Baroplastic Block Copolymer Toner for Low-Temperature Fusing
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Solution Overview
Problem
Current toner fusing processes in electrophotographic printing consume significant energy, with the fusing subsystem being a major contributor to power consumption, despite advancements in ultra-low melt polyester-based toners that allow for lower temperature fusion and energy savings.
Innovation Solution
Development of toners using baroplastic polymers, specifically block copolymers with soft and hard segments, that exhibit Newtonian flow at reduced temperatures under pressure, enabling toner formation and fixation at lower temperatures without the need for high heat, thus reducing energy requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional toner processes are used, then toner can be produced with standard properties, but energy consumption during fusing is high
Solution Approach 1:
The patent changes the physical and chemical parameters of the toner by incorporating baroplastic polymers with specific glass transition temperatures and molecular weights. These parameter changes enable the toner to flow and fuse at lower temperatures under pressure, directly reducing energy consumption while maintaining performance through controlled rheological properties
Solution Approach 2:
The patent uses composite materials by combining baroplastic polymers with conventional toner components (colorants, waxes, charge control agents). This composite approach allows the toner to exhibit both the low-temperature flow properties of baroplastic materials and the functional properties of conventional toners, resolving the contradiction between energy efficiency and performance
2Temperature
If ultra-low melt polyester-based toners are used, then fusing temperature is reduced, but energy consumption remains significant
Solution Approach 1:
The patent replaces the thermal-based fusing mechanism with a pressure-based mechanism. By applying pressure to induce Newtonian flow in the baroplastic polymer, the toner can fuse at lower temperatures without relying heavily on thermal energy, thus reducing overall energy consumption while achieving effective fixation
3Temperature
If high pressure is applied to induce Newtonian flow, then toner can be processed at low temperature, but processing complexity increases
Solution Approach 1:
The patent changes the rheological parameters of the toner through the use of baroplastic polymers with specific molecular architectures and glass transition temperatures. This allows the toner to transition to a Newtonian flow state under pressure at low temperatures, enabling simple pressure application without complex processing equipment
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 use of baroplastic polymers allows for toner production and fixation at significantly lower temperatures and pressures, leading to substantial energy savings and improved print speed and reduced fuser wear, while maintaining performance comparable to conventional toners.
Implementation Method 1
applying a pressure of at least about 100 psi to the block copolymeric composition such that the block copolymeric composition exhibits Newtonian flow at a processing temperature less than about 150° C.
Implementation Method 2
The use of baroplastic polymers allows for toner production and fixation at significantly lower temperatures and pressures
Data Source
AI summary
Toners are provided which include a resin including at least one baroplastic polymer. The baroplastic polymer, in embodiments, may be a block copolymer with discrete low glass transition temperature (Tg) domains and high Tg domains that plasticize one another at ambient temperature when subjected to pressures of from about 500 psi (about 3.45 MPa) to about 10,000 psi (about 69 MPa), enabling them to be extruded and molded without heat. The resulting polymers, in turn, may then be utilized to form toners.