Amorphous Polyester Toner Low Temperature Fixability
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Solution Overview
Problem
Current toner manufacturing methods face challenges in achieving low temperature fixability and preservability while reducing energy consumption, as lowering the glass transition temperature of the binder resin can lead to deteriorated preservability and conventional low temperature polymerization of polyester resin does not ensure adequate fixability and preservability.
Innovation Solution
A toner with a binder resin comprising an amorphous polyester-based resin, specifically controlled for aromatic ring concentration, weight average molecular weight, and glass transition temperature, along with a crystalline polyester resin, is synthesized using a method that includes dehydration-condensation and urethane-extension processes at reduced temperatures, incorporating elements like iron, silicon, and sulfur to enhance fixability and preservability, and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the glass transition temperature of the binder resin is lowered to achieve low temperature fixability, then the fixability at low temperature is improved, but the preservability of the toner deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the glass transition temperature within 40-60°C, aromatic ring concentration within 4.0-6.0 mol/kg, and weight average molecular weight within 5,000-50,000. These controlled parameter ranges enable the binder resin to achieve both low temperature fixability and maintained preservability, resolving the contradiction between lowering Tg and preserving toner stability.
Solution Approach 2:
The patent uses composite materials by combining amorphous polyester-based resin with crystalline polyester resin in specific weight ratios (30-70 wt%). This composite structure allows the amorphous phase to provide low temperature fixability while the crystalline phase maintains preservability, effectively resolving the contradiction between fixability and preservability.
2Reliability
If conventional polyester resin polymerization is performed at high temperature to ensure fixability and preservability, then the toner performance is maintained, but the energy consumption in manufacturing increases
Solution Approach 1:
The patent applies parameter changes by conducting polyester resin polymerization at reduced temperatures (50-150°C) compared to conventional high temperature processes. The controlled temperature range, combined with precise control of aromatic ring concentration (4.0-6.0 mol/kg) and molecular weight (5,000-50,000), enables the resin to achieve adequate fixability and preservability while significantly reducing manufacturing energy consumption.
3Reliability
If the aromatic ring concentration of the amorphous polyester-based resin is increased to improve fixability, then the fixability is enhanced, but the glass transition temperature increases which deteriorates low temperature fixability
Solution Approach 1:
The patent applies parameter changes by optimizing the aromatic ring concentration within 4.0-6.0 mol/kg and controlling the glass transition temperature within 40-60°C simultaneously. This balanced parameter control ensures that the resin achieves adequate fixability through sufficient aromatic ring content while maintaining low enough Tg for effective low temperature fixing, resolving the contradiction between these two requirements.
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
The solution achieves excellent low temperature fixability and preservability of the toner while minimizing energy consumption in the manufacturing process, as evidenced by the specific ranges of aromatic ring concentration, molecular weight, and glass transition temperature, and the inclusion of selected elements.
Implementation Method 1
a binder resin comprising an amorphous polyester-based resin... is synthesized using a method that includes dehydration-condensation and urethane-extension processes
Implementation Method 2
dehydration-condensation and urethane-extension processes at reduced temperatures
Data Source
AI summary
A toner for developing an electrostatic charge image includes three or more elements selected from a group including an iron element, a silicon element, a sulfur element and a fluorine element and a binder resin including an amorphous polyester-based resin.