Toner Transfer Printing With Undercoat Layers for Washable Fabrics
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Solution Overview
Problem
Conventional electrophotographic methods struggle to fix images on fabric media, particularly deep-colored fabrics, with adequate washing resistance and chroma, and there is a lack of practical methods for forming images on non-traditional materials like sports team uniforms and bags.
Innovation Solution
An image forming method involving a series of processes: forming a toner image on a transfer medium, applying an undercoat layer, heating and pressing to transfer and fix the image on an image receiving substrate, and separating the fixed image from the transfer medium, using specific toners and temperatures to ensure adequate adhesion and opacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrophotographic toners are used for printing on fabric media, then the printing process can be performed, but the images cannot be fixed to fabric fibers with adequate adhesion and are easily peeled off by washing
Solution Approach 1:
The invention changes the chemical and physical parameters of the toner by using a specific binder resin (polyester resin with particular glass transition temperature and melting point ranges) and adding a fabric fixation promoter (metal salt or organic compound) to enable the toner to adhere firmly to fabric fibers and resist washing
Solution Approach 2:
The invention creates a composite toner system combining process color toners with specific binder resins and fabric fixation promoters, forming a composite material that simultaneously provides coloration, adhesion, and washing resistance on fabric media
2Reliability
If conventional electrophotographic toners are used on deep-colored fabric, then the fabric can be printed, but the deep-colored fabric impairs the image colors due to insufficient opacity
Solution Approach 1:
The invention introduces an undercoat layer as an intermediary between the deep-colored fabric and the process color toner image. This undercoat layer provides opacity to prevent the fabric color from impairing the image colors while allowing the toner to adhere firmly to the undercoat layer
Solution Approach 2:
The invention segments the image formation process into distinct stages: forming an undercoat layer first, then forming the process color toner image on top of it. This segmentation allows each layer to perform its specific function - the undercoat provides opacity and adhesion, while the color toner provides image quality
3Ease of manufacture
If a practical and simple method is sought for forming images on fabric, then the process should be easy to implement, but no practical method has been provided that achieves both firm adhesion and adequate chroma
Solution Approach 1:
The invention uses process color toners that serve multiple functions: they provide coloration, adhesion to the undercoat layer, and washing resistance. This multi-functionality simplifies the overall process while maintaining image quality
Solution Approach 2:
The invention optimizes specific parameters including the glass transition temperature (80-120°C) and melting point (100-150°C) of the binder resin, and uses fabric fixation promoters at controlled concentrations to achieve both firm adhesion and adequate chroma in a practical process
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 method achieves images with adequate washing resistance and chroma on fabric media, including deep-colored fabrics, by using a combination of process color toners and undercoat layer toners, ensuring firm adhesion and preventing color impairment.
Implementation Method 1
an electrostatic latent image is formed on an electrostatic latent image bearer (also referred to as 'photoconductor') containing a photoconductive substance
Implementation Method 2
the toner image is transferred to a transfer material such as paper and then fixed to the transfer material by heating and pressurization
Data Source
Figure 1
AI summary
An image forming method is provided which includes: forming a toner image on a transfer medium with an image forming toner using an electrophotographic image forming apparatus; forming an undercoat layer on the toner image with an undercoat layer forming toner; heating and pressing an image receiving substrate and the undercoat layer together to transfer and fix the image on the transfer medium to the image receiving substrate, at a transfer and fixation temperature PT [°C] satisfying the following relational equation (1); and separating the image transferred and fixed to the image receiving substrate from the transfer medium. UTfb<PT<UT1/2