Bio-based Polyester Resin Synthesis via Abietic Acid Macromers
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Solution Overview
Problem
Current polyester-based toners derived from Bisphenol A pose environmental and health concerns due to its carcinogenic and endocrine-disrupting properties, and the industry seeks sustainable alternatives to reduce carbon footprint and reliance on fossil fuels.
Innovation Solution
A two-step process is developed to synthesize bio-based polyesters using pre-formed macromers from resin acids like abietic acid and bio-based polyols, such as glycerol, which are then polycondensed with diacids to produce binder polymers for emulsion-aggregation toners, offering greater control over polymerization and reducing the need for vacuum distillation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Bisphenol A monomer is used to produce polyester-based toners, then the toners achieve desired performance properties, but environmental and health concerns arise due to carcinogenic and endocrine-disrupting properties
Solution Approach 1:
The patent extracts and removes the harmful Bisphenol A monomer from the polyester synthesis process, replacing it with alternative monomers that do not possess carcinogenic or endocrine-disrupting properties, thereby eliminating the harmful effects while maintaining toner performance
Solution Approach 2:
The patent changes the chemical composition parameters of the polyester by using different monomer types and ratios, specifically avoiding Bisphenol A and using alternative monomers to achieve the desired toner properties without the harmful effects
2Productivity
If conventional polyester synthesis methods are used, then production is achieved, but carbon footprint and reliance on fossil fuels increase
Solution Approach 1:
The patent changes the feedstock source from fossil-based to bio-based monomers, thereby reducing carbon footprint and fossil fuel dependence while maintaining production capability through sustainable renewable resources
Solution Approach 2:
The patent converts the potential harm of using petroleum-derived monomers into benefit by utilizing bio-based alternatives, transforming the production process into one that reduces environmental impact while maintaining productivity
3Manufacturing precision
If pre-formed macromers are used in polycondensation, then control over polymerization is improved and vacuum distillation is reduced, but process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming macromers before the polycondensation step, which allows better control over the final polymerization process and reduces the need for vacuum distillation, despite the additional initial step
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
This method results in bio-based polyester resins with higher C/O ratios and improved molecular weights, providing toners with enhanced properties and a reduced environmental impact, while eliminating the use of Bisphenol A and minimizing reliance on fossil fuels.
Implementation Method 1
synthesized from pre-formed macromers... esterification between a resin acid, such as abietic acid and dehydroabietic acid, and a bio-based polyol such as glycerol
Implementation Method 2
the macromer formed in first step is polycondensed with at least one diacid to form the final polyester product
Implementation Method 3
The aggregated toner particles are heated to enable coalescence/fusing, thereby achieving aggregated, fused toner particles
Data Source
AI summary
An improved polycondensation method for bio-based polyesters synthesized from pre-formed macromers and the corresponding compositions, which are useful for producing binder polymers for imaging applications such as emulsion-aggregation (EA) toner.