Magnetic One-Component Toner for Stable Image Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing magnetic one-component toners face challenges in maintaining high transfer efficiency and image quality due to issues with particle size miniaturization, flowability, compressibility, and uniformity, leading to nonuniform image formation and potential fog.
Innovation Solution
A magnetic one-component toner with a volume average particle size of 6.0 to 9.0 μm, compressibility of 15 to 50%, and mean roundness of 0.950 to 0.960, containing a magnetic powder with 0.10 to 0.50% phosphorus by weight, which enhances transfer efficiency and maintains image density, and is suitable for use with stainless steel or amorphous silicon photosensitive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the particle size of toner is miniaturized to achieve high quality image, then image quality is improved, but toner flowability deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the volume average particle size within 6.0 to 9.0 μm and mean roundness within 0.950 to 0.960. This optimization resolves the contradiction by finding the specific particle size range that maintains both high image quality and adequate flowability, rather than simply minimizing particle size without bounds.
Solution Approach 2:
The patent uses composite materials by combining binding resin with magnetic powder containing phosphorus (0.10 to 0.50% by weight). This composite structure improves toner flowability while maintaining the miniaturized particle size needed for high quality images, thus resolving the flowability deterioration problem.
2Manufacturing precision
If the compressibility of toner is reduced to achieve uniform image, then image uniformity is improved, but toner layer nonuniformity occurs on sleeve
Solution Approach 1:
The patent applies parameter changes by setting compressibility within 15 to 50% and volume average particle size within 6.0 to 9.0 μm. This precise parameter control resolves the contradiction by identifying the optimal compressibility range that ensures both uniform image formation and stable toner layer composition on the sleeve.
Solution Approach 2:
The patent uses composite materials with magnetic powder containing phosphorus (0.10 to 0.50% by weight) combined with binding resin. This composite structure stabilizes toner layer composition on the sleeve while maintaining image uniformity, resolving the contradiction between image uniformity and layer stability.
3Productivity
If the mean roundness of toner is increased to improve transfer efficiency, then transfer efficiency is improved, but toner charge uniformity deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling mean roundness within 0.950 to 0.960 and volume average particle size within 6.0 to 9.0 μm. This optimization resolves the contradiction by finding the specific roundness range that achieves high transfer efficiency while maintaining uniform charge distribution on the toner particles.
Solution Approach 2:
The patent uses composite materials with magnetic powder containing phosphorus (0.10 to 0.50% by weight). This composite structure ensures uniform charge distribution even in highly rounded particles, thus maintaining charge uniformity while achieving high transfer efficiency through the optimized roundness.
4Manufacturing precision
If the volume average particle size of toner is reduced to achieve high quality image, then image quality is improved, but toner density decreases
Solution Approach 1:
The patent applies parameter changes by optimizing volume average particle size within 6.0 to 9.0 μm and compressibility within 15 to 50%. This precise parameter control resolves the contradiction by finding the particle size range that maintains high image quality while preserving sufficient toner density for proper image formation.
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 achieves stable high-quality image formation over a long period with reduced fog and improved transfer efficiency, even with challenging materials like stainless steel or amorphous silicon, by optimizing particle size, compressibility, and roundness, and stabilizing toner charge with phosphorus on the magnetic powder surface.
Implementation Method 1
the surface of a photosensitive material is charged by corona discharge or the like, and then exposed by laser or the like to form an electrostatic latent image
Implementation Method 2
a magnetic one-component toner for use in image forming apparatuses, such as copying machines, printers and facsimiles, employing electrophotography method, electrostatic storage method, or the like
Implementation Method 3
exposed by laser or the like to form an electrostatic latent image
Implementation Method 4
This toner image is then transferred to a storage medium to obtain a high quality image
Data Source
AI summary
A magnetic one-component toner of the invention contains at least a binding resin and a magnetic powder, and has a volume average particle size of 6.0 to 9.0 μm, a compressibility of 15 to 50%, and a mean roundness of 0.950 to 0.960. The magnetic powder has at its surface a phosphorus element of 0.10 to 0.50% by weight. This toner is suitable for use in an image forming apparatus provided with a developer carrier made of stainless steel, or an image forming apparatus provided with an amorphous silicon photosensitive material. This toner has high transfer efficiency and less fog, thereby enabling to maintain image density for a long period of time, and form high image-quality image.