Abstract: An ink jet printer includes an ink feed apparatus. The ink feed apparatus includes an ink feed channel for conducting discrete substantially solid ink sticks along a feed channel path, a plurality of ink sticks in the ink feed channel, each of the ink sticks comprising an ink stick body having an ink stick sensing feature on an external surface of the ink stick body that is located between a first end and a second end of the ink stick body, and each of the ink stick bodies has substantially the same mass as the other ink stick bodies in the plurality, a detector positioned at a fixed position proximate the ink feed channel and configured to be triggered by an ink stick sensing feature on an ink stick in the ink feed channel as the ink stick moves along the ink feed path past the detector, and a counter configured to accumulate the number of times the detector is triggered.

Abstract: A method of manufacturing an ink stick for use in a phase change ink jet imaging device comprises heating phase change ink material to an extrusion temperature at which the phase change ink material is in a malleable state. The heated ink material is then extruded through an extrusion orifice to form an extruded element. A forging element is then pressed against the extruded element to form an ink stick.

Abstract: A method of manufacturing an ink stick for use in a phase change ink jet imaging device comprises heating phase change ink material to an extrusion temperature at which the phase change ink material is in a malleable state. The ink material is then extruded through an extrusion orifice to form an extruded rail of ink. The extruded rail of ink is then roll formed to partially form a portion of a shape transverse to the extrusion direction as the rail of ink moves in the extrusion direction. A swaging process is then carried out to further form and divide the extruded rail of ink into ink sticks.

Abstract: A system for use with a solid ink delivery system of a phase change ink imaging device comprises an insertion opening configured to enable insertion of ink sticks therethrough and into the ink delivery system. An insertion key is movably supported adjacent the insertion opening such that a portion of the insertion key protrudes into the insertion opening. The portion of the insertion key has a shape that is complementary to a key contour on a first ink stick and a second ink stick. A key positioner is operably coupled to the insertion key to move the insertion key between at least two different predetermined positions on the perimeter of the insertion opening. The predetermined positions include a first position that is complementary to a position of the key contour of the first ink stick and a second position that is complementary to a position of the key contour of the second ink stick.

Abstract: A system is provided for forming solid ink sticks comprising a molten ink delivery station for introducing molten ink material into a forming tub to form a solid ink stick. The forming tub includes an open top for receiving the molten ink material and a cavity defining a lower portion of a solid ink stick shape. The system includes a top surface conditioning station for altering the top surface of the ink material introduced into the cavity of the forming tub.

Abstract: A system for use with a solid ink delivery system of a phase change ink imaging device comprises an insertion opening configured to enable insertion of ink sticks therethrough and into the ink delivery system. An insertion key is movably supported adjacent the insertion opening such that a portion of the insertion key protrudes into the insertion opening. The portion of the insertion key has a shape that is complementary to a key contour on a first ink stick and a second ink stick. A key positioner is operably coupled to the insertion key to move the insertion key between at least two different predetermined positions on the perimeter of the insertion opening. The predetermined positions include a first position that is complementary to a position of the key contour of the first ink stick and a second position that is complementary to a position of the key contour of the second ink stick.

Abstract: An ink jet printer includes an ink feed apparatus. The ink feed apparatus includes an ink feed channel for conducting discrete substantially solid ink sticks along a feed channel path, a plurality of ink sticks in the ink feed channel, each of the ink sticks comprising an ink stick body having an ink stick sensing feature on an external surface of the ink stick body that is located between a first end and a second end of the ink stick body, and each of the ink stick bodies has substantially the same mass as the other ink stick bodies in the plurality, a detector positioned at a fixed position proximate the ink feed channel and configured to be triggered by an ink stick sensing feature on an ink stick in the ink feed channel as the ink stick moves along the ink feed path past the detector, and a counter configured to accumulate the number of times the detector is triggered.

Abstract: An ink jet printer includes an ink supply system and a printhead with nozzles for ejecting ink drops. The printer determines the average size of the ejected ink drops by comparing the number of ink drops ejected in a predetermined time with the quantity of ink delivered through the printers ink supply system during that time. If the determined average ink drop size does not match predetermined ink drop size criteria, the printer adjusts the activation signals for the ink jet nozzles to alter the ink drop size. A solid ink printer determines the quantity of ink delivered through the ink supply system by counting the number of whole or partial ink sticks that pass a predetermined point in the ink supply system. The counter detects a sensing element formed on an external surface of the ink stick. Exemplary detectors include a mechanical arm, or a thermistor to detect a change in the printer melt plate temperature due to a change in the cross sectional area of an ink stick being melted.

Abstract: An ink jet printer includes an ink supply system and a printhead with nozzles for ejecting ink drops. The printer determines the average size of the ejected ink drops by comparing the number of ink drops ejected in a predetermined time with the quantity of ink delivered through the printers ink supply system during that time. If the determined average ink drop size does not match predetermined ink drop size criteria, the printer adjusts the activation signals for the ink jet nozzles to alter the ink drop size. A solid ink printer determines the quantity of ink delivered through the ink supply system by counting the number of whole or partial ink sticks that pass a predetermined point in the ink supply system. The counter detects a sensing element formed on an external surface of the ink stick. Exemplary detectors include a mechanical arm, or a thermistor to detect a change in the printer melt plate temperature due to a change in the cross sectional area of an ink stick being melted.

Abstract: A system is provided for forming solid ink sticks comprising a molten ink delivery station for introducing molten ink material into a forming tub to form a solid ink stick. The forming tub includes an open top for receiving the molten ink material and a cavity defining a lower portion of a solid ink stick shape. The system includes a top surface conditioning station for altering the top surface of the ink material introduced into the cavity of the forming tub.

Abstract: A method of manufacturing an ink stick for use in a phase change ink jet imaging device comprises heating phase change ink material to an extrusion temperature at which the phase change ink material is in a malleable state. The heated ink material is then extruded through an extrusion orifice to form an extruded element. A forging element is then pressed against the extruded element to form an ink stick.

Abstract: A method of manufacturing an ink stick for use in a phase change ink jet imaging device comprises heating phase change ink material to an extrusion temperature at which the phase change ink material is in a malleable state. The ink material is then extruded through an extrusion orifice to form an extruded rail of ink. The extruded rail of ink is then roll formed to partially form a portion of a shape transverse to the extrusion direction as the rail of ink moves in the extrusion direction. A swaging process is then carried out to further form and divide the extruded rail of ink into ink sticks.

Abstract: An ink jet printer includes an ink supply system and a printhead with nozzles for ejecting ink drops. The printer determines the average size of the ejected ink drops by comparing the number of ink drops ejected in a predetermined time with the quantity of ink delivered through the printers ink supply system during that time. If the determined average ink drop size does not match predetermined ink drop size criteria, the printer adjusts the activation signals for the ink jet nozzles to alter the ink drop size. A solid ink printer determines the quantity of ink delivered through the ink supply system by counting the number of whole or partial ink sticks that pass a predetermined point in the ink supply system. The counter detects a sensing element formed on an external surface of the ink stick. Exemplary detectors include a mechanical arm, or a thermistor to detect a change in the printer melt plate temperature due to a change in the cross sectional area of an ink stick being melted.