Toner Wax Distribution for Fixability and Storability
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Solution Overview
Problem
Toner formulations face challenges in achieving low-temperature fixability while maintaining heat-resistant storability and preventing image defects, as existing solutions either compromise on mechanical strength or suffer from excessive wax adhesion during high-temperature exposure.
Innovation Solution
A toner composition with controlled wax distribution, where the wax concentration near the surface and in the surface region is optimized using specific infrared spectroscopy measurements to ensure efficient wax exudation and mechanical strength, adhering to the formulas Ps/Pd ≤ 0.90, 2.20 ≤ Ph/Pd, and 0.50 ≤ Pd ≤ 3.00, enhancing both low-temperature fixability and heat-resistant storability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a large amount of wax is located near the outermost toner surface to improve wax exudation property, then low-temperature fixability is improved, but mechanical strength of the outer layer is reduced and the toner may adhere to members when external force is applied
Solution Approach 1:
The patent applies local quality by creating distinct wax concentration zones at different depths from the toner surface. The outermost surface layer (0-0.3μm) has controlled wax concentration to maintain mechanical strength, while the surface region below (0.3-1.0μm) has higher wax concentration to ensure adequate exudation during low-temperature fixing. This spatial differentiation of wax distribution resolves the contradiction between mechanical strength and wax exudation property.
2Ease of operation
If wax is distributed eccentrically near the surface layer to facilitate wax exudation in low-temperature fixing, then low-temperature fixability is improved, but heat-resistant storability deteriorates because the low-melting-point component of the wax near the outermost surface may melt out of the toner
Solution Approach 1:
The patent resolves this contradiction by implementing local quality through depth-dependent wax concentration control. The outermost surface layer maintains lower wax concentration to prevent premature melting during high-temperature storage, while the subsurface region (0.3-1.0μm depth) contains higher wax concentration that will exude during low-temperature fixing processes, ensuring both heat-resistant storability and low-temperature fixability.
Solution Approach 2:
The patent applies preliminary action by pre-positioning wax in specific depth zones during toner manufacturing. The wax is distributed in advance to create a reservoir in the surface region below the outermost layer, which will naturally migrate to the surface during low-temperature fixing without compromising the outermost layer's integrity during high-temperature storage.
3Ease of operation
If excessive wax is located near the surface layer to improve exudation property, then wax exudation is enhanced, but the toner adheres to members when external force is applied leading to image defects
Solution Approach 1:
The patent applies local quality by differentiating wax concentration at different depths: the outermost surface layer (0-0.3μm) maintains controlled, lower wax concentration to prevent adhesion and image defects, while the surface region below (0.3-1.0μm) contains higher wax concentration to ensure efficient exudation during fixing. This spatial differentiation eliminates the harmful adhesion effect while preserving beneficial exudation properties.
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 achieves effective wax exudation during low-temperature fixing processes without causing image defects and maintains superior heat-resistant storability by efficiently managing wax concentration and mobility, ensuring reliable performance under varying temperature conditions.
Implementation Method 1
the wax moves efficiently to near the toner surface during heating
Implementation Method 2
The toners used in printers and copiers are fixed on media by heating and melting
Implementation Method 3
heating the toner at 150° C. for 0.10 seconds and then leaving it to cool to 25° C.
Data Source
AI summary
Provided is a toner having a toner particle containing a binder resin and a wax, wherein the wax concentrations near the outermost surface of the toner and in the surface layer region below the outermost surface are controlled, so that the wax moves with high efficiency to near the outermost surface during heating.