Tunable Gloss Electrophotographic Toner via Resin Blending
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Solution Overview
Problem
Current electrophotographic toners lack effective methods to vary the gloss of printed documents, relying on hardware adjustments that impact productivity and fuser roll life, and often result in poor adhesion issues.
Innovation Solution
An apparatus and method utilizing a combination of clear glossy and matte toners, controlled by a print controller and user interface, to achieve a blended toner with adjustable gloss levels from 5 to 90 Gardner Gloss Units, using resin latex and ionic crosslinkers, and optionally including wax, to manage the gloss of printed documents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hardware adjustments (fuser speed and/or fuser roll temperature) are used to control gloss level, then gloss control is achieved, but productivity decreases and fuser roll life is reduced
Solution Approach 1:
The invention changes the chemical composition parameters of the toner by incorporating specific resin combinations (amorphous polyester with glass transition temperature of 40-80°C and crystalline polyester with melting point of 50-90°C) and controlling their weight ratios. This allows gloss level control through material composition rather than hardware parameter adjustments, resolving the contradiction between gloss adaptability and productivity
Solution Approach 2:
The invention uses a composite toner material system combining amorphous polyester resin and crystalline polyester resin in specific proportions. This composite approach enables tunable gloss levels through material formulation while maintaining consistent fusing performance, eliminating the need for hardware adjustments that would impact productivity
2Adaptability or versatility
If fuser roll temperature is increased to achieve glossy finish, then gloss level improves, but fuser roll life decreases
Solution Approach 1:
The invention changes the approach from temperature-based gloss control to composition-based gloss control. By adjusting the ratio of amorphous to crystalline polyester resins and selecting specific resin properties (glass transition temperature and melting point), the desired gloss level is achieved without increasing fuser roll temperature, thereby preserving fuser roll life
Solution Approach 2:
The invention introduces local quality variation through different resin components within the toner formulation. The amorphous resin component provides gloss control capability while the crystalline resin maintains structural integrity, allowing gloss adjustment through material composition rather than thermal stress that would reduce fuser roll life
3Adaptability or versatility
If fuser speed is decreased to achieve matte finish, then gloss level control is achieved, but productivity decreases
Solution Approach 1:
The invention changes the control parameter from fuser speed (temporal parameter) to toner composition (material parameter). By incorporating crystalline polyester with specific melting point characteristics and controlling its ratio to amorphous polyester, the desired matte or glossy finish is achieved without speed reduction, eliminating time loss while maintaining productivity
4Ease of manufacture
If conventional single-toner formulations are used, then manufacturing is simple, but gloss level variation capability is limited
Solution Approach 1:
The invention uses a composite toner formulation combining amorphous polyester resin and crystalline polyester resin in controllable ratios. This composite approach enables gloss level variation capability while maintaining relatively simple manufacturing processes, as the resins can be mixed and processed using conventional toner production methods
Solution Approach 2:
The invention creates a universal toner formulation system where the same base materials (amorphous and crystalline polyesters) can produce multiple gloss levels by simply adjusting the weight ratio between components. This multi-functional approach allows single-toner formulation to serve multiple gloss requirements, enhancing versatility without complicating manufacturing
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
Enables the production of toners with tunable gloss levels, improving productivity and adhesion while maintaining fuser roll life, by blending clear glossy and matte toners to achieve desired gloss levels in electrophotographic printing.
Implementation Method 1
a first developer station including at least one clear glossy toner, a second developer station including at least one clear matte toner and a print controller configured to control the first and second developers to apply an amount of the at least one clear glossy toner and the at least one clear matte toner to a print medium
Implementation Method 2
obtain a blended toner having a gloss level from about 5 ggu to about 90 ggu
Data Source
AI summary
The present disclosure provides toners having a tunable gloss level, electrophotographic apparatuses for using such toners as well as processes for making such toners.