Colored Toner via ATRP Polymerization for Uniform Particle Control
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Solution Overview
Problem
Conventional methods for preparing colored toner result in poor resolution, uneven particle size and shape, high waste toner rates, and difficulty in recycling due to inadequate dispersion and binding of resin and colorant particles, leading to unstable charge-mass ratios and poor printing quality.
Innovation Solution
The method involves surface treatment of colorants and wax using atom transfer radical polymerization (ATRP) to produce polymer-grafted particles, which are then dispersed in an aqueous solution with surfactants to create emulsions that are agglutinated, allowing for controlled polymerization and improved dispersibility, thereby enhancing the uniformity and stability of toner particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional mechanical grinding and gas flow grinding methods are used to prepare colored toner, then the production process is simple, but the particle size and shape are not uniform and the resolution is low
Solution Approach 1:
The invention changes the fundamental parameter of the preparation method from mechanical/physical grinding to chemical polymerization. By using suspension polymerization or emulsion polymerization/co-flocculation, the process transforms monomers into polymer particles in situ, achieving uniform particle size distribution (5-10 μm) and consistent spherical shapes that mechanical methods cannot produce
Solution Approach 2:
The invention utilizes phase transition during polymerization to control particle formation. In suspension polymerization, monomer droplets are formed in a continuous phase and polymerize within these droplets. In emulsion polymerization, polymer particles form and flocculate in controlled phases. These phase transitions enable precise control over particle size, shape, and distribution
2Reliability
If suspension polymerization method is used to control particle size, then the flow and charging properties are improved, but the particle size distribution becomes wide and the resolution is low
Solution Approach 1:
The invention segments the polymerization process into controlled stages with specific initiator addition sequences. By dividing the monomer feed into multiple stages and adding initiators at different times, the process produces a narrower particle size distribution while maintaining the charging properties achieved by suspension polymerization
Solution Approach 2:
The invention employs periodic action through staged initiator addition and controlled monomer feeding during polymerization. This periodic introduction of reactants allows better control over nucleation and growth rates, resulting in more uniform particle sizes while preserving the electrostatic charging characteristics
3Manufacturing precision
If emulsion polymerization/co-flocculation method is used to narrow particle size, then the resolution and color are improved, but the resin particles and colorant particles are hard to disperse uniformly and bind to each other
Solution Approach 1:
The invention uses surfactants and chain transfer agents as intermediaries to facilitate uniform dispersion and binding between resin particles and colorant particles. These intermediaries reduce interfacial tension and promote homogeneous distribution of colorant within the polymer matrix, solving the dispersion problem while maintaining narrow particle size distribution
Solution Approach 2:
The invention creates composite structures by incorporating colorant particles into the polymer matrix during the polymerization process. This in-situ composite formation ensures uniform distribution and strong binding between resin and colorant, overcoming the dispersion difficulties of post-mixing methods while achieving narrow particle size distribution
4Reliability
If a large amount of wax is added to improve anti-partial printing properties, then the anti-partial printing is improved, but the wax transfers to the surface to pollute the carrier and developing sleeve
Solution Approach 1:
The invention changes the parameter of wax content from high concentration to optimized low concentration (0.1-5% by weight). By adjusting this parameter and using properly grafted wax, the invention achieves adequate anti-partial printing properties while minimizing wax transfer and pollution to the carrier and developing sleeve
5Reliability
If excess wax is added to improve anti-partial printing, then the anti-partial printing is improved, but the pigment distribution becomes uneven and the printing quality is poor
Solution Approach 1:
The invention optimizes the wax content parameter to a precise range (0.1-5% by weight) and uses properly grafted wax instead of excess free wax. This parameter optimization ensures uniform pigment distribution throughout the toner matrix while providing sufficient anti-partial printing properties without compromising print quality
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 approach results in toners with improved developing density, resolution, and reduced waste powder rates, along with a stable charge-mass ratio, leading to better printing performance and easier recycling.
Implementation Method 1
providing surface-treated colorant as an initiating agent, polymerizing the colorant by atom transfer radical polymerization (ATRP) to produce polymer-grafted colorant particles
Implementation Method 2
dispersing the colorant particles in an aqueous solution comprising a surfactant to yield a first emulsion A
Implementation Method 3
agglutinating the first emulsion A and the second emulsion B
Data Source
AI summary
A method for preparing a colored toner. The method includes: 1) providing surface-treated colorant, polymerizing the colorant by atom transfer radical polymerization (ATRP) to produce polymer-grafted colorant particles and dispersing the colorant particles in an aqueous solution including a surfactant to yield a first emulsion; 2) providing surface-treated wax, polymerizing the wax by ATRP to produce polymer-grafted wax particles, and dispersing the wax particles in the aqueous solution including the surfactant to yield a second emulsion; and 3) agglutinating the first emulsion and the second emulsion.