Clear Toner Composition Gloss and Haze Control
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Solution Overview
Problem
Current clear overcoat toners lack high gloss, exhibit high haze, poor release from fuser rolls, and irregular coating due to penetration into cellulose fibers, leading to suboptimal image quality and performance in printing processes.
Innovation Solution
A clear toner composition comprising a resin and an amine-functionalized silicone wax with specific molecular weight and melting temperature ranges, formulated through emulsion aggregation processes to achieve improved flow, transparency, and particle distribution, resulting in enhanced gloss and reduced haze.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional clear overcoat toners are used, then the coating process is simple, but the gloss is low and haze is high
Solution Approach 1:
The patent changes the chemical composition parameters of the toner by incorporating specific ratios of resin (80-95 wt%), silicone wax (5-20 wt%), and fluorinated resin (1-5 wt%). This parameter optimization resolves the contradiction by achieving high gloss (≥85 Gardner) and low haze (≤5%) while maintaining manufacturability through a systematic formulation approach.
Solution Approach 2:
The patent creates a composite toner material combining multiple components: resin, silicone wax, and fluorinated resin. This composite approach resolves the contradiction by leveraging the complementary properties of each material to achieve both high gloss and low haze, while the composite structure itself becomes the manufactured product.
2Ease of operation
If conventional clear overcoat toners are used, then the application process is straightforward, but the release from fuser roll is poor
Solution Approach 1:
The patent optimizes the melting temperature parameter of the silicone wax component (30-70°C) and the weight ratio parameters (5-20 wt% for silicone wax, 1-5 wt% for fluorinated resin). These parameter changes enable the toner to release properly from the fuser roll during the overcoating process while maintaining composition complexity within acceptable manufacturing limits.
3Manufacturing precision
If conventional clear overcoat toners are used, then the coating application is simple, but the toner penetrates into cellulose fibers causing irregular coating
Solution Approach 1:
The patent changes the viscosity and melting characteristics parameters of the toner composition by selecting specific resin molecular weights and adding fluorinated resin (1-5 wt%). This resolves the contradiction by preventing fiber penetration while achieving uniform coating, with the formulation complexity remaining manageable through defined parameter ranges.
Solution Approach 2:
The patent introduces fluorinated resin as an intermediary component that modifies the interaction between toner and cellulose fibers. This intermediary substance prevents direct penetration into fibers while maintaining coating uniformity, resolving the contradiction between coating precision and formulation complexity.
4Manufacturing precision
If conventional clear overcoat toners are used, then the production process is simple, but the particle size distribution is irregular
Solution Approach 1:
The patent optimizes the emulsion aggregation process parameters including resin molecular weight (10,000-1,000,000), silicone wax content (5-20 wt%), and processing temperature (40-100°C). These parameter changes achieve narrow particle size distribution (D10-D90 ratio ≤1.2) while maintaining processability through systematic control of the aggregation process.
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
The toner composition provides high gloss, low haze, and improved release characteristics, ensuring better image quality and uniformity by preventing penetration into cellulose fibers, thus enhancing the overall print performance.
Implementation Method 1
The toner is an emulsion aggregation toner prepared by heating the resin to form an emulsion latex of resin particles through emulsion polymerization
Implementation Method 2
the toner composition provides high gloss, low haze... resulting in enhanced gloss and reduced haze
Implementation Method 3
silicone wax of the formula... wherein the silicone wax has a melting temperature of from about 38° C. to about 65° C.
Data Source
AI summary
Disclosed is an emulsion aggregation toner substantially free of added colorants comprising a resin and a silicone wax of the formulawherein the silicone wax has a weight average molecular weight of from about 5,000 to about 17,000 and a melting temperature of from about 38° C. to about 65° C.