will be critical. Cross-toner contamination critical. Cross-toner contamination must be controlled. must be controlled.

Filling - Start up process while Filling - Start up process while production demand is low will be done production demand is low will be done with bottles. (Kitting)with bottles. (Kitting)

Filling systems will require triplication Filling systems will require triplication or extremely aggressive cleanout. or extremely aggressive cleanout. Some existing fillers will not handle Some existing fillers will not handle color toner.color toner.

Sealing systems ….Sealing systems ….

3737

SuppliersSuppliers

Some major shift to buy direct on some Some major shift to buy direct on some high volume componetryhigh volume componetry

RM Suppliers – Imaging Materials RM Suppliers – Imaging Materials ManufacturersManufacturers Testing differentials OEM v Market “fitness for Testing differentials OEM v Market “fitness for

use”use” Initial cost and RD EffortsInitial cost and RD Efforts Partnerships possible depending on Partnerships possible depending on

commitmentcommitment

SCC, FG, Oasis, TP vested and committedSCC, FG, Oasis, TP vested and committed

3838

Working with VendorsWorking with Vendors

Provide RM’s with as much information as Provide RM’s with as much information as possible on color performancepossible on color performance Resolution standardsResolution standards Spatial resolutionSpatial resolution File formatsFile formats File sizeFile size Possible printer optionsPossible printer options File format (TIFF,JPEG,PDF,)File format (TIFF,JPEG,PDF,)

Future Print Image FormatsFuture Print Image Formats PNGPNG JPEG 2000JPEG 2000