Transparent Toner Layering for Label Adhesion
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Solution Overview
Problem
In image forming systems using electrophotographic processes, the wax or mold release agent in toner can exude during the fusing process, leading to reduced adhesive force between the surface layer and adhesive layer of label paper, causing the laminated portion to separate from the label paper during cutting.
Innovation Solution
An image forming system that includes a bonding device and an image forming apparatus, where transparent toner without wax or mold release agent is used to cover the color toner, maintaining adhesive force and preventing separation by controlling the supply of transparent toner to specific positions within the toner image area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If toner containing wax or mold release agent is used to ensure separability from the fusing unit, then the toner can be separated from the fixing belt, but the wax or mold release agent exudes during the fusing process and reduces adhesive force between the surface layer and adhesive layer of the label paper
Solution Approach 1:
The patent segments the toner layer into two distinct parts: a color toner layer containing wax/mold release agent for separability, and a transparent toner layer without wax/mold release agent for maintaining adhesive force. This segmentation allows each layer to fulfill its specific function without interfering with the other, resolving the contradiction between separability and adhesive strength.
Solution Approach 2:
The patent applies local quality by creating a transparent toner layer with specific properties (no wax or mold release agent) only in the regions where adhesive force is critical. This localized modification ensures that the transparent toner layer maintains strong adhesion to the adhesive layer while the color toner layer provides the necessary separability from the fusing unit.
2Reliability
If transparent toner is supplied to cover the color toner, then adhesive force is maintained and separation is prevented, but the device complexity increases due to additional toner supply control
Solution Approach 1:
The patent applies partial action by supplying transparent toner only to specific regions where it is most needed to prevent separation, rather than uniformly across the entire image area. This selective application maintains bonding strength in critical areas while minimizing the additional complexity of the toner supply control system.
Solution Approach 2:
The transparent toner layer is formed in advance over the color toner layer before the lamination process. This preliminary action ensures that the adhesive force is maintained from the outset, preventing separation issues during subsequent cutting and lamination operations without requiring complex real-time control mechanisms.
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
Prevents separation of the laminated portion from the label paper by maintaining adhesive force, ensuring the laminated portion remains bonded during cutting and lamination processes.
Implementation Method 1
irradiates (exposes) a photoreceptor drum (image carrier) electrically charged with laser light based on image data to form an electrostatic latent image
Implementation Method 2
the toner image directly or indirectly transferred to paper is heated, pressed, and fused by a fuser nip
Implementation Method 3
the laminated portion L and the label paper P are conveyed to a lamination unit 5, and are heated and pressed
Data Source
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AI summary
Provided is an image forming apparatus (1) and an image forming system (100) by which when a surface member is bonded to a surface of a recording medium, the surface member can be prevented from being separated from the recording medium. The image forming apparatus (1) includes a color toner supply unit (40) configured to supply, to a recording medium, color toner (T1) for forming a toner image on the recording medium, a transparent toner supply unit (40) configured to supply, to the recording medium, transparent toner (T2) having no releasability from the surface member bonded to the surface of the recording medium on which the toner image is formed, and a control unit (101) configured to control the transparent toner supply unit (40) to supply the transparent toner (T2) to cover the color toner (T1) supplied from the color toner supply unit (40) to the recording medium.