Patent Application
20140369723
This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2013-126099 filed Jun. 14, 2013.
The present invention relates to image-forming apparatuses.
According to an aspect of the invention, there is provided an image-forming apparatus including an image unit that forms an image using at least one of a white toner and a color toner having a lower storage modulus than the white toner and a fixing unit that fixes the image to a medium with heat. A time P calculated by subtracting a fixing time for which an image of the color toner alone is fixed to normal paper used as the medium from a fixing time for which an overlaid image of the white toner and the color toner is fixed to color paper used as the medium is more than 0 ms and less than 30 ms.
Exemplary embodiments of the present invention will be described in detail based on the following figures, wherein:
Exemplary embodiments of the present invention will now be described with reference to the drawings. The structure of an image-forming apparatus will be described first, and then the normal and special operations of the image-forming apparatus will be described. In the following description, the direction indicated by arrow Y in
As shown in
The toner-image forming units 60Y, 60M, 60C, 60K, 60S, and 60W are examples of image units. The intermediate transfer device 80 is an example of a transfer unit. The fixing device 90 is an example of a fixing unit.
Yellow (Y), magenta (M), cyan (C), black (K), special color (S), and white (W) are examples of toner colors. The white (W) toner is an example of a white toner. The yellow (Y), magenta (M), cyan (C), and black (K) toners are examples of color toners.
The special color (S) is a color other than yellow (Y), magenta (M), cyan (C), black (K), and white (W). Examples of special colors (S) include gold (G), silver (S), transparent color (CL), and corporate colors (C/C). Corporate colors (C/C) are colors that are unique to individual users and are more frequently used than other colors.
The toner-image forming units 60Y, 60M, 60C, 60K, 60S, and 60W have substantially the same structure except for the toner used. Therefore, in
The photoreceptor drum 62 is an example of an image carrier. The charging device 64 is an example of a charging unit. The exposure device 66 is an example of a latent-image forming unit. The developing device 68 is an example of a developing unit.
The toner-image forming units 60Y, 60M, 60C, 60K, 60S, and 60W form yellow (Y), magenta (M), cyan (C), black (K), special color (S), and white (W) toner images, respectively, on the outer surfaces of the photoreceptors drum 62Y, 62M, 62C, 62K, 62S, and 62W. As shown in
As shown in
As shown in
As shown in
As shown in
As shown in
As shown in
As shown in
The intermediate transfer belt 82 is an endless belt entrained about the six first transfer rollers 84 and the rollers 88 and thereby set in a predetermined shape. In this exemplary embodiment, as shown in
Of the rollers 88 shown in
As shown in
As shown in
The fixing device 90 includes a fixing belt 90A and a pressing roller 90B. As shown in
The medium transport section 40 includes a medium feed unit 42 that feeds the media P to the image-forming section 20 and a medium output unit 44 that outputs a medium P on which an image is formed.
The medium feed unit 42 feeds the media P one by one to the transfer nip T2 in the image-forming section 20 in accordance with the timing of transfer. The medium output unit 44 outputs a medium P to which a toner image is fixed by the fixing device 90 outside the image-forming apparatus 10.
The medium transport section 40 also includes a retransport unit 48 that feeds a medium P to which a toner image is fixed on the front side thereof to the image-forming section 20 again. The medium transport section 40, including the retransport unit 48 as well as a transport roller 44A and a transport-direction switching unit 46, described later, allows a toner image to be formed on the front or back side of a medium P to which a toner image is fixed on the front side thereof.
To form images on both sides of the medium P, the medium transport section 40 outputs the leading portion of the medium P outside the image-forming apparatus 10. The medium transport section 40 then rotates the transport roller 44A in the reverse direction to draw the medium P back into the image-forming apparatus 10. At the same time, the medium transport section 40 switches the transport-direction switching unit 46, which is disposed between the fixing device 90 and the transport roller 44A, to transport the medium P to the retransport unit 48. Thus, the retransport unit 48 feeds the medium P to the image-forming section 20, with the back side of the medium P facing the outer surface of the intermediate transfer belt 82.
To form an image on one surface (front surface) of the medium P again, after the medium P is output from the fixing device 90, the medium transport section 40 switches the transport-direction switching unit 46 to transport the medium P to the retransport unit 48. The retransport unit 48 then feeds the medium P to the image-forming section 20 again, with the front side of the medium P facing the outer surface of the intermediate transfer belt 82.
The document reader 50 reads image information from a document and transmits the image information to the controller 100.
The controller 100 controls the various sections of the image-forming apparatus 10 based on image information received from the document reader 50 or an external device (not shown) such as a computer.
The controller 100 converts the image information into image signals for four colors (Y, M, C, and K) and transmit the image signals to the exposure devices 66Y, 66M, 66C, and 66K. The controller 100 also generates image signals for the special color (S) and white (W) and transmit the image signals to the exposure devices 66S and 66W.
Next, the normal operation of the image-forming apparatus 10 according to the first exemplary embodiment will be described with reference to
The medium P used in this operation is normal paper (also referred to as PPC paper). Normal paper is an example of the medium P. This operation is hereinafter referred to as “first mode”.
Upon receiving image information, the controller 100 operates the image-forming apparatus 10. The controller 100 converts the image information into image data for yellow (Y), magenta (M), cyan (C), and black (K). The controller 100 then outputs the image data to the exposure devices 66Y, 66M, 66C, and 66K.
The exposure devices 66 emit exposure light L based on the image data. The exposure light L is incident on the outer surfaces of the photoreceptor drums 62 charged by the charging devices 64 to form electrostatic latent images corresponding to the image data on the outer surfaces of the photoreceptor drums 62.
The electrostatic latent images formed on the outer surfaces of the photoreceptor drums 62 are developed by the developing devices 68 to form toner images.
The toner images are transferred from the outer surfaces of the photoreceptor drums 62 to the outer surfaces of the intermediate transfer belt 82 by the first transfer rollers 84 disposed opposite the outer surfaces of the photoreceptor drums 62.
A medium P is fed from any medium container 30 to the medium feed unit 42 and is transported to the transfer nip T2 in accordance with the timing when the portion of the intermediate transfer belt 82 to which the toner image is transferred reaches the transfer nip T2. The toner image is transferred from the outer surface of the intermediate transfer belt 82 to the medium P transported to and passing through the transfer nip T2.
The medium P to which the toner image is transferred is transported to the fixing device 90. In the fixing device 90, the fixing belt 90A and the pressing roller 90B heat and press the toner image to fix the toner image to the medium P.
The medium P to which the toner image is fixed is output from the medium output unit 44 outside the image-forming apparatus 10. Thus, the image-forming operation is completed.
To form images on both sides of the medium P, the image-forming apparatus 10 operates as follows. Specifically, as shown in
The transport roller 44A is then rotated in the reverse direction to draw the medium P back into the image-forming apparatus 10. At the same time, the transport-direction switching unit 46 is switched to transport the medium P to the retransport unit 48. The medium P is fed to the image-forming section 20 again, with the back side of the medium P facing the outer surface of the intermediate transfer belt 82.
Thereafter, a toner image is transferred to the back surface of the medium P in the transfer nip T2 and is fixed by the fixing device 90. Finally, the medium P to which the toner images are fixed on both sides thereof is output from the medium output unit 44 outside the image-forming apparatus 10. Thus, the image-forming operation is completed.
Next, the operation of the image-forming apparatus 10 according to the first exemplary embodiment for the use of the white (W) toner will be described with reference to
The time required to form an image in this operation is set to be longer than that in the normal operation. Specifically, the controller 100 changes the conditions required for the operation of the various units of the image-forming section 20; for example, it reduces the rotational speed of the photoreceptor drums 62. The controller 100 also changes the transport speed of the medium P transported by the medium transport section 40.
The medium P used in this operation is color paper such as black, blue, or red paper, i.e., paper other than white paper, rather than normal paper. Color paper is an example of the medium P. This operation is hereinafter referred to as “second mode”.
Upon receiving image information, the controller 100 operates the image-forming apparatus 10. This image information contains information about the formation of an image on color paper.
The controller 100 converts the image information into image data for yellow (Y), magenta (M), cyan (C), and black (K). The controller 100 also generates image data for white (W) based on the image data for yellow (Y), magenta (M), and cyan (C). The controller 100 outputs the image data to the exposure devices 66Y, 66M, 66C, 66K, and 66W. The image data for white (W) is used to form an underlayer for a color toner image.
The exposure devices 66Y, 66M, 66C, and 66K emit exposure light L based on the image data. The exposure light L is incident on the outer surfaces of the photoreceptor drums 62Y, 62M, 62C, and 62K charged by the charging devices 64Y, 64M, 64C, and 64K to form electrostatic latent images corresponding to the image data on the outer surfaces of the photoreceptor drums 62Y, 62M, 62C, and 62K.
In synchronization with this, the exposure device 66W emits exposure light L based on the image data for white (W). The exposure light L is incident on the outer surface of the photoreceptor drum 62W charged by the charging device 64W to form an electrostatic latent image corresponding to the image data for white (W) on the outer surface of the photoreceptor drum 62W.
The electrostatic latent images formed on the outer surfaces of the photoreceptor drums 62Y, 62M, 62C, and 62K are developed by the developing devices 68Y, 68M, 68C, and 68K to form color toner images. The electrostatic latent image formed on the outer surface of the photoreceptor drum 62W is developed by the developing device 68W to form a white toner layer.
The yellow (Y), magenta (M), cyan (C), and black (K) toner images are transferred from the outer surfaces of the photoreceptor drums 62Y, 62M, 62C, and 62K to the outer surface of the intermediate transfer belt 82 by the first transfer rollers 84 disposed opposite the outer surfaces of the photoreceptor drums 62Y, 62M, 62C, and 62K. The white toner layer is transferred from the outer surface of the photoreceptor drum 62W to the outer surface of the intermediate transfer belt 82 by the first transfer roller 84 disposed opposite the outer surface of the photoreceptor drum 62W.
In this case, the white toner layer is transferred to the outer surface of the intermediate transfer belt 82 such that the white toner layer is overlaid on the color toner images previously transferred thereto.
Color paper is fed from any medium container 30 to the medium feed unit 42 and is transported to the transfer nip T2 in accordance with the timing when the underlayer-based image on the outer surface of the intermediate transfer belt 82 reaches the transfer nip T2. The underlayer-based image is transferred from the outer surface of the intermediate transfer belt 82 to the color paper transported to and passing through the transfer nip T2.
After passing through the transfer nip T2, the color paper is transported to the fixing device 90. In the fixing device 90, the fixing belt 90A and the pressing roller 90B heat and press the underlayer-based image to fix the underlayer-based image to the color paper. In this exemplary embodiment, the temperature of the outer surface of the fixing belt 90A is 160° C. In this case, the temperature at which the underlayer-based image is fixed to the color paper (hereinafter referred to as “fixing temperature”) is 160° C.
The color paper is then output from the medium output unit 44 outside the image-forming apparatus 10. Thus, the image-forming operation is completed.
To form images on both sides of the color paper, after the underlayer-based image is fixed to the front side of the color paper, the color paper is drawn back into the image-forming apparatus 10 and is transported by the retransport unit 48, as in the normal operation of the image-forming apparatus 10. The color paper is then fed to the image-forming section 20 again, with the back side of the color paper facing the outer surface of the intermediate transfer belt 82, and an underlayer-based image is formed on the back side of the color paper.
In this operation, the difference in fixing time for color paper passing through the nip between the fixing belt 90A and the pressing roller 90B in the fixing device 90 satisfies expression 1 below.
0<P(ms)<30 (expression 1)
where P (ms)=P1−P2.
In expression 1, the fixing time P1 is the time set to fix an underlayer-based image to color paper in the second mode, and the fixing time P2 is the time set to fix an image of a color toner alone to normal paper in the first mode. As used herein, the term “fixing time” refers to the value (time) calculated by dividing the fixing nip width (mm) in the transport direction of the medium P by the transport speed (mm/ms) of the medium P.
The fixing nip width may be measured by the following method. Specifically, the image-forming apparatus 10 is used to transfer a solid image to a medium P. While the medium P passes through the fixing device 90, the image-forming operation is suspended for a predetermined period of time (e.g., 10 s). The image-forming operation is then resumed, and the medium P on which the solid image is formed is output from the image-forming apparatus 10. Because the solid image on the medium P has a portion (corresponding to the fixing nip width) with a different gloss, the width of that portion is measured as the fixing nip width.
In the first exemplary embodiment, the storage modulus of a white toner at the fixing temperature is higher than that of a color toner at the fixing temperature. If the storage modulus of the white toner is lower than that of the color toner, part of the white toner is absorbed into the color paper at the fixing temperature at which the color reproducibility after the fixing of the color toner is within the acceptable range. This decreases the hiding power of the white toner on the color paper.
The storage modulus of the white toner is 1.0×104 Pa or less or about 1.0×104 Pa or less. If the storage modulus of the white toner is more than 1.0×104 Pa or more than about 1.0×104 Pa, the white toner is partially not melted at a fixing temperature of 160° C. and thus forms an uneven underlayer with gaps. This decreases the hiding power of the white toner.
The storage modulus G′ of a toner is the real part of the shear complex modulus G* at a measurement temperature of T° C. Specifically, the storage modulus G′ is measured by a viscoelastometer according to the method specified in JIS K 7244-6, entitled “Plastics—Determination of Dynamic Mechanical Properties—Part 6: Shear Vibration—Non-Resonance Method”.
In this operation, as represented by expression 1, the fixing time P1 for which an underlayer-based image is fixed to color paper is longer than the fixing time P2 for which an image of a color toner alone is fixed to normal paper. The difference between the times P1 and P2 (time P) is less than 30 ms.
For P≦0, as illustrated in the conceptual diagram in
In contrast, if expression 1 is satisfied, as illustrated in the conceptual diagram in
For P≧30, as illustrated in the conceptual diagram in
In contrast, if expression 1 is satisfied, as illustrated in the conceptual diagram in
Thus, according to the first exemplary embodiment, the decrease in the color reproducibility of an underlayer-based image on color paper may be reduced compared to the case where expression 1 is not satisfied (see
The fixing energy applied to the medium P depends on the pressure on the medium P, the time for which the medium P is heated, and the temperature of the member that heats the medium P, such as a fixing belt. In the first exemplary embodiment, the fixing energy applied to color paper is adjusted depending on the fixing time without varying the pressure on the color paper or the temperature of the fixing belt 90A in the first and second modes.
If the pressure on the color paper is changed (increased), defects such as mixing of the white toner with the color toner and displacement of the white toner may occur during the passage of the color paper through the fixing nip. In the first exemplary embodiment, few defects such as mixing of the white toner with the color toner and displacement of the white toner may occur because the fixing energy is adjusted depending on the fixing time without varying the pressure on the color paper in the first and second modes.
If the temperature of the fixing belt 90A is changed (increased), the gloss of the underlayer-based image on the color paper varies after the passage of the color paper through the fixing nip. In the first exemplary embodiment, the gloss of the underlayer-based image on the color paper may vary little because the fixing energy is adjusted depending on the fixing time without varying the temperature of the member such as the fixing belt 90A in the first and second modes.
Thus, according to the first exemplary embodiment, the decrease in the color reproducibility of an underlayer-based image on color paper may be reduced compared to the case where an underlayer-based image is fixed to color paper such that the pressure on the color paper or the temperature of the member such as the fixing belt is higher than that in the first mode.
Next, a second exemplary embodiment will be described with reference to
Instead of expression 1, the second exemplary embodiment satisfies expression 2 below.
10<F(ms)<80 (expression 2)
where F (ms)=F1−P2.
In expression 2, the fixing time F1 is the time set to fix an underlayer-based image to a film in the third mode.
In the second exemplary embodiment, as represented by expression 2, the fixing time F1 for which an underlayer-based image is fixed to a film is longer than the fixing time P2 for which an image of a color toner alone is fixed to normal paper. The difference between the times F1 and P2 (time F) is more than 10 ms and less than 80 ms.
For F≦10, as illustrated in the conceptual diagram in
In contrast, if expression 2 is satisfied, as illustrated in the conceptual diagram in
For F≧80, as illustrated in the conceptual diagram in
In contrast, if expression 2 is satisfied, as illustrated in the conceptual diagram in
Thus, according to the second exemplary embodiment, the decrease in the color reproducibility of an underlayer-based image on a film may be reduced compared to the case where expression 2 is not satisfied (see
Next, a third exemplary embodiment will be described, focusing on the differences from the exemplary embodiments described above. The third exemplary embodiment combines the functions of the first and second exemplary embodiments described above. That is, the third exemplary embodiment has the first, second, and third modes. The controller 100 selects one of the three modes based on received medium information to perform an image-forming operation.
Color paper and films, which are used as the medium P in the exemplary embodiments described above, differ in the toner mass per unit area (hereinafter referred to as “TMA (g/m2)”) required for the white toner to provide sufficient color reproducibility. Specifically, the TMA of the white toner in the second mode is set to be higher than that of the white toner in the third mode. This is because color paper has protrusions and recesses in the surface thereof, and the white toner is absorbed into the recesses, which decreases the hiding power on the protrusions. In addition, because films tend to absorb the thermal energy applied thereto, poor fixing due to lack of thermal energy is more likely to occur on films than on color paper. Furthermore, as the underlayer of the white toner becomes thicker, it requires a larger thermal energy. This may result in insufficient fixing of the underlayer of the white toner, which decreases the hiding power and thus decreases the color reproducibility. Thus, the thickness (TMA) of the underlayer on films may be minimized taking into account the properties of films, which are different from those of color paper.
Thus, according to the third exemplary embodiment, an image may be formed while reducing the decrease in color reproducibility depending on the medium P selected compared to the case where the functions of the first and second exemplary embodiments described above are not combined. The other advantages are the same as those of the exemplary embodiments described above.
Next, a modification of the third exemplary embodiment will be described, focusing on the differences from the exemplary embodiments described above. In this modification, the difference P in fixing time for the formation of an image on color paper is smaller than the difference F in fixing time for the formation of an image on a film (see expression 3).
P(ms)<F(ms) (expression 3)
The relationship of expression 3 is based on the following reasons. First, films have higher heat capacities than color paper. Second, the white toner is less easily fixed to films than to color paper because films absorb little white toner. If the white toner is not completely melted, then even if the color toner is completely melted, the color toner may come off the film together with the underlayer of the white toner. Thus, films require a larger thermal energy than color paper.
In contrast, according to the modification of the third exemplary embodiment, in which expression 3 is satisfied, the decrease in the color reproducibility of an underlayer-based image on color paper or film may be reduced compared to the case where expression 3 is not satisfied.
Next, a fourth exemplary embodiment will be described, focusing on the differences from the exemplary embodiments described above. The fourth exemplary embodiment does not have the second mode or the third mode as in the third exemplary embodiment; instead, it has a single mode (fourth mode). Specifically, an image is formed within the overlapping range of P in expression 1 and F in expression 2. The overlapping range (M) of P and F is represented by expression 4 below.
10<M(ms)<30 (expression 4)
The fourth exemplary embodiment has the same advantages as the exemplary embodiments described above.
Next, a fifth exemplary embodiment will be described, focusing on the differences from the exemplary embodiments described above. The fifth exemplary embodiment forms an overlaid image of a white toner and color toners in which the color toners and the white toner are overlaid on a film in the above order. This image is intended to be viewed from the side where no image is formed. The fifth exemplary embodiment satisfies expression 2.
An image-forming apparatus 10A (not shown) according to the fifth exemplary embodiment is a modification of the image-forming apparatus 10. Specifically, the image-forming apparatus 10 is modified as the image-forming apparatus 10A by replacing the toner-image forming unit 60Y with the toner-image forming unit 60W and shifting the toner-image forming units 60Y, 60M, 60C, 60K, and 60S downstream in the transport direction of the intermediate transfer belt 82. With this arrangement, an underlayer of the white toner is initially transferred to the intermediate transfer belt 82. Thus, the image-forming apparatus 10A forms an overlaid image of the white toner and the color toners in which the color toners and the white toner are overlaid on a film in the above order.
The fifth exemplary embodiment has the same advantages as the exemplary embodiments described above.
Although particular exemplary embodiments of the present invention have been described in detail, the present invention is not limited to these exemplary embodiments; various other exemplary embodiments are possible within the scope of the present invention.
If the white toner is frequently used in image-forming operation, the toner-image forming unit 60S may be configured for use with the same white toner as the toner-image forming unit 60W. Alternatively, the toner-image forming units 60S and 60W may be configured for use with white toners having different color-forming properties.
Films are not limited to transparent films made of resins such as polyethylene terephthalate (PET) and polyvinyl chloride, but include color films containing dyes.
Although a white toner layer has been described as an underlayer for a color toner image, the image-forming apparatuses may have a mode in which images such as characters and patterns are formed using a white toner.
Although a black (K) toner image has been described as being formed above a white toner layer formed as an underlayer, a black (K) toner image may be directly formed on color paper or film without forming a white toner layer as an underlayer.
Although the fixing time has been described as being set using the transport speed of the medium P as a parameter, the fixing nip width may instead be adjusted to satisfy expressions 1 and 2.
Although the fixing device 90 has been described as being configured as a fixing device for fixing in contact with the surface of the medium P, it may instead be configured as a non-contact fixing device including, for example, a halogen lamp disposed opposite the medium P without contact. In this case, the width of light emitted from the halogen lamp in the transport direction of the medium P may be adjusted instead of changing the fixing nip width.
The time required for the image-forming operation has been described as being set to be longer in the second and third modes than in the first mode. The image-forming operation, however, may be performed at the same speed as the normal operation until the rear end of the medium P passes through the transfer nip T2, and then the transport speed of the medium P may be reduced so that the fixing time becomes longer.
Although an underlayer-based image has been described as being simultaneously transferred to the medium P by second transfer, color toner images and a white toner layer may be formed on the respective image carriers and may then be sequentially transferred to the medium P.
Although toner images have been described as being formed by toner-image forming units provided for individual colors, color toner images and a white toner layer may be sequentially formed on a single photoreceptor drum and transferred to the intermediate transfer belt 82 and may then be simultaneously transferred to the medium P.
Next, methods for manufacturing the toners used in the exemplary embodiments (including the modification) described above will be described. The binder used for the toners will be described first, and then the toners and developers will be described.
A three-necked flask dried by heating is charged with 266 parts of 1,12-dodecanedicarboxylic acid, 169 parts of 1,10-decanediol, and 0.035 part of tetrabutoxy titanate as a catalyst. After the air pressure in the flask is reduced by a pressure-reducing operation, nitrogen gas is supplied to create an inert atmosphere. The mixture is refluxed at 180° C. with mechanical stirring for 6 hours. Thereafter, the mixture is gradually heated to 220° C. under vacuum distillation and is stirred for 2.5 hours. When the mixture becomes viscous, the acid value thereof is measured. When the acid value reaches 15.0 mg KOH/g, vacuum distillation is stopped, and the reaction product is cooled in air to yield a crystalline polyester resin.
The weight average molecular weight (Mw) of the resulting crystalline polyester resin is measured to be 13,000. The melting temperature of the resulting crystalline polyester resin is 73° C. as measured by differential scanning calorimetry (DSC).
To a stainless steel beaker are added 180 parts of the resulting crystalline polyester resin and 585 parts of deionized water. The beaker is heated to 95° C. in a hot bath. After the crystalline polyester resin melts, the mixture is stirred at 8,000 rpm with a homogenizer (ULTRA-TURRAX T50 available from IKA Works, Inc.) while adding dilute aqueous ammonia to a pH of 7.0. The mixture is dispersed and emulsified while adding dropwise 20 parts of an aqueous solution containing 0.8 part of an anionic surfactant (Neogen R available from Dai-Ichi Kogyo Seiyaku Co., Ltd.) to prepare crystalline polyester resin particle dispersion A (resin particle content=40% by mass) with a volume average particle size of 0.23 μm.
A two-necked flask dried by heating is charged with 74 parts of dimethyl adipate, 192 parts of dimethyl terephthalate, 216 parts of ethylene oxide adduct of bisphenol A, 38 parts of ethylene glycol, and 0.037 part of tetrabutoxy titanate as a catalyst. Nitrogen gas is supplied to the flask to maintain an inert atmosphere. The mixture is heated with stirring to effect a co-condensation polymerization reaction at 160° C. for about 7 hours. Thereafter, the mixture is heated to and maintained at 220° C. for 4 hours while gradually reducing the pressure in the flask to 1.3×103 Pa. After the pressure in the flask is returned to normal pressure, 9 parts of trimellitic anhydride is added. The pressure in the flask is then gradually reduced to 1.3×103 Pa again and is maintained thereat for 1 hour to synthesize an amorphous polyester resin.
The glass transition temperature of the resulting amorphous polyester resin is 60° C. as measured in the same manner as described above, i.e., by DSC. The weight average molecular weight (Mw) of the resulting amorphous polyester resin is 12,000 as measured by GPC. The acid value of the resulting amorphous polyester resin is measured to be 25.0 mg KOH/g.
A mixture of 115 parts of the resulting amorphous polyester resin, 180 parts of deionized water, and 5 parts of an anionic surfactant (Neogen R available from Dai-Ichi Kogyo Seiyaku Co., Ltd.) is prepared and is heated to 120° C. The mixture is sufficiently dispersed with a homogenizer (ULTRA-TURRAX T50 available from IKA Works, Inc.) and is then dispersed with a pressure discharge Gaulin Homogenizer for 1 hour to prepare amorphous polyester resin particle dispersion B (resin particle content=40% by mass).
A mixture of 100 parts of a white pigment (titanium oxide, A220 available from Ishihara Sangyo Kaisha, Ltd., primary particle size=0.16 μm), 15 parts of an anionic surfactant (Neogen R available from Dai-Ichi Kogyo Seiyaku Co., Ltd.), and 400 parts of ion exchange water is prepared. The mixture is dispersed with an Ultimaizer high-pressure impact disperser (HJP30006 available from Sugino Machine Ltd.) for about 3 hours to prepare white colorant dispersion W1. The volume average particle size of the colorant (titanium oxide) in white colorant dispersion W1 is 0.240 μm as measured by a laser diffraction particle size analyzer. The solids content of white colorant dispersion W1 is 23% by mass.
This comparative experiment uses two types of white toners. White toner 1 is used in Examples 1 to 5 and Comparative Examples 1 to 4 in
A round stainless steel flask is charged with 37.5 parts of crystalline polyester resin dispersion A, 292.5 parts of amorphous polyester resin dispersion B, 391.3 parts of white colorant dispersion W1, 90.0 parts of a release agent dispersion, and 484 parts of deionized water. The mixture is sufficiently mixed and dispersed with an ULTRA-TURRAX T50. To the mixture is added 0.37 part of polyaluminum chloride, and dispersion is continued with the ULTRA-TURRAX. The flask is then heated to 52° C. with stirring in a heating oil bath. After the mixture is maintained at 52° C. for 3 hours, 150 parts of amorphous polyester resin dispersion B is gradually added.
Thereafter, the reaction system is adjusted to a pH of 8.5 with 0.5 N aqueous sodium hydroxide solution, and the stainless steel flask is sealed. The mixture is then heated to and maintained at 90° C. under continued stirring with a stirrer for 3.5 hours. After the reaction is completed, the reaction product is cooled, filtered, and sufficiently washed with ion exchange water. The solids are separated from the liquid by Nutsche suction filtration. The solids are then dispersed again in 3 L of ion exchange water at 40° C. and are stirred and washed at 300 rpm for 15 minutes.
This operation is repeated another five times. When the filtrate has a pH of 6.88, an electrical conductivity of 8.4 μS/cm, and a surface tension of 7.02 Nm, the solids are separated from the liquid by Nutsche suction filtration through No. 5A filter paper and are dried in vacuo for 12 hours to yield toner particles. The glass transition temperature of the resulting white toner particles is measured to be 55.0° C. The volume average particle size D50v of the resulting white toner particles is measured to be 6.5 μm.
To 100 parts of the resulting white toner particles is added 1 part of hydrophobic silica particles (RY-50 available from Nippon Aerosil Co., Ltd.). The mixture is mixed in a Henschel mixer to yield white toner 1. The storage modulus of white toner 1 is measured to be 1.0×103 Pa (see
A round stainless steel flask is charged with 330.0 parts of amorphous polyester resin dispersion B, 391.3 parts of white colorant dispersion W1, 90.0 parts of a release agent dispersion, and 484 parts of deionized water. The mixture is sufficiently mixed and dispersed with an ULTRA-TURRAX T50. To the mixture is added 0.37 part of polyaluminum chloride, and dispersion is continued with the ULTRA-TURRAX. The flask is then heated to 52° C. with stirring in a heating oil bath. After the mixture is maintained at 52° C. for 3 hours, 150 parts of amorphous polyester resin dispersion B is gradually added.
Thereafter, the reaction system is adjusted to a pH of 8.5 with 0.5 N aqueous sodium hydroxide solution, and the stainless steel flask is sealed. The mixture is heated to and maintained at 90° C. under continued stirring with a stirrer for 3.5 hours. After the reaction is completed, the reaction product is cooled, filtered, and sufficiently washed with ion exchange water. The solids are separated from the liquid by Nutsche suction filtration. The solids are then dispersed again in 3 L of ion exchange water at 40° C. and are stirred and washed at 300 rpm for 15 minutes.
This operation is repeated another five times. When the filtrate has a pH of 6.88, an electrical conductivity of 8.4 μS/cm, and a surface tension of 7.02 Nm, the solids are separated from the liquid by Nutsche suction filtration through No. 5A filter paper and are dried in vacuo for 12 hours to yield toner particles. The glass transition temperature of the resulting white toner particles is measured to be 58.0° C. The volume average particle size D50v of the resulting white toner particles is measured to be 6.5 μm.
To 100 parts of the resulting white toner particles is added 1 part of hydrophobic silica particles (RY-50 available from Nippon Aerosil Co., Ltd.). The mixture is mixed in a Henschel mixer to yield white toner 2. The storage modulus of white toner 2 is measured to be 1.0×104.2 Pa (see
Color toners are manufactured from crystalline polyester resin dispersion A and amorphous polyester resin particle dispersion B (resin particle content=40% by mass) in the same manner as the white toners described above.
Specifically, a round stainless steel flask is charged with 37.5 parts of crystalline polyester resin dispersion A, 292.5 parts of amorphous polyester resin dispersion B, 391.3 parts of a color colorant dispersion, 90.0 parts of a release agent dispersion, and 484 parts of deionized water. The mixture is sufficiently mixed and dispersed with an ULTRA-TURRAX T50. To the mixture is added 0.32 part of polyaluminum chloride, and dispersion is continued with the ULTRA-TURRAX. The flask is then heated to 52° C. with stirring in a heating oil bath. After the mixture is maintained at 52° C. for 3 hours, 150 parts of amorphous polyester resin dispersion B is gradually added.
Thereafter, the reaction system is adjusted to a pH of 8.5 with 0.5 N aqueous sodium hydroxide solution, and the stainless steel flask is sealed. The mixture is heated to and maintained at 90° C. under continued stirring with a stirrer for 3.5 hours. After the reaction is completed, the reaction product is cooled, filtered, and sufficiently washed with ion exchange water. The solids are separated from the liquid by Nutsche suction filtration. The solids are then dispersed again in 3 L of ion exchange water at 40° C. and are stirred and washed at 300 rpm for 15 minutes.
This operation is repeated another five times. When the filtrate has a pH of 6.88, an electrical conductivity of 8.4 μS/cm, and a surface tension of 7.02 Nm, the solids are separated from the liquid by Nutsche suction filtration through No. 5A filter paper and are dried in vacuo for 12 hours to yield toner particles.
The glass transition temperature of the resulting color toner particles is measured to be 54.0° C. The volume average particle size D50v of the resulting color toner particles is measured to be 6.5 μm.
A mixture of 99 parts of carbon black (Regal 330 (available from Cabot Corporation)), 15 parts of an anionic surfactant (Neogen R available from Dai-Ichi Kogyo Seiyaku Co., Ltd.), and 300 parts of ion exchange water is prepared and is dispersed with a homogenizer (ULTRA-TURRAX T50 available from IKA Works, Inc.) for 10 minutes. The mixture is then processed in a circulating ultrasonic disperser (RUS 600TCVP available from Nihonseiki Kaisha Ltd.) to yield black colorant dispersion B1.
The volume average particle size of the colorant (carbon black) in black colorant dispersion B1 is 0.25 μm as measured by a laser diffraction particle size analyzer. The solids content of black colorant dispersion B1 is 23% by mass.
A black toner is manufactured in the same manner as white toner 1 except that crystalline polyester resin dispersion A and amorphous polyester resin dispersion B are initially added in amounts of 75.0 parts and 435.0 parts, respectively, and black colorant dispersion B1 is added in an amount of 78.3 parts instead of white colorant dispersion W1.
To 1.25 parts of toluene is added 0.12 part of carbon black (available under the trade name VXC 72 from Cabot Corporation), and it is stirred and dispersed in a sand mill for 20 minutes to prepare a carbon dispersion. To the carbon dispersion, 1.20 parts of an 80% ethyl acetate solution of a trifunctional isocyanate (Takenate D110N available from Takeda Pharmaceutical Company Limited) is added with stirring to prepare a coating resin solution. A kneader is charged with the coating resin solution and Mn—Mg—Sr ferrite particles (volume average particle size=35 μm). The mixture is stirred at room temperature for 5 minutes and is then heated to 150° C. under normal pressure to remove the solvent. After the mixture is stirred for another 30 minutes, the heater is powered off, and the mixture is allowed to cool to 50° C. with stirring. The resulting coated carrier is passed through a 75 μm mesh to obtain a carrier.
A developer of each color is prepared by mixing 95 parts of the carrier and 8 parts of the resulting toner in a V-blender.
Next, a fixing test and an image quality test are performed under the fixing conditions shown in the table in
Samples for the fixing test and the image quality test are prepared using a modified DocuCentre-IV C5575 (available from Fuji Xerox Co., Ltd.) and a modified Color 1000 Press (available from Fuji Xerox Co., Ltd.).
In these modified printers, the developing device for black (K) is charged with the white (W) developer, and the developing device for cyan (C) is charged with the magenta (M) developer. When an image is produced on a film, the developing device for black (K) is charged with the magenta (M) developer, and the developing device for cyan (C) is charged with the white (W) developer.
The fixing devices in these modified printers are adapted so that the temperature, the fixing nip width, the pressure, and the speed are variable. These modified printers are used to prepare the following samples.
Samples of images of color toners directly formed on white paper, color paper (black paper), and films are prepared by forming a blue solid image with a TMA of 8 g/m2. The TMA of the magenta (M) toner in the blue solid image is 4 g/m2, and the TMA of the cyan (C) toner in the blue solid image is 4 g/m2.
Samples of images of white and color toners formed on color paper (black paper) and films are prepared by forming a white (W) toner layer with a TMA of 6 g/m2 and then forming a blue solid image with a TMA of 8 g/m2 on the white (W) toner layer. The TMA of the magenta (M) toner in the blue solid image is 4 g/m2, and the TMA of the cyan (C) toner in the blue solid image is 4 g/m2.
The fixing test is performed on the four types of samples prepared using the modified printers described above as follows.
The color paper is tested by a crease test. The crease test is performed by rolling a roller with a weight of about 500 g and an outer diameter of 60 mm twice at constant speed over a sample lightly bent in half, lightly rubbing the crease formed in the fixed image with cloth, and measuring the width of the missing portion of the image. A sample having a missing portion with a width of less than 0.5 mm is rated as good, and a sample having a missing portion with a width of 0.5 mm or more is rated as poor.
The films are tested by a pencil hardness test. The pencil hardness test is a pencil scratch test according to JIS K5400 in which the samples are evaluated for pencil hardness. A sample with a pencil hardness of H or higher is rated as good. A sample with a pencil hardness of HB or lower is rated as poor.
The results of the fixing test are shown in the table in
Samples different from those used for the fixing test are prepared for the image quality test.
A sample is prepared using color paper (black paper) by forming a white (W) toner layer on color paper and then forming a solid image of the magenta (M) toner on the white (W) toner layer. The solid image is formed in a pattern called a solid patch with a size of 5 cm×5 cm.
Two types of samples are prepared using films. One sample is prepared by forming a white (W) toner layer on a film and then forming a solid image of the magenta (M) toner (5 cm×5 cm solid patch) on the white (W) toner layer (sample A). The other sample is prepared by forming a solid image of the magenta (M) toner (5 cm×5 cm solid patch) on a film and then forming a white (W) toner layer on the solid image (sample B).
The sample of color paper and sample A are tested on the side where an image is formed. Sample B is tested on the side opposite the side where an image is formed.
For color reproducibility, the a* value is measured to determine the color reproducibility of magenta (M) (whether white (W) appears in the surface), and the c* value is measured to determine the hiding power. The measurements are performed using an Xrite, with the black portion of a JIS hiding power chart (available from Motofuji) placed below the films. The results of the image quality test are shown in the table in
The black paper used is TANT N-1 (ream weight: 70 kg, A4, long grain, available from Takeo Co., Ltd.). The white paper used for comparison is TANT N-9 (ream weight: 70 kg, A4, long grain, available from Takeo Co., Ltd.). The films used are OHP films (available from Fuji Xerox Co., Ltd.).
The foregoing description of the exemplary embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-126099 | Jun 2013 | JP | national |
