Recharger Magazinedownload.101com.com/rec/expo2005/pres/Mark_Hibbard_Real...Real World Toner Testing...

Real World Toner Testing

Cartridge New Product Introduction

Recharger Magazine Expo 2005

Eastport Engineering Ω Eastport, Maine markhibbard@ptc-me.net

Expo 2005 - Eastport Engineering - Hibbard2

Toner Testing Objectives

o Basic EP principles

o Basic image formation

o Human visual response to images

o Test target selection

o Image analysis tools

o Subjective measurement

o Statistical image measurement

o Test Plan and Data Base

• Constant Improvement2Understand limitations of the printer and

process 2Governs product development2Corrective action 2Standards are here .. And will continue

2ASTM 1856, 1531 … ISO 13660 … ISO 19751

Evaluation Development

Basic Cartridge

** Color toner hopper / catridge

EP Process

Key Component

• Clean• Cleaning Blade ~ Toner ~ OPC ~ Process

• Charge• OPC ~ PCR ~ Process

• Writing• OPC ~ Laser ~ Process

• Developing• OPC ~ Toner ~ Developer Sleeve ~ Process

• Transferring• OPC ~ Toner ~ Media ~ Process

• Fixing• Toner ~ Media ~ Fuser ~ Process

Critical Components

o Image is cleaned from the OPCo Image is formed in/on the OPC o Image is developed onto the OPCo Image is transferred from the OPC

Much of the electrophotography science is happening here !!! ON a high commodity component ( << $10) DO NOT Overlook this components contribution to overall image performance

Cleaning

• Preparation for new latent image• wiper blade Care and cleaning/handling

• recovery blade

PCR (charge roller technology)

Cleaning Problems

• Vertical streaking• smearing• ghosting (double imaging)• background haze• peppering of loose toner

Conditioning

Primary charge roller applies a uniform negative charge(-600V to -720 V DC)

Writing

• Laser beam used to discharge the conditioned charge on drum surface

• aluminum substrate is connected to an electrical ground

Gears & Ground path

Writing

• Photo conductive material becomes electrically conductive when exposed to light

• The negative charges moves onto the surface of the drum conduct to the aluminum base when exposed to light creating the latent image

Writing

• Image area will attract toner in the later development stage

• Ground contacts• DEVELOPMENT Spacing

Contact development – NON Magnetic toner

Zone Development – HP – Magnetic toner

Developing

• Latent image becomes visible image• process contains four major components

Metering blade

Cleaning Blade

Developing

• Toner• developer roll assembly• metering blade• AC/DC charge

Developing

• Toner attracted to developer roll by internal magnet or electro-static charge

• Roller carries toner particles to the metering blade and creates tribo-electric charge (friction) on surface of toner particles

Developing

• Metering blade(doctor blade) allows even distribution of toner to drum

• developer roller then charged with an AC/DC charge from high voltage power supply

• allows toner to jump from developer roller to the opc and is attracted to latent image

Developing …………….. Toner

Interaction• Light print • Blasting• Backgrounding• Leaking or spilling• Excess waste toner• Toner build-up on the fuser assembly

Transferring

• Transfer of image on the drum to a piece of paper• As paper passes under drum it passes over a corotron assembly• The assembly places a positive charge on the back of the page

TRANSFER Eff % -KEY for yield and density

Fusing

• Toner is attracted off the drum• Poor transfer of toner creates more waste• Toner is permanently affixed to the paper

Fusing

Fuser Assembly• Heated roller• Pressure roller• Heating element• Thermistor• Thermal fuse• Cleaning pad

• Time …. Duty Cycle … Print Job length

Fusing

• Heating element placed inside of aluminum roller coated with teflon• Roller heated to 355°F (180 °C)• Pressure roller is rigid foamed silicon roller• Pressure is applied to heated roller

Fusing

• The paper passes between the rollers• The heated roller melts the toner particles while the

pressure roller presses the toner into the fiber weave of the paper

Transferring/Fusing

Problems• Raised print• Toner flaking• Light print• Ghosting• Offset

Image Formation

• OPC response forms a proper image• OPC active layer responds proportional to the resolution of

the printer.

• Toner is charged properly and is formulated such that the latent image is correct.

• Transfer to the media is correct, mechanically• Fusing, toner formulation minimizes spread• Repetitive defects (component related)

Toner Manufacturing- Understanding performance and $$Design Criteria

Raw MaterialsRaw Materials

CompoundingGrindingClassifying

Particle Size & DistributionClassifying EfficiencyContamination

Chemical Toners

- Their shape can be almost spherical

- Their size can be smaller (about 5 microns) and much more regular.

- Their electrostatic characteristics make them easier to mix together to get custom colors.

- Their transfer efficiency from photoreceptor to paper is almost 100%.

- Cheaper to produce, they put less strain on printing engines.

This new process requires less energy to make, generate less waste, contribute to printer reliability.

Raw Materials

• Magnetic Toner• Resin system (melt point,grindability,wetting,cross-linked)• Iron oxide (coercivity,shape,wetting,purity)• Carbon Black (wetting,particle size,purity)• Post additives (Fumed Si, Ti, Polyproplene wax)

• Non Magnetic Toner• Resin system (melt point,grindability,wetting,crosslinked)• Carbon Black (wetting,particle size,purity)• Post additives (Fumed Si, Ti, Polypropylene wax)

• Chemically Prepared Toner• Resin system• Pigment• Post-adds

Toner Requirements

• Provide desirable output image on a given media

• Stable in different environmental conditions

• Economical considerations• Health risks• Careful control of materials

Dry Toner Manufacturing ProcessSimplified

Raw Material

Mixers

FineClassification

AdditiveMixing

TheFines

FinishedProduct

DustCompounding

CoarseClasification

Fine Mixing

Compounding Technique

• MeltMixing• Distributive mixing• Batch or continuous • Must control of flux point• Layered additions (technique)• Wear protection• $$$$ electricity• Secondary mixing on Roll Mill• Cleanouts $$$$ time

Toner “Finishing” Process Control

• Coulter , Lasentec• Measurement technique• Accuracy• Meaningful results• Forensics

• Q/M• Prepared / Actual samples• Temp & rh%• CCA

Particle Size

• 5-10 microns Typical laser product• Cut is important : not Average PSD• Sub 5u why ?• Additive issues• Health hazard warning

Melt Mix Dry Toner Resin Systems

Physical Properties Specific Gravity

Mechanical Properties Strength (Tensile and Flexural)

Modulus (Tensile and Flexural) Elongation Hardness Impact Resistance

Thermal Properties Heat Deflection Temperature Glass Transition Temp Heat Capacity Thermal Conductivity Thermal Expansion Coefficient

Processing Characteristics Melt Flow Index Melt Strength Melting Point, No-flow Temp Shear Rate/Viscosity Relation Compressibility (Pressure/Volume/Temperature

Relation)

Optical Properties Light Transmission Haze Refractive Index

Electrical Properties Surface and Volume Resistivity

Dielectric Constant Dielectric Strength Dissipation Factor Breakdown Voltage

Environmental Properties Chemical Resistance UV Resistance Flame Resistance (UL Rating) Oxygen Index Water Absorption

Morphology CrystallinityOrientation Composition (Neat, Blended,

Filled)

Toner Handling and Filling Product and Process

• Contamination• Oils• Water• Other toners• Dry Lubes

• Flow-ability• OPC Cleaning Properties• Filling Systems

Human Response to Imaging

Light response is logarithmicEdge definition and shade difference is keyHalftones (Gray Scales) 0-15 % are keyImproper line formation is easily detectedGhosting or shade variance is easily detected

Test Target SelectionFWhite FGray (25%)FBlack FGhost FHalftonesFFine LinesFSolid FillF5% Character Coverage

Cartridge Life500 pages of 5% coverage and then a sequence of imaging targets:White , Halftone, Solid fill Blocks

BID and Solid Fill Areas http://www.qea.com/pdf/QEA%20Test%20Target%20rev%204f.pdfhttp://www.imagexpert.com/site-new/docs/toner_test_targets_720dpi.pdf

Fine Lines and Halftones

•Gray scales …. Are very critical with the 1200 dpi printers

•Watermarks and GS values under 15% are hard to develop

•Postscript from Adobe pushes the envelop of halftone cell development

Ghosting

Ghost images are formed in solid areas as lighter shaded artifacts or as dark artifacts in light shaded objects. The developer sleeve and opc can cause ghost formations.

Measure shade differences

Repetitive Defects

•Repetitive-Defect Rulers are available from HP Manual & FG,SCC,Oasis

•Engine Specific ( Process Orientation )

•Develop good forensics

•Offset (Cold - Hot) OPC, DS, Transfer roller

Image Analysis Tools

• Create a toner cartridge print specification sheet • Have samples of acceptable and unacceptable

prints• Always have a good cartridge available for

comparison• Have samples of OEM prints

• Gold Cartridge/System (trace, baseline)

Solution Samples

• Document solutions to print defects on the Process Notes Log.

• Make a defect book from all the different defects that you find, both common and unusual.

• Example: If you have a test sheet that shows one dark band line on the top and you fixed it by scraping the grounding surface on the drum, write it down and keep it on file. If it happens again, you can identify the problem immediately.

Statistical Measurements

• Make a run chart and list different defects

• Look for trends in your process• Plan out what you can do to prevent common defects

• Training• Task Rotation• Tools … loupes, light, etc.

Character Formation

Characters that are hollow or contain voids have improper formation. The occurrence of voids also is toner related. Opc sensitivity can play a part when character formation problems exist. GUIDE is ISO13660

Repetitive Defects Key

•Defect Rulers are available from HP & others

•Engine Specific ( Process Orientation )

•Develop good forensics

•Engine charts and knowledge base

Moving Forward• Canon WX (HP-8000) Defect Ruler Inches MM

• Registration Roller 1-3/4 44 mm• Primary Charge Roller 1-3/4 44 mm• Developer Roller 2-1/8 54 mm• Delivery Roller (B) 1-7/8 48 mm• Transfer Roller (B) 2-1/4 58 mm

• Lower Fuser Roller (B) 3-11/16 94 mm• OPC Drum 3-11/16 94 mm• Upper Fusing Roller 4-7/8 125 mm

• Hewlett Packard HP-4000 Defect Ruler Inches MM

• Primary Charge Roller 1-1/2 38 mm• Transfer Roller (B) 1-7/8 47 mm• Feed Roller 2 51 mm• Pre-Transfer Roller (B) 2 51 mm• Developer Roller 2 51 mm• Lower Fuser Roller (B) 2-1/2 63 mm• Tray Feed Roller 2-15/16 75 mm• Separation Roller 2-15/16 75 mm• Upper Fuser Roller 2-15/16 75 mm• OPC Drum 3-11/16 94 mm

• Create a toner cartridge print specification designed around you customers key requirements

• Have samples of acceptable and unacceptable prints for your techs to use as baseline

• Always retain a gold standard cartridge available for comparison testing between printers

• Have samples of OEM prints to refresh engine designed performance.

• Clean well lit table space for observing prints• Eye loupe visual aids (Graticule)• Reflectance Densitometer (Tobias, MacBeth)• Training

Problem & Product - Solution Samples

ù Document solutions to print defects on the Process sheet. ù Make a defect book from all the different defects

that you find, both common and unusual.

Statistical Measurements

• Make a run chart and list different defectsé When you get a defect, mark the chart

• Look for trends in your process• Plan out what you can do to prevent

common defects• Training• Task Rotation• Tools … loupes, light, etc.

Develop Test Plan for YOUR Process

Incoming Inspection:

•Visual

•Sift/retain

•Print Test

Final Inspection

•Print Test

•Build in SPC and Process Control

Toner Basics

• Density• Compound technique and PSD

• Resolution• PSD/Shape (CPT)

• Charge rate

• Background• Classifying cut

• Fusing• High speed / permanent

• Gloss

Imaging Materials Science – Where defects are organic

• Toner Resins• Charging ,Fusing, Processing, Permanence

• Ink Pigments• Black or color, compound-ability, Magnetic properties

• Toner Charge control• Charging rate• Saturation

• Toner Modifiers• Fusing release agents (pe, Polyolefin)• OPC Cleaning

• Coated Media Cost has dropped HUGE since paper manufacturers start to coat at the source

• Character formation• Archivability• UV Stability

Tribo electric : “charging”

• Controlling charge rate is critical for image performance over the life of the cartridge

• Detailed science of combining toner componentry has won attention in polymetric science circles

• The last few years many high tech companies have looked at polymer science for imaging consumables as a viable business

• Many resin companies have found the lucrative toner resin market

Development Physics

• Link toner net charge with particle size distribution• Smaller particles have a higher charge rate• Higher charge particles accumulate on developer

components

• Physics are simple charge rate vs residence time

• Toner particles are subject to incredible force .. Bring in the ME• Strain, Temperature, elastic yield

• Environmental stability

Consumption per Thousand pages

Pages printed

oner OEM

OPC1/T1

OPC2/T2

OPC1/T2

OPC2/T1

Toner Consumption HP 4250

Charge Distribution

• Perfect toner distributions …• The compounding process is perfectly

homogenous • All particles exactly the same diameter and

• Current polyester resins allow for excellent compounding … Mostly for fusing in hi speed printers, runs a little cleaner

Toner Development

Q/M for Canon Engines

-50.00

-45.00

-40.00

-35.00

-30.00

-25.00

-20.00

-15.00

-10.00

0.0020s 2m 20m 2hr

Charge time

HP8100

HP4000

Fused Image Formation

Process Velocity and Fusing

0 20 40 60 80 100 120 140

Process mm/s

Cold Offset Region

Hot Offset Region

FusingRegion

Glossy

Safety Requirements

• Ames Testing• Low Odor• Particle size ( Less than 5 um)

• Inhalant hazard (volume in air space)• Long term effects• OEM 4000 is ~17% “fines”

• EUROPEAN Concerns --- law suit has

found in favor of plaintiff “toner in an officeenvironment

Commitment to laser printing

• Major OPC chemistry advancements by Hitachi, Mitsubishi, Kodak, Xerox

• Strong polymeric science advancement from resin manufacturers for imaging • Improved fusing• Consistent controlled compounding of

formulations• Consistent Grinding and Classification• LOWER COST

Demands on Toner

• PSD - Particles now have controlled shape and size distribution CPT & MMT

• Materials design will help with charge rate and compounding, classification,fusing

• Small changes in materials & PSD will enhance image performance at current digital density

Remanufacturing Success Metrics ------------------ CPT• Image Performance

• Halftone reproduction• Line art

• Yield• Solid fill uniformity• Printer maintenance reduced

• Fuser performance• cleanliness

• Standards and industry uniformity

CPT …………………….. Mono & Color

• Timing• Color thinkers produce documents that demand color printing• Ink Jet will defeat some barriers but will lose because of ppm,

in business imaging for NOW … watch HP IJ new system

• CPT dominates color market

A soft wax core in each particle melts as the toner is fused to the paper, ensuring fast, even fusing. Improved, patented pigments are another key ingredient in HP toner.

CPT Comparison

Unique chargeability

Yield is wonderful in a balanced system

Image performance is more controllable

CPT Pixel Magic

ë Dots within a cellâ Dithering - is the art of placing single pixels of Mono or CMY adjacent to

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

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

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

Standards and Current Work …. ASTM

• Business Imaging F-05 (04 EP) (07 IJ)• Committee of industry representatives• Approx. 20 active members

• Charter• Outline imaging standards for consumer• Develop methods, accept proposals from within industry

• Timeliness• Year 1989 was start of process for 1531 … finished in 1994• Year 1991 was start of 1856 …. Completed 1998

• Process• Industry dependent “What’s at stake”• Marketing Quality …………. ISO ??

Standard Practice for Determining Toner Usage in Printer Cartridges F-1856-98

• Evaluation of OEM and RM’d Cartridges• METHOD of extrapolating actual consumption

• Mass Balance• Toner movement from hopper• Toner transfer to the OPC• Toner transfer to the media

• Metrics• Eff %• PPM• GPP• G/1000

Standard Practice for Determining Toner Usage in Printer Cartridges F-1856-98

• Coverage estimates and printer development variation• Method Variance

• Test Masters (5%)• RH% and Temperature• Relative comparison for your customer & for internal development

Standard Practice for Comparing Printer or Copier Cartridges Cartridges F-1531-94

• Summary• Packaging & Marking• Leakage• Component Condition• Copy/Print Quality• Yield• Noise & Odor• Operational conditions• Mass Balance

Standard Practice for Comparing Printer or Copier Cartridges Cartridges F-1531-94

• Baseline method for reference total performance of remanufactured product.

• Reliability is determined through a designed trial using OEM or other reference metric

• Reporting format • Operational• Mass Balance• Leakage• Visual• Packaging & Marking

ISO 13660

• ISO-13660 - international standard for print quality evaluation• The standard defines fourteen PQ attributes and specifies techniques

for measuring them• Provides a framework for communication industry-wide• ISO-13660 requires that measurement instruments be calibrated to

physical units. This is critical for ensuring reproducible results.

ISO 13660

• Baseline method for reference total performance of remanufactured product.• ISO 19751 “Appearance based image quality standards for printers” includes

standardizing color reproduction quality (scheduled for review 2005)

Imaging Artifact/Comparison Artifact

Halftone Dot/Dot shapeHalftone Dot/Dot gainHalftone Dot/Dot locationHalftone Dot/Dot surround/satellitesHalftone Dot/Dot edgeLine/Line densityLine/Edge sharpnessLine/Resolution/line modulationLine/Line widthLine/Edge raggednessSolid Fill Area/DensitySolid Fill Area/ColorSolid Fill Area/Halftone noiseSolid Fill Area/Gloss

Moving Forward

• Standards laboratory• Cartridge certification

Small/Medium/Large Testing Plan

• NPI development• Vendor data and print results (cartridge

• Gold Cartridge – Silver test• Initial Life Tests• Graphics data / Text • Digital imaging data (Photoshop)• Test Targets• SPC / Control parametrics• Link to engine and Cartridge

componetry• DataBase

• Production• Sampling Life• EOL testing …. NPI (AQL to zero)

(Audit)• SPC on key variables • Realtime ---- Shift

REAL world

• Driving out cost

•Component Change

•Process Change

•Multi-function toners

•Filling systems

•Temp / Rh

•Storage

•Humidity limits testing

Bibliography

• http://www.zeon.co.jp/business_e/enterprise/toner/toner5.html• http://www.qea.com/pdf/Paper_1999%20ISJ-JH%20Applications%20of%20ISO-13660.pdf

Applications of ISO-13660, A New InternationalStandard for Objective Print Quality Evaluation• ISO and Standards – http://www.iso.ch/iso/en/CatalogueDetailPage.CatalogueDetail?CSNUMBER=22145• http://www.iso.org/iso/en/CatalogueDetailPage.CatalogueDetail?CSNUMBER=22145&ICS1=37&ICS2=100&ICS

3=10• Halftone and color science – http://www.adobe.com/support/techguides/color/colortheory/variables.html• http://imagine.gsfc.nasa.gov/docs/science/know_l1/emspectrum.html• http://gretagmacbeth.com/Source/Gm.asp?part=Products&page=ProductsDisplay&id=6878&code=c&typ=prod

uct• http://www.loglight.com/• Avedon, Don M. and Courtot, Marilyn E., Glossary of Imaging Technology. AIIM TR2-1992. Silver Spring, MD:

Association for Information and Image Management; 1992.• A comprehensive glossary of technical terms; Electro-Optics Handbook, Waynant, R.W. and Ediger, M.N.,

Editors, Optical and Electro-Optical Engineering Series, McGraw-Hill, 1994• Fortner, Brand and Meyer, Theodore E., Number by Colors, Springer-Verlag, 199• Halliday & Resnick, Fundamentals of Physics, 3E, Wiley 1988• Halliday, Resnick, Walker, Fundamentals of Physics Extended, 5th Ed, Wiley 1997• Hecht, Eugene, Optics, Schaum’s Outline Series, McGraw-Hill, 1975• Light and Color, General Electric Company Publication TP-119• Minnaert, M. G. J., Light and Color in the Outdoors, Springer-Verlag, 1993• Waldman, Gary, Introduction to Light, The Physics of Light, Vision and Color, Prentice-Hall, 1983• Williamson, S J and Cummins, H Z, Light and Color in Nature and Art, Wiley 1983• Young, Hugh, University Physics, 8th Edition, Addison-Wesley, 1992. • http://www.wide-format-printers.org/autodownloads_FLAAR_reports/QEA_analisys.pdf

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