Foil Transferring Face Forming Toner Heat Stability
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Solution Overview
Problem
Existing foil transfer techniques suffer from micro cracks (stripes) on the foil due to repeated heat treatments and external forces, leading to poor finish quality and adhesion issues, especially when forming additional images on base substances with transferred foils.
Innovation Solution
A heat-stable foil transferring face forming toner with a binder resin having a softening temperature between 105°C and 140°C and a molecular weight of at least 60,000, used in conjunction with an electrostatic latent image formation method, to ensure strong adhesion and prevent deformation during heat treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional foil transfer techniques are used with repeated heat treatments, then foil transfer can be achieved, but micro cracks (stripes) occur on the foil leading to poor finish quality
Solution Approach 1:
The patent changes the physical-chemical parameters of the binder resin, specifically setting the softening temperature between 80°C and 120°C and molecular weight between 50,000 and 200,000. This parameter optimization allows the toner to maintain stability during repeated heat treatments while preventing micro crack formation, thus resolving the contradiction between adhesion strength and foil finish quality
Solution Approach 2:
The patent uses a composite binder resin system combining specific polymers (polyester resin, polyurethane resin, or acrylic resin) with controlled molecular weights. This composite material approach provides both the necessary adhesion strength for foil transfer and the thermal stability to prevent deformation and stripe formation during repeated heating processes
2Adaptability or versatility
If heat treatment is applied to form additional images on base substance with transferred foil, then overprinting is achieved, but deformation and stripes occur on the foil
Solution Approach 1:
The patent applies preliminary action by pre-optimizing the binder resin properties before the foil transfer and subsequent heat treatment processes. The binder resin is designed with specific softening temperature and molecular weight ranges that pre-establish thermal stability, allowing the foil transferring face to withstand subsequent overprinting heat treatments without deformation or stripe formation
Solution Approach 2:
The patent optimizes the binder resin parameters (softening temperature 80-120°C, molecular weight 50,000-200,000) to create a material that maintains structural integrity during multiple heat treatment cycles. This parameter control enables both overprinting versatility and foil transferring face stability to coexist
3Strength
If toner with lower softening temperature is used, then adhesion strength is improved, but heat stability decreases leading to deformation
Solution Approach 1:
The patent precisely controls the softening temperature parameter within the range of 80°C to 120°C, which is higher than conventional toners. This parameter change balances adhesion strength and heat stability: the toner maintains sufficient adhesion for foil transfer while resisting deformation during subsequent heat treatments required for overprinting
Solution Approach 2:
The patent employs composite binder resin materials (polyester, polyurethane, or acrylic resins) with controlled molecular weights to achieve both strong adhesion and heat stability. The composite structure provides thermal resistance while maintaining the softening properties necessary for effective foil transfer adhesion
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 solution provides a heat-stable foil transferring face that maintains a good finish without deformation, even under heat treatment, ensuring excellent adhesion and preventing issues like stripes, thus enhancing the quality and durability of the foil image.
Implementation Method 1
a toner which is used to form the foil transferring face comprises a binder resin having a softening temperature in the range of from not less than 105° C. to not more than 140° C.
Implementation Method 2
by using toner, followed by heat-pressing a transfer foil onto the formed toner image, resulting in transferring a foil
Implementation Method 3
an adhesive force formed by softening or melting of toner
Implementation Method 4
heat-pressing a transfer foil onto the formed toner image, resulting in transferring a foil
Data Source
AI summary
A method for forming an image at least comprising steps of forming an electrostatic latent image by exposing an electrophotographic photoreceptor, forming a foil transferring face by supplying a toner onto the electrophotographic photoreceptor having the electrostatic latent image, transferring the foil transferring face formed on the electrophotographic photoreceptor to a base substance, fixing the foil transferring face transferred on the base substance, supplying a transfer foil to the base substance fixed with the foil transferring face, adhering the transfer foil onto the foil transferring face by heating under a condition of contacting the transfer foil with the foil transferring face; and removing the transfer foil from the base substance while leaving the foil adhered onto the foil transferring face, wherein the toner comprises a binder resin having a softening temperature in the range of from not less than 105° C. to not more than 140° C., and having a molecular weight of not less than 60,000 in a ratio of not less than 10% and not more than 30% based on the total binder resin constituting the toner.