Image Forming Apparatus Powder Alignment Resin Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for achieving metallic and pearl-like appearances in printing, such as using metal foil or luster pigments, often result in wastage of materials or fail to produce desired textures like mirror-like and pearl-like effects.
Innovation Solution
An image forming apparatus and method that involves supplying non-spherical powders to a softened resin layer and rubbing them to align and adhere to the surface, using a flexible pressing member like a sponge, to create mirror-like or pearl-like appearances in specific image portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal foil is transferred only to a toner portion using toner as an adhesive layer, then metallic appearance is achieved in specific image portions, but all the rest foil is wasted
Solution Approach 1:
The patent replaces expensive metal foil with inexpensive non-spherical powder particles that can be applied freely without waste concerns. These powder particles serve the same aesthetic function (metallic/pearl-like appearance) but are disposable in the sense that excess powder can be removed without economic loss, resolving the contradiction between achieving metallic appearance and preventing material wastage
2Ease of manufacture
If luster pigment is incorporated into toner, then metallic image can be formed only in necessary portions, but required metallic appearance and/or pearlescent appearance cannot be obtained in some cases
Solution Approach 1:
The patent changes the physical parameters of the pigment particles from spherical to non-spherical shapes with specific size ranges (0.1-10 μm). This parameter change in particle morphology enables the powder to reflect light in ways that produce authentic metallic and pearl-like appearances, resolving the contradiction between localized application capability and appearance quality
3Manufacturing precision
If paint powders are attached to a toner image, then highly metallic images can be obtained, but mirror-like and/or pearl-like images are difficult to obtain
Solution Approach 1:
The patent uses composite powder particles that combine metallic pigments with resin coatings in specific ratios. This composite structure allows the powder to exhibit both metallic luster and pearl-like iridescence simultaneously, resolving the contradiction between achieving high metallic image quality and producing mirror-like/pearl-like appearances
4Manufacturing precision
If powders are supplied to a softened resin layer and rubbed, then proper alignment and adhesion of powders is achieved, but additional process steps are required
Solution Approach 1:
The patent softens the resin layer before applying the powder, creating a tacky surface that naturally adheres to the powder particles. This preliminary softening action prepares the substrate in advance, ensuring that when powder is applied and rubbed, it automatically aligns and adheres properly without requiring complex additional processing steps
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
Effectively imparts mirror-like or pearl-like appearances to desired image portions, enhancing the texture and appearance of printed images while minimizing material wastage and ensuring proper alignment and adhesion of powders.
Implementation Method 1
in which the resin layer is adjusted to be in a softened state
Implementation Method 2
a rubbing device for rubbing, from a side of the resin layer, the resin image to which the powders have been supplied
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The present invention relates to an image forming apparatus and an image forming method. According to an image forming apparatus and an image forming method of the present invention, an image is formed by arranging powders (200) on a surface of a resin image composed of sheet S and a color toner layer (resin layer) (100) arranged thereon. The image forming apparatus includes: a powder spraying section (98) for supplying powders (200) on the surface of resin layer (100) which is adjusted to be in a softened state; and rubbing roller (74) for rubbing, from a side of resin layer (100), the resin image to which powders (200) have been supplied.