Chemically Prepared Toners
A Study of Markets and Technologies Edition 4 


	
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1	Overview	8
1.1	Market for Polymerized Full Color Toner	8
1.2	Market for Polymerized Black Toner	9
2	The Anatomy of a Toner	10
2.1	What Toner Parameters Affect Which Part of the Process?	10
2.1.1	Toner Composition	11
2.1.1.1	The Polymer	12
2.1.1.2	The Pigment	15
2.1.1.3	Colored Toner Pigments	16
2.1.1.4	Iron Oxide Pigment / Magnetite	18
2.1.1.5	Internal Charge Control Agent	18
2.1.1.6	Surface Additives	19
2.1.1.7	Other Ingredients	21
3	Why Chemically Prepared Toner?	23
3.1	The Need for Small Mean Particle Size	23
3.1.1	Challenges of Producing Small Particle Size Toner	24
3.1.1.1	Energy Consumption	24
3.2	Toner Manufacturing Methods Compared	27
3.3	What Improvements Can Chemically Prepared Toner Technology Offer?	29
3.4	A little History	31
3.5	Why So Long Before Commercialization?	32
4	Chemically Prepared Toner Basics	34
4.1	The Features of CPT technologies	34
4.1.1	Small Mean Particle Size	35
4.1.2	Toner Particle Shape Control	41
4.1.2.1	Why is particle shape so important?	41
4.1.2.2	Flow Performance of Different Shaped Particles	42
4.1.2.3	Toner Shape Characteristics	44
4.1.2.4	Electrostatic Performance of Different Shaped Particles	45
4.1.2.5	Toner Adhesion	46
4.1.2.6	Toner Particle Shape Control and Measurement	47
4.1.2.7	Particle Shape Control in Chemically Prepared Toner Technologies	50
4.1.2.8	Combination of Affects of Toner Shape	50
4.2	Chemically Prepared Toner Technologies	53
4.2.1	Suspension Polymerization	53
4.2.1.1	Suspension Toner Manfacture	54
4.2.2	Emulsion Polymerization and Aggregation	57
4.2.3	Polyester (Elongation) Polymerization (PxP)	59
4.2.4	Chemical Milling	60
4.2.5	Microencapsulation	62
4.2.6	Dispersion Polymerization	64
4.2.7	Condensation Polymerization	64
4.2.8	Other Alternate Toner Manufacturing Methods	65
4.2.9	Washing/Isolation/Filtration/Drying and Blending	65
4.2.9.1	Filter Press and Vacuum Dry	65
4.2.9.2	Fluidized Bed Drying	67
4.2.10	Cost Estimate Summary	67
4.2.11	Conclusions	68
5	The Chemically Prepared Toner Market	69
5.1	Overview of the Players	69
5.2	Current Commercial Products	70
5.3	The Chemical Toner Market	71
5.3.1	Worldwide toner production volume	72
5.3.1.1	Overall production	72
5.3.1.2	Chemically Prepared Black Toner	75
5.3.1.3	Chemically Prepared Color Toner	76
5.3.2	The Toner Binder Resin Market and the Affects of the Growth in Chemically Prepared Toners	77
5.3.2.1	Overview	77
5.3.2.2	The Resin Manufacturers	77
5.3.2.2.1	Sanyo Chemical Industries	77
5.3.2.2.2	Fujikura Kasei	78
5.3.2.2.3	Mitsui Chemical	78
5.3.2.2.4	Mitsubishi Rayon	78
5.3.2.2.5	Sekisui Chemical	79
5.3.2.2.6	Dainippon Ink and Chemical	79
5.3.2.2.7	Kao	79
5.3.2.2.8	Nippon Carbide Industries	79
5.3.2.2.9	Zeon Corporation	79
5.3.2.2.10	Nippon Ink Chemical	80
6	Review of the Manufacturers and Developers of Chemically Prepared Toners	81
6.1	Canon	81
6.1.1	Canon’s R&D into chemically prepared toner	81
6.1.2	Technology trends in Conventional toner	81
6.1.3	Production locations	82
6.1.4	Canon S Toner Technology	82
6.1.5	Description Of The Process	84
6.1.5.1	Canon Encapsulated Toner Manufacture	85
6.1.5.2	Dispersion Stabilizer Preparation and Aqueous Dispersion Medium	86
6.1.5.3	Costing Data	87
6.1.5.3.1	Magenta Canon S Toner Production Costing Estimate - Year 2004	89
6.1.5.3.2	Black Canon S Toner Production Costing Estimate - Year 2004	92
6.1.5.4	Capital Costs	95
6.1.5.5	Throughput	95
6.1.5.6	Chemically Prepared Toner Applications	95
6.2	Ricoh	98
6.2.1	Technology trends and developments	103
6.2.1.1	Conventional Toner	103
6.2.1.2	Production Locations	103
6.3	Xerox Corporation and Fuji Xerox	104
6.3.1	Xerox/Fuji Xerox Research and Development	104
6.3.2	Overview of the Xerox/Fuji Xerox Technology	105
6.3.2.1	Latex Formation	105
6.3.2.2	Dispersion of Colorant and Internal Additives	105
6.3.2.3	Aggregation	105
6.3.2.4	Coalescence	106
6.3.2.5	Washing, Filtration, Drying and Dry blending additives	106
6.3.3	Capabilities of Xerox/Fuji Xerox EA Technology	106
6.3.3.1	High Print Quality	106
6.3.3.1.1	Particle Size Distribution	106
6.3.3.1.2	Small Mean Particle Size	108
6.3.3.1.3	Toner Particle Shape	108
6.3.3.1.4	Hollow Characters	110
6.3.3.1.5	Particle Surface	110
6.3.3.2	Low Contribution to Total Cost of Ownership	111
6.3.3.3	Low Energy/Oilless Fixing	111
6.3.3.4	Core Shell Structure	112
6.3.3.5	Fuji Xerox Spherical Particle Section Diagram	114
6.3.4	Fuji Xerox Manufacturing Process	115
6.3.4.1	Manufacturing Procedure	117
6.3.4.1.1	Latex Preparation	117
6.3.4.1.2	Preparation of Latex 1	117
6.3.4.1.3	Preparation of Latex 2	118
6.3.4.2	Pigment Dispersion	119
6.3.4.2.1	Black Pigment Dispersion	120
6.3.4.2.2	Cyan Pigment Dispersion	120
6.3.4.2.3	Yellow Pigment Dispersion	120
6.3.4.2.4	Magenta Pigment Dispersion	120
6.3.4.3	Wax Dispersion	121
6.3.4.4	Aggregate Particle Preparation	121
6.3.4.5	Coalescence or Adhered Particle Preparation	122
6.3.4.6	Surface Treatment	122
6.3.4.7	Surface Additive Blending	123
6.3.5	Fuji Xerox Magenta Toner Production Costing Estimate - Year 2004	124
6.3.6	Fuji Xerox Black Toner Production Costing Estimate - Year 2004	130
6.3.7	Product and Performance	136
6.3.8	Fuji Xerox Manufacturing Operations	138
6.3.8.1	Environmentally Friendly Manufacturing and Usage	140
6.3.9	Current Applications of EA Technology	142
6.3.9.1	Fuji Xerox Toner for the DCC500 and DCC400/320	142
6.3.10	Description of the Nippon Carbide Manufacturing Process	144
6.3.10.1	Monomer Mixture Preparation	146
6.3.10.1.1	Aqueous Medium Preparation	146
6.3.10.1.2	Secondary Particle Formation	147
6.3.10.1.3	Associated Particle Formation	147
6.3.11	Fuji Xerox (Nippon Carbide) Non-Magnetic Black Toner Production Costing Estimate - Year 2004	148
6.3.12	Fuji Xerox (Nippon Carbide) Magenta Toner Production Costing Estimate - Year 2004	151
6.3.13	Fuji Xerox (Nippon Carbide) Magnetic Toner Production Costing Estimate - Year 2004	154
6.4	Konica Minolta	157
6.4.1	R&D into chemically prepared toner	157
6.4.2	Printed Results	159
6.4.3	Product Applications	160
6.4.3.1	Konica 7035 and 7165	160
6.4.3.2	Minolta DiAlta Di650	160
6.4.4	Outlook for chemically prepared toner and future business	161
6.4.5	Production locations	161
6.5	Avecia	162
Zeon Corporation	165
Zeon Corporation	166
6.5.1	Production	166
6.5.2	Production Locations	166
6.5.3	Single Layer Manufacturing Technology	166
6.5.3.1	Description Of The Process	166
6.5.3.2	Monomer Mixture Preparation Part A	167
6.5.3.3	Aqueous Medium Preparation Part B	168
6.5.3.4	Aqueous Medium Preparation Part C	169
6.5.3.5	Preparation of Colloidal Magnesium Hydroxide	169
6.5.3.6	Primary Particle Formation	169
6.5.3.7	Secondary Particle Formation	169
6.5.3.8	Polymerization	170
6.5.4	Colored Toner Developments	172
6.5.5	Costing Data	172
6.5.5.1	Capital Costs	172
6.5.5.2	Throughput	172
6.5.5.3	Zeon Corporation Non-Magnetic Black Toner Production Costing Estimate - Year 2004	173
6.5.5.4	Zeon Corporation Magnetic Black Toner Production Costing Estimate - Year 2004	176
6.5.6	Micro-encapsulated Type Toners	179
6.5.6.1	Microencapsulated Toner Properties	180
6.5.6.1.1	Hot offset characteristic	183
6.5.6.1.2	Dependency of fixing ratio on pressure	184
6.5.6.1.3	Carbon Black Dispersion in Toner Particles	185
6.5.6.1.4	Particle Size Distribution	185
6.5.6.1.5	Toner Flowability	186
6.5.6.1.6	Transfer Ratio of Toner	186
6.5.6.1.7	Printed Image Quality	187
6.5.7	Conclusions	188
6.6	DPI Solutions, Inc.	190
6.6.1	Introduction	190
6.6.2	General Description of CM Process	190
6.6.3	Polyester base resin	191
6.6.4	Particle formation by chemical milling	191
6.6.5	Coloring of polyester particles	192
6.6.6	Toner production Process	192
6.6.7	Chemically Milled Toner (CM toner)	193
6.6.8	Color Gamut	193
6.6.9	Particle Surface Texture and Charging Behavior	195
6.6.10	Summary	196
6.7	The Other Companies	197
6.7.1	Kyocera Mita	197
6.7.1.1	Chemically Prepared Toner R&D	197
6.7.2	Kyocera	197
6.7.2.1	R&D Into Chemically Prepared Toner	197
6.7.3	Sharp	198
6.7.4	Toshiba TEC	198
6.7.4.1	R&D Into Chemically Prepared Toner	198
6.7.5	Matsushita	198
6.7.6	Tomoegawa	199
6.7.6.1	R&D Into Chemically Prepared Toner	199
6.7.6.2	Production Locations	199
6.7.7	Mitsubishi Chemical	199
6.7.7.1	Production Locations	200
6.7.8	Dainippon Ink and Chemical	200
6.7.8.1	Production Locations	200
6.7.9	Kao	200
6.7.9.1	R&D Into Chemically Prepared Toner	201
6.7.9.2	Production Locations	201
6.7.10	Toyo Ink	201
6.7.11	Tokyo Printing Ink	201
6.7.11.1	Production Locations	201
6.7.12	FDK (Fuji Denka Kogyo)	202
6.7.12.1	R&D Into Chemically Prepared Toner	202
6.7.12.2	Production Locations	202
6.7.13	Hitachi Metals	202
6.7.13.1	Product R&D Details:	202
6.7.14	Hitachi Chemical	202
6.7.14.1	Production Locations	202
6.7.15	Sakata Inks	202
6.7.15.1	Production Locations	203
6.7.16	Imex	203
6.7.16.1	Production Locations	203
6.7.17	Nippon Shokubai	203
6.7.18	Toshiba Chemical	203
7	Polymerization Technology Primer	204
7.1	Polymers	204
7.2	Definitions	204
7.3	Physical Properties of Polymers	205
7.4	Addition Polymers compared to Condensation Polymers	207
7.5	Condensation Polymerization	207
7.6	Addition Polymerization	207
7.7	The Polymerization Process	207
7.8	Chain polymerization polymers	208
7.9	Chain polymerization polymers	208
7.10	Chemistry Free Radical Polymerization	208
7.10.1	Initiators	209
7.10.2	Molecular weight control	210
7.10.3	Temperature	210
7.10.4	Concentration of Initiator	210
7.10.5	Type of Initiator	211
7.11	Bulk Polymerization	211
7.12	Solution Polymerization	212
7.13	Suspension Polymerization	213
7.14	Emulsion Polymerization	214
7.15	Patents Related to Chemically Prepared Toners 1996 –2004	218





 
 

	

		


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