Toner Fixation on Embossed Sheets via Adhesion Force
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Solution Overview
Problem
Existing image forming technologies face challenges in achieving reliable fixation of toner on embossed sheets with surface irregularities due to insufficient adhesion force at low temperatures, as heat and pressure transmission is limited to concave portions.
Innovation Solution
A toner formulation incorporating a non-linear amorphous polyester resin and a linear amorphous polyester resin, combined with a fixing device having an elastic layer and a release layer, ensures an adhesion force of 100 gf or more on standard paper at 140°C, enhancing low-temperature fixability and hot offset resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional toner and fixing device are used, then energy consumption is reduced by lowering fixing temperature, but adhesion force between toner and embossed sheet becomes insufficient at concave portions
Solution Approach 1:
The patent changes the physical and chemical parameters of the toner by incorporating a specific binder resin with controlled glass transition temperature (−40°C to 30°C) and storage elastic modulus (1×10^5 to 1×10^7 Pa), enabling the toner to maintain sufficient adhesion force at lower fixing temperatures without compromising bond strength
Solution Approach 2:
The patent creates a composite toner system combining a binder resin with specific viscoelastic properties and crystalline polyester resin, where the binder resin provides low-temperature flexibility and adhesion while the crystalline polyester resin ensures structural integrity and heat resistance during fixing
2Manufacturing precision
If fixing belt applies heat and pressure to embossed sheet, then toner fixation is achieved on convex portions, but heat and pressure cannot effectively transmit to concave portions
Solution Approach 1:
The patent modifies the viscoelastic parameters of the binder resin to enable it to flow and penetrate into concave portions of embossed sheets during fixing, ensuring uniform toner fixation across the entire surface including difficult-to-reach areas
Solution Approach 2:
The patent ensures that the binder resin provides different functional characteristics at different locations: high flexibility and adhesion at concave portions for penetration and bonding, while maintaining structural integrity at convex portions for overall fixation stability
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 reliable fixation of toner on embossed sheets with surface irregularities at low temperatures, maintaining heat-resistant storage stability and hot offset resistance while ensuring sufficient adhesion force, addressing the limitations of existing technologies.
Implementation Method 1
The toner exhibits an adhesion force of 100 gf or more, where the adhesion force is the maximum value of a pull force between a layer of the toner and standard paper determined by a tacking test with a probe temperature of 140° C.
Implementation Method 2
The fixing device includes an elastic layer having an average thickness t1 in the range of 300 to 500 μm
Implementation Method 3
The release layer has an average thickness t2 of 10 μm or less. The fixing device has a nip portion having a surface pressure of 2.0 kg/cm2 or more.
Data Source
AI summary
An image forming method is provided. The method includes the steps of forming an electrostatic latent image on a photoconductor; developing the electrostatic latent image into a toner image with a toner; transferring the toner image onto a recording medium having a smoothness of 20 s or less; and fixing the toner image on the recording medium. The toner exhibits an adhesion force of 100 gf or more, where the adhesion force is the maximum value of a pull force between a layer of the toner and standard paper determined by a tacking test with a probe temperature of 140° C.