Use of certain packaging materials for electrophotographic development materials and a packaging method

Abstract: A packaging material for electrophotographic development materials is disclosed. The packaging material comprising a film having a moisture permeability of 0.7 g/m 2 /day, or a packaging material for electrophotographic development materials in which inner-most layer is an adhesive layer, the top layer is a polyester layer, and between them, there are at least an aluminum layer and a polyamide layer. The packaging material exhibits high moisture-resistance and film strength, and can cope with environmental issues.

Description: DETAILED DESCRIPTION OF THE INVENTION The present invention relates to the use of packaging materials to package materials such as electrophotographic toner, developer material, etc., and a packaging method, FIELD OF THE INVENTION When packaging an electrophotographic toner and developer material, resins such as Saran film, comprising halogen, have widely been employed. However, such resins have not exhibited sufficient properties for moisture resistance and film strength required for a packaging material for developer material having a substantial weight. Further, problems may occur in coping with the major environmental issue of much concern recently. Accordingly, it is assumed that a packaging material which contains no halogens and which exhibits improved moisture resistance, as well as film strength, is increasingly demanded while meeting requirements for high productivity and low cost. A packaging material such as a container or a packaging film is employed for transportation or storage of the toner or developer for electrophotography. The packaging place or the packaging material are made dirty by scattered toner or other material due to electrification. A certain amount of toner or other material is lost since the scattered toner or other material are abolished. They are also lost in a package since they are not fully supplied to the developing apparatus of the electrophotographic machine because of electrification. EP-A-0 691 198 discloses a bag for packaging a catalyst which comprises a laminate of a PET layer, an aluminium layer and a polyethylene layer as an innermost layer. JP-A-9054454 discloses a packaging material for an electrophotographic polyester toner. The package comprises polyvinylidene chloride, optionally laminated with polypropylene or polyethylene. While the packaging material may comprise aluminium it is stated that aluminium is unsuitable as it is inappropriate for recycling. SUMMARY OF THE INVENTION An object of the present invention is to provide for a packaging material which exhibits high moisture resistance and strength as well as adaptability to environmental issues. The other object is to provide for packaging material which makes it possible to reduce the amount of lost toner or developer and to reduce the environmental contamination by scattered toner when they are supplied to the package or developing apparatus of the electrophotographic machine. A further object is to provide for a packaging material giving reduced change of characteristics such as charging voltage or flocculation of toner or developer during storage or transportation. Further, other properties of packaging materials include flexibility, facilitating bag production, no degradation of the external appearance due to formation of wrinkles, no defects which may cause problems during packaging, conveyance, etc. Obviously, packaging materials should exhibit these properties. The present inventors have diligently investigated and have accomplished the present invention, while finding that in the packaging materials for electrophotographic toner, developer material, etc., in order to maintain an electrostatic charge, the material is required to have a moisture permeability of no more than 0.7 (g/m 2 )/day, and those having a moisture permeability of more than this value do not exhibit sufficient performance as a packaging material, and finding a specific means to result in high moisture resistance as well as strength particularly film strength. The above-mentioned value of moisture permeability is required to maintain, in the initially provided appropriate level, the amount of a specific electrostatic charge. Accordingly, this is a characteristic property for electrophotographic development materials, which are not required of other packaging materials. However, this is an extremely important characteristic for packaging materials for the electrophotographic development materials. However, it has been not clarified yet how important they are, nor has it been known that a packaging material having a moisture permeability of no more than 0.7 (g/m 2 )/day is desirable. Use of a material which securely meets this value, is a nonpollutant to the environment, and sufficiently exhibits other performance characteristics as a packaging material, has not been specifically envisaged. The present invention and the embodiments emanate from the appended claims. The layers of the packaging material are arranged in such a manner that the inner-most layer is an adhesive layer, the uppermost layer is a polyester layer, and between these layers, there are at least an aluminum layer and a polyamide layer. The layers may be also arranged in such a manner that the inner-most layer is an adhesive layer, the uppermost layer is a polyester layer, and between these layers, there are at least an aluminum layer and a polyamide layer, and the moisture permeability is no more than 0.7 g/m 2 /day. The thickness of the aluminum layer is preferably 3 to 20 µm, which is composed of an aluminum foil or evaporated layer.The thickness of the polyester layer is preferably 3 to 40 µm. The thickness of the polyamide layer is preferably 5 to 50 µm. The entire layer thickness is preferably 30 to 200 µm. The inner-most layer is an adhesive layer, and from the uppermost layer, layers are laminated in the order of a polyester layer, an aluminum layer, and an polyamide layer. A bag is prepared employing a packaging material so that the inside has an adhesive layer and the opening of the bag is thermally press-sealed. The electrophotographic development material may be packaged by such steps that a bag is prepared by employing a continuous film-shaped packaging material described above, electrophotographic development material is placed into the bag, the opening is thermally press-sealed, and bags are successively cut and separated. BRIEF DESCRIPTION ON DRAWING Fig. 1 is a view of a puncture resistance measurement method. DETAILED DESCRIPTION OF THE INVENTION The moisture permeability as described in the present invention is a value measured by the Cup method and specifically, a value measured by a method specified in JIS Z 0208 (1976). The packaging material preferably has a moisture permeability of not more than 0.5, more preferably not more than 0.3 (g/m 2 )/day. The electrification quantity of the developer is variable. The charge of the developer increases by frictional electrification with the surface of the packaging material, or decreases extremely by resistance of the surface of the packaging material contacting with the developer. Further, when the surface of the packaging material in contact with the developer is charged, it sometimes causes toner scattering. The surface in contact with the developer is preferably set at a surface resistivity of not more than 10 12 Ω·cm, more preferably not more than 10 11 Ω·cm, particularly from 10 8 to 5 x 10 10 Ω·cm. The structure of the packaging material is as described above. The function of each incorporated layer is briefly described below. In order to obtain a film-shaped packaging material having a low moisture permeability, it is preferable to employ metallic foil such as aluminum foil, preventing potential growth of pinholes. In case that the aluminum layer or other metal layer is excessively thick, its stiffness is excessive, which may result in the generation of wrinkles when preparing bags, and may cause frequent transporting problems due to degraded transporting properties of the film. As described above, disadvantages also result in cost as well as weight. The optimal thickness of the aluminum layer is between 3 and 20 µm. The aluminum layer or other metal layer is formed by laminating aluminum foil or by aluminum evaporation. The tensile strength of the polyamide layer is from 4 to 20 kg/mm 2 , preferably from 6.3 to 12.7 kg/mm 2 according to the test by ASTM D882-61T. A suitable component in the polyamide layer is a polymer having an amide bond within the primary chain, and preferable examples include nylon, including nylon, nylon 11, nylon 12, nylon 6, nylon 66, nylon 610, nylon 612, nylon MXD, and nylon 6 is particularly preferable. The polyamide is preferably biaxially stretched in view of strength, oxygen permeability and shape preservability. The optimal thickness of the polyamide layer is between 5 and 50 µm, and this is required for securing the enhancement of the layer strength such as tear strength, etc. Furthermore, a polyester layer plays a role in securing heat resistance of the uppermost surface which is brought into direct contact with a heated plate when being thermally sealed as a packaging material. At the same time, the polyester layer plays a role in securing lubricating properties when it is placed in a bag-making apparatus. In view of this, the polyester layer preferably is stable in its characteristics against heat up to more than 100 °C, more preferably more than 120 °C. It is preferable to have heat resistance up to 250 °C or preferably up to 200 °C for the purpose of convenience of production process. The optimal thickness of the polyester layer is between 3 and 40 µm. Tensile strength of polyester layer is from 10 to 30 kg/mm 2 , preferably from 14 to 25 kg/mm 2 according to the test by ASTM D882-61T. A suitable component in the polyester layer is a polymer having an ester bond within primary chain, and preferable examples include, polyethylene terephthalate, polyethylene naphthalate and polybutylene terephthalate in view of high heat resistance and easy handling. The polyamide layer or polyester layer may comprise a compound other than polyamide or polyester respectively or may be composed of plural polyamide resins or polyester resins as far as not giving adverse effect. Further, other components may be copolymerised with the polyamide or polyester as far as not giving adverse affect. Each layer may be composed of a single layer or plural layers. Further, an adhesive layer employed for thermal sealing, is provided on the inner most surface of the packaging material which contacts with the developing material when packaged. Further, the thickness of the adhesive layer is selected so that the developer can be sealed in adequately. For example, if the average particle size of the developer is D, the thickness is required to be not less than 2/5 x D, preferably not less than 1/2 x D. In the case that the developer includes a carrier, D is that of the carrier. The thickness of the adhesive layer is preferably from 19 to 190 µm. The tensile strength of the adhesive layer is from 0.5 to 25 kg/mm 2 , preferably from 1.1 to 5.0 kg/mm 2 according to the test by ASTM D882-61T. The adhesive layer comprises a polyethylene layer, (particularly low density polyethylene or linear low density polyethylene), ethylene/vinyl acetate copolymer, ionomer (particularly copolymer of ethylene/methacrylic acid crosslinked by metal ion). The polyethylene layer provides excellent sealing strength, foreign matter compatibility, hot-tacking properties, smoothness, as well as being low in cost. The main component of the polyethylene layer is polyethylene, preferably low density polyethylene having a density of not more than 0.93. The polyethylene layer may comprise a compound other than polyethylene or the resin employed in the layer may be copolymerised with a monomer other than ethylene. The adhesive layer may be composed of a single layer or plural layers. A suitable example is a laminate composition of a layer containing a low density polyethylene and a layer containing a linear low density polyethylene. The polyethylene layer may contain other component as far as not giving adverse affect. Accordingly, for the complete layer composition, the uppermost layer is a polyester layer, followed by an aluminum layer, and a polyamide layer, in this order, and as the inner-most layer, a heat sealing polyethylene adhesive layer. The total layer thickness is optimally between 20 and 200 µm. An excessively thick layer is not preferred for a film packaging material because wrinkles form during manufacture of the bags due to excessive stiffness, and the film transporting properties are degraded. In addition, disadvantages result in cost as well as weight. The packaging material can be produced by any method of, for example, a heat extrusion method, a T-die method, an injection molding method or an immersion coating method. The electrophotographic development materials as described herein are those employed for electrophotographic development, being specifically a toner or a developer material. In this case, the developer material, of course, includes a single component developer material or a double component developer material. Materials used as toner particles commonly are binder resins and colorants. As binder resins, styrene-acrylic resins or polyester resins are most commonly employed. Colorants include carbon black, magnetic materials, etc. for monochromatic use and various types of dyes and pigments for color use. Further, various performance-improving agents such as releasing agents, charge-controlling agents, etc. may be incorporated into the toner particles. The particle diameter of these toner particles is preferably between 4 and 20 µm in terms of volume average particle diameter, and is more preferably between 6 and 10 µm. Further, fine silica particles, etc. as an external additive are commonly added to these toner particles. Further, in a double component developer material, magnetic material particles with a volume average particle diameter of from 24 to 120 µm are commonly incorporated as a carrier. Employed as the magnetic material particles are iron powder, ferrite, magnetite, etc., and a coating carrier is preferred in which these particles are covered by a resin. Furthermore, regarding the mixing ratio of the toner to the carrier in the double component developer material, a toner ratio of from 3 to 25 weight percent is usually employed. EXAMPLES The present invention will be detailed with reference to examples. However, the present invention is not limited to these. Example 1 From the top, a 12 µm polyester layer composed of polyethylene terephthalate, a 9 µm aluminum layer, and a 25 µm polyamide layer composed of biaxially stretched nylon 6 were successively provided in this order. As the inner-most layer, a polyethylene adhesive layer composed of low density polyethylene was provided and thus a film-shaped packaging material was prepared. Examples 2 to 5 and Comparative Examples 1 to 3 Each packaging material was prepared in the same manner as Example 1, except that some of the conditions were varied as described in Table 1. Bags were prepared employing the resulting materials and the bags were inspected for the properties as described below: Moisture Permeability Moisture permeability was measured by the Cup method, as described above. Bag Preparing Properties Evaluation was carried out as described below, based on visual appearance. A: no problem noted B: when carefully observed, slight wrinkles were noted C: wrinkles were clearly evident Puncture Resistance A 3 mm rod tapered to 60° point as shown in Fig. 1 was placed on a film sample and the weight necessary to break through the film was expressed in number of grams. A: more than 150 g B: 100 to 150 g C: less than 100 g Charge Amount Holding Ratio After packaging a double component developer material, the resulting package was stored at high temperature and humidity (30 °C and RH 80%) for 20 days. Thereafter, the ratio of the resulting charge amount to the initial charge was determined. AA: 80% or more A: 60% or more but less than 80% B: 40% or more but less than 60% C: less than 40% As can be clearly seen in the results presented in Table 1, all properties of Examples 1 to 5, of the present invention are commercially viable. On the contrary, at least one of the properties of Comparative Examples 1 to 4 is not in the commercially viable range. Accordingly, the Comparative Examples exhibit problems of commercial viability. According to the present invention, it is possible to provide for films useful for packaging an electrophotographic development whereby this packaging material without halogen exhibits high moisture-resistance and film strength, and can cope with environmental issues.

Claims: Use of a film comprising an aluminium layer having a polyethylene layer and a polyamide layer on one side of the aluminium layer and a polyester layer on the other side of the aluminium layer, where the polyethylene layer is the innermost layer and is in contact with the development material, as a packaging material for an electrophotographic development material, the packaging material having a moisture permeability of no more than 0.7 (g/m 2 )/day. A use according to claim 1, wherein the surface resistivity of the packaging material is not more than 10 12 Ω·cm. A use according to any one of claims 1 or 2, wherein the electrophotographic development material comprises a toner whose binder resin is composed of styrene/acryl resin or polyester resin. A use according to any preceding claim, wherein the polyester of the polyester layer is polyethylene naphthalate, polyethylene terephthalate or polybutylene terephthalate. A use according to any preceding claim, wherein the polyamide of the polyamide layer is nylon. A use according to any preceding claim, wherein the metal layer is an aluminium layer and the thicknesses of the metal layer, the polyamide layer and the polyester layer are 3 to 20 µm, 5 to 50 µm and 3 to 40 µm, respectively. A use according to any preceding claim, wherein the surface resistivity of the surface in contact with the development material is not more than 10 12 Ω·cm. A use according to claim 7, wherein the surface resistivity is from 10 8 to 5x10 10 Ω·cm. A use according to any preceding claim, wherein the polyamide layer has a tensile strength of from 4 to 20 kg/mm 2 and the polyester layer has a tensile strength of from 10 to 30 kg/mm 2 . Use of a film according to any preceding claim, which comprises preparing a bag having the adhesive layer inside and the opening of the bag is thermally press-sealed. A method of packaging, which method comprises packaging an electrophotographic development material with a packaging material is a film comprising an aluminium layer having a polyethylene layer and a polyamide layer on one side of the aluminium layer and a polyester layer on the other side of the aluminium layer, where the polyethylene layer is the innermost layer and is in contact with the development material.

Inventors: INOUE SUSUMU, KIJIMA EIICHI, NAKANISHI TATSUO, INOUE, SUSUMU, KIJIMA, EIICHI, NAKANISHI, TATSUO, Inoue, Susumu, c/o Konica Corporation, Kijima, Eiichi, c/o Konica Corporation, Nakanishi, Tatsuo, c/o Konica Corporation
Applicants: KONISHIROKU PHOTO IND, KONICA CORPORATION
Application year: 1999
Main classification: B32B33
IPC codes: B65B51, B32B15, B65D65, G03C3, G03G15, B65D81