by Peter Knak / IMEX

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BUSINESS-INFORM 2012

What Is Toner?SizeParticle size distribution of 2-16 µ1 µ = 1/1000 mm(Human hair diameter is 60-70 micron in average)　CompositionResin, pigment, magnetite, wax, charge control agent (CCA), silica, etc. → Complex of inorganic and organic compounds

Required characteristicsCharging, fluidity and heat characteristics, preservation stability, dispersibility, etc. → Multiple characteristics of electrical, chemical and physical features are required.

Main Components of Toner

ab

cd

e

a. Binder resin (macromolecule polymer)

　　　　 Fusing, charging characeristicsb. Pigment, magnetic powder

　　　　 Makes the image visible

c. Wax　　　　 Prevent toner built-up on the fuser roller

d. Charge control agent　　　　 Produce, hold and stabilize charging

e. External additives　　　 Provide flowability, charging and cleaning characteristics of OPC

Toner Categories

Two-component formulation

Toner

Magnetic toner

Non-magnetic toner

Magnetic force, friction charge.Because the magnetic powder is black (iron oxide), it is difficult to colorize.Static Friction charge only.Colorization is possible.Pigment is used.

One-component toner

Two-component toner

Toner only

Carrier + Toner

One-component toner

Two-component toner

Toner only standard toner today

HP1010 2420 4250HP P 1005 1505 2015 4515 etc.

RICOH NX720,SP6100

Carrier + toner Niche toners

EPSON LP-S5000,CANON CT502, etc.

HP2600 3500 4700 / CP1215 3525 5225Lexmark / Samsung

Behavior of Magnetic One-Component Formulation

N

N

N S

S

S

OPC drum

Stir the toner with a paddle.

The toner is transferred from the toner hopper to the magnetic roller, because of magnetic force.

Toner moves to the image on the organic photo conductor by magnetic force and static electrical charge.

Magnetic toner

Magnetic roller

Electric field

Behavior of Non-magnetic One-Component Toners

Non-magnetic tonerOPC drum

Stir the toner with a stirring paddle.

Toner is transferred with a sponge roller.

Toner is dispersed with the transfer roller.

Electric field

Toner Production1. Preliminary mixing 2. Compounding

3. Crushing 4.Classifying

ResinPigmentCharge control agentWax

5. Blending

Add additives such as silica or titan oxide on the surface of the toner

1 - 2 mm

Crash chips with each other using air

3 - 10 mToner powder　contains much fine powder

Toner particles

Exclude fine powder

compounded chip

External additives

Toner Requirements

Paper

Transfer roller

Primary charge roller

OPC Drum

(Photo-receptor

)

Fixing device

Waste hopper

Laser beam exposure

Smoothness,damage-free OPC

surface

Photoreceptor filming, collection failure

Transfer characteristics; OPC offset, uniformity of charge

Toner leak from the waste section

Fusing characteristics: Fixing properties, release characteristics to paper

Offset, poor fusing

Development characteristics; Uniform transfer, correct toner quantity and charging

Background, high/low image density, carrier contamination (black spots), component wear

Toner Physical EvaluationPowder characteristics

1. Particle size distribution Significantly affects charging. 2. Fluidity Affects the transfer of toner to the Developer 　　　　　　　　　　　 Roller or the mix of toner with the carrier. 3. Circularity Uniform charging, thin toner layer on components. Influences transfer efficiency.

Electro-magnetic characteristics

1. Charging strength Friction charge with the carrier, charging strength on the developer roller. 2. Magnetic characteristics Transfer-ability of the toner to the developer roller and attraction force to the development sleeve.　　　　　　　　　　Heat characteristics

1. Glass transition temperature A measure of storage stability or fixing property of the toner. 2. Flow Confirms the viscosity of the toner

　　　　　　　

Image EvaluationEnivronmental Test LaboratoryEnivronmental Test Laboratory

10C/20% (Low temperature, low humidity) and 30C/80% (High temperature, high humidity)

Evaluation items

- Page yield, toner consumption - Image density, colour gamut, image quality, - Background - Transfer efficiency - Toner characteristics on the sleeve - Component state change - Fusing property - Developer roller torque - Environmental test

etc.

Aftermarket Toner Design

1. Wide tolerance when designing toner, addressing deterioration of components

　　 - For eliminating problems such as image density drop caused by the detoriated developer roller or Dr. Blade

- Compatibility with different aftermarket OPC drums

→ Sophisticated technology to allow homogeneous particle size distribution

　　

2. Environmentally-friendly toner design

　　 - Conformity with Eco-mark standards

　　 - No use of hazardous chemical substances, Ames test negative

　　　　

3. Low cost design

　　 - Cost reduction by mass production (universalising, globalisation)

　　

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Toner Manufacturing Process

IMEX Spherical Toner

1. Compounding Process

2. Pulverizing Process

3. Classifying Process

4. Circulating Process

5. Blending Process

Circulating ProcessToner particles are exposed into heat flow to get a circular shape.

Before Circulating After Circulating

Circular particle shape

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IMEX IMEX Spherical Toner Application

• Color toner , TMC Series

• New HP monocolor toner, CMG-3

• Brother toner, NSB

• Kyocera-Mita toner, MSK

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Benefits of Spherical TonerDeveloping Process

IMEX Spherical TonerConventional Toner

DVR DVR

DB DB

Thinner and regular toner layer on DVR

Irregular toner layer on DVR

Higher toner charging Lower toner charging

Poor BG, dusting Higher print quality without BG and dusting

OPC OPC

Benefits of Spherical TonerTransfer Process

Conventional Toner IMEX Spherical Toner

Higher Transfer EfficiencyLower Transfer EfficiencyCharacter void

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50

60

70

80

90

100

0.920 0.940 0.960 0.980

Tran

sfer

(%)

Ave. Circularity

Benefits of Spherical TonerTransfer Process

IMEX Spherical Toner

Conventional Toner

Even Print Image

Rough Image

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IMEX TMCIMEX TMC 　Ｓｅｒｉｅｓ　Ｃｏｌｏ　Ｓｅｒｉｅｓ　Ｃｏｌｏｒ　Ｔｏｎｅｒｒ　Ｔｏｎｅｒ

• Spheridized Polyester Toners

• Highly universal because of superiour dispersion

• Stabile performance in a wide range of applications

• Uniform particle size and shape

• Uniform charging, low pile height and good fusing

• Minimal batch to batch variation through stringent QC

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