Solid Ink Printer Standby Power Management

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Solution Overview

Problem

Solid ink printers face challenges in balancing power consumption and restart time due to the need for maintaining elevated temperatures for ink and transfer surfaces, which is exacerbated by environmental regulations requiring reduced power modes and longer recovery times.

Innovation Solution

The printer method involves turning off the support structure heater and varying the print head's heat settings when entering standby mode, either by tilting the print head away or keeping it adjacent to the intermediate transfer surface, to manage temperature and power usage, allowing for faster restarts while meeting energy efficiency standards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the support structure heater is kept on during standby mode, then the intermediate transfer surface remains at elevated temperature, but power consumption increases

Engineering Contradiction:

Improveintermediate transfer surface temperatureVSAvoidpower consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The heating system is divided into two independent parts: the print head heater and the support structure heater. This segmentation allows independent control of each heater, enabling the support structure heater to be turned off during standby mode while the print head heater remains active to maintain print head temperature. This resolves the contradiction by eliminating unnecessary heating of the support structure during low-activity periods.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different temperature maintenance strategies are applied to different parts of the system. The print head requires consistent temperature for ink ejection and is kept warm during standby, while the support structure can tolerate temperature reduction during standby. This local differentiation of thermal requirements optimizes overall power consumption while maintaining critical functionality.

Inventive Principle:

Principle #3Local quality

2Use of energy by moving object

If the print head is moved away from the intermediate transfer surface during standby, then power consumption is reduced, but the restart time increases

Engineering Contradiction:

Improvepower consumptionVSAvoidrestart time

Core Design Contradiction:

Use of energy by moving objectVSLoss of time

Solution Approach 1:

The support structure is preheated during the printing operation before the printer enters standby mode. This preliminary heating ensures that when the printer resumes operation, the intermediate transfer surface is already at the required temperature, eliminating the need for extended warm-up time after standby. The system performs the heating action in advance while still in active mode.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The print head heater operates continuously during standby mode to maintain print head temperature, ensuring that the critical ink ejection function remains ready. This continuous maintenance of essential components while allowing non-critical components (support structure) to cool creates a balanced approach to power savings and restart readiness.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If the print head heater operates at high temperature continuously, then the ink remains molten and ready for printing, but energy consumption increases

Engineering Contradiction:

Improveink molten state readinessVSAvoidpower consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The print head heater operates in periodic cycles rather than continuously, switching between high-power heating phases and lower-power maintenance phases. During active printing, the heater operates at full power to maintain ink in molten state. During standby periods, it reduces power consumption while maintaining minimum temperature. This periodic operation pattern reduces overall energy consumption while ensuring ink readiness when needed.

Inventive Principle:

Principle #19Periodic action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces power consumption and shortens restart times from standby mode, optimizing power savings and warm-up efficiency while maintaining acceptable print quality and adhering to environmental regulations.

Implementation Method 1

a print head heater that heats the print head

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a support structure heater that heats the support structure

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

Heat settings used to heat a print head are then varied to heat the print head and the support structure

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS7543901B2Faster warm-up, lower energy, and quieter modes for solid ink printers

Publication Date: 2009.06.09 GENESEE VALLEY INNOVATIONS LLC

AI summary

A method of operating a printer turns off a support structure heater when the printer enters standby mode. The print head is then moved away from an intermediate transfer surface supported by a support structure. Heat settings used to heat a print head are then varied to heat the print head and the support structure. Another method of operating a printer turns off a support structure heater when the printer enters standby mode and holds a print head adjacent to an intermediate transfer surface while the printer is in standby mode.