Toner Circularities 0.974-0.985 for Cleanability and Transfer
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Solution Overview
Problem
Existing toner technologies face challenges in achieving both high cleanability and transfer efficiency, with spherical toners leading to cleaning failures due to slipping and reduced contact areas, while highly deformed toners may have poor transfer efficiency due to excessive unevenness.
Innovation Solution
A toner with a specific composition including a binder resin, colorant, inorganic filler, and release agent, featuring an average circularity of 0.974 to 0.985 and surface roughness parameter Sz of 200 to 500 nm, controlled by the arrangement of inorganic fillers to optimize contact areas and friction conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spherical toners are used, then manufacturing is easier and particle shape is simple, but cleanability deteriorates due to slipping through cleaning members
Solution Approach 1:
The patent applies asymmetry by controlling the toner particles to have a specific circularity range (0.974-0.985) rather than perfect sphericity. This controlled asymmetry prevents the particles from slipping through cleaning members while maintaining ease of manufacture, resolving the contradiction between manufacturing simplicity and cleanability.
Solution Approach 2:
The patent changes the geometric parameters of toner particles by specifying precise circularity (0.974-0.985) and surface roughness (Sz: 200-500 nm) values. These parameter changes optimize both cleanability and transfer efficiency while maintaining manufacturability, resolving the technical contradiction.
2Reliability
If highly deformed toners are used, then cleanability improves by preventing slipping, but transfer efficiency deteriorates due to excessive unevenness
Solution Approach 1:
The patent optimizes the balance between cleanability and transfer efficiency by precisely controlling geometric parameters (circularity: 0.974-0.985, surface roughness: Sz 200-500 nm). This parameter optimization ensures sufficient deformation to prevent slipping while maintaining enough regularity for effective transfer, resolving the contradiction.
Solution Approach 2:
The patent applies local quality by creating controlled surface roughness (Sz: 200-500 nm) on the toner particles. This localized surface modification provides sufficient friction to prevent slipping during cleaning while maintaining overall particle regularity for efficient transfer, resolving the contradiction between cleanability and transfer efficiency.
3Manufacturing precision
If smaller toner particle diameter is used, then image quality improves through better dot and line reproduction, but cleanability deteriorates due to increased slipping
Solution Approach 1:
The patent resolves the contradiction between small particle size and cleanability by changing the geometric parameters (circularity: 0.974-0.985, surface roughness: Sz 200-500 nm). These parameter changes ensure that even small particles maintain sufficient friction to prevent slipping during cleaning while achieving high image quality through their small size.
Data Source
AI summary
A toner includes: toner base particles including a binder resin, a colorant, an inorganic filler, and a release agent; and an external additive. An average circularity of the toner is 0.974 or more but 0.985 or less. A surface roughness parameter Sz of a surface of the toner is 200 nm or more but 500 nm or less, the surface roughness parameter Sz being measured with an atomic force microscope (AFM).