Curable Toner Composition for High-Gloss Non-Contact Fusing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current toner compositions fused with non-contact fusing systems, such as flash or radiant fusing, typically produce matte prints or require long dwell times, failing to achieve high print gloss efficiently.
Innovation Solution
A process involving emulsion aggregation and coalescence of polymeric resin particles with a photoinitiator and optional wax, optimizing particle size and aggregating agent usage to form toner particles that can be fused with non-contact infrared fusing, achieving high gloss levels in short dwell times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If non-contact fusing systems are used to fuse toner, then fusing speed and productivity are improved, but print gloss deteriorates (producing matte prints)
Solution Approach 1:
The patent modifies the chemical composition parameters of the toner by incorporating specific unsaturated polymeric resins (containing vinyl, vinylidene, or allyl groups) and photoinitiators. This enables the toner to undergo photo-crosslinking under UV irradiation during non-contact fusing, allowing rapid fusing speed while achieving high print gloss through chemical curing rather than relying solely on thermal melting.
Solution Approach 2:
The patent creates a composite toner system combining unsaturated polymeric resin, photoinitiator, and optional wax components. This composite formulation enables dual functionality: thermal response for rapid fusing and photo-reactivity for gloss enhancement, resolving the contradiction between fusing speed and print quality.
2Loss of time
If conventional toner compositions are used with non-contact fusing, then fusing time is reduced, but print quality (gloss) deteriorates
Solution Approach 1:
The patent incorporates photoinitiators and unsaturated polymeric resins into the toner composition in advance. During non-contact fusing, UV irradiation immediately triggers photo-crosslinking, providing instant gloss enhancement without requiring extended dwell times. The chemical components are pre-positioned to activate upon exposure to UV light.
3Manufacturing precision
If contact fusing is used to achieve high print gloss, then print quality is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent replaces the mechanical contact-based fusing system with a non-contact system using UV irradiation. The photo-crosslinking mechanism substitutes for the physical pressure and heat of contact fusing, achieving high print gloss through chemical curing in the air gap without requiring complex contact fuser mechanics.
4Use of energy by moving object
If non-contact fusing is used with conventional toner, then energy efficiency is improved, but print gloss deteriorates
Solution Approach 1:
The patent changes the energy interaction parameters by introducing photo-reactive components that respond to UV irradiation. The toner composition is modified to absorb UV energy and convert it to chemical crosslinking, providing gloss enhancement with minimal additional energy input compared to conventional thermal fusing.
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 process results in toner particles with high gloss levels (20-100 Gardner Gloss Units) and low melting temperatures, enabling high-temperature document offset resistance and solvent resistance, while maintaining short fusing times.
Implementation Method 1
contacting the aggregated particles with at least one unsaturated polymeric resin in combination with a photoinitiator to form a shell over the aggregated particles
Implementation Method 2
a non-contact fuser comprising a source of infrared light operating at a wavelength of from about 750 nm to about 2500 nm
Data Source
AI summary
An emulsion aggregation toner composition includes toner particles including: an unsaturated polymeric resin, such as amorphous resins, crystalline resins, and combinations thereof; an optional colorant; an optional wax; an optional coagulant; and a photoinitiator. By optimizing the particle size of the emulsion, the aggregant concentration utilized in the emulsion aggregation process, and the solids content of the emulsion, toners may be produced capable of generating images with non-contact fusing that have high gloss.