Toner Cohesion Cluster Segmentation for Flowability and Soiling
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Solution Overview
Problem
In electrophotographic systems with longer lifetimes, maintaining the flowability of toners without changes throughout their lifetime, especially in high-temperature, high-humidity environments, is challenging. This leads to image defects due to toner aggregation and soiling of electroconductive members.
Innovation Solution
A toner with cohesion clusters containing fine silica particles and a binder component on its surface, along with particles of a fatty acid metal salt, is developed. The cohesion clusters have a specific size range and distribution, and the toner is treated under specific ultrasonic wave conditions to maintain flowability and prevent aggregation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the amount of external additive is increased to maintain flowability throughout long lifetime, then flowability is improved, but soiling of electroconductive members becomes significant
Solution Approach 1:
The external additive is segmented into two distinct size categories: fine particles (5 nm to 200 nm) for flowability and coarse particles (2 μm to 10 μm) for preventing soiling. This segmentation allows each size to perform its specific function optimally without the adverse effects of the other.
Solution Approach 2:
Different regions of the external additive population have different properties: fine particles provide flowability while coarse particles prevent soiling. This local quality differentiation resolves the contradiction by having different parts of the system perform different functions.
2Productivity
If printing process is repeatedly performed to achieve long lifetime, then productivity is improved, but external additive embeds in or comes off from toner base material causing image defects
Solution Approach 1:
Coarse external additive particles are applied to the toner surface in advance before the printing process begins. This preliminary action creates a protective layer that prevents embedding and coming-off during repeated printing operations, thereby maintaining image quality throughout the toner's lifetime.
3Adaptability or versatility
If toner is used in high-temperature, high-humidity environment, then adaptability is improved, but toner particles aggregate together causing insufficient flowability
Solution Approach 1:
The external additive composition is changed to include hydrophobic coarse particles that do not absorb moisture. This parameter change in the additive's properties prevents toner aggregation in high-humidity environments, maintaining flowability across different environmental conditions.
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 maintains high image quality throughout its long lifetime by preventing toner aggregation and reducing soiling of electroconductive members, even in high-temperature, high-humidity environments.
Implementation Method 1
a cohesion cluster containing fine silica particles and a binder component is present on surfaces of the toner particles
Implementation Method 2
the toner after being treated under an ultrasonic wave condition
Data Source
AI summary
A toner includes toner particles. A cohesion cluster containing fine silica particles and a binder component is present on surfaces of the toner particles. The toner includes fatty acid metal salt particles. An arithmetic mean value of a Feret diameter of the cohesion cluster is 1,000 to 8,000 nm. A number percentage CI of toner particles having the cohesion cluster is 1 to 15 number %. Number percentages of toner particles having the cohesion cluster in the toner after treatment under ultrasonic wave conditions A and B are represented by Ca and Cb, respectively. CI, Ca, and Cb satisfy formulae (1) and (2): ultrasonic wave condition A: output frequency 30 kHz, output capacity 0.75 W, irradiation time 300 s, ultrasonic wave condition B: output frequency 30 kHz, output capacity 25 W, irradiation time 300 s0.9≤Ca /CI≤1.Formula (1)0.1≤Cb/CI≤0.40.Formula (2)