Bio-based Polyester Toner Compositions for Carcinogen Elimination

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Solution Overview

Problem

Current toner production methods rely on fossil fuel-based materials, leading to environmental concerns and the use of carcinogenic monomers like bisphenol A, necessitating the development of more sustainable and cost-effective bio-based alternatives.

Innovation Solution

The use of bio-based amorphous and crystalline polyester resins derived from dimer diol, D-isosorbide, naphthalene dicarboxylate, and dicarboxylic acids in emulsion aggregation processes to create toner compositions, incorporating optional colorants, waxes, and coagulants, resulting in core-shell toner particles with improved charging characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If fossil fuel-based polyester resins are used in toner production, then manufacturing cost and process maturity are maintained, but environmental impact increases and carcinogenic monomers like bisphenol A must be used

Engineering Contradiction:

Improveenvironmental impact and carcinogenic monomer useVSAvoidmanufacturing process maturity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent changes the chemical composition parameters of the polyester resin by using bio-based monomers (isosorbide, dimer diol, naphthalene dicarboxylate, dicarboxylic acids) instead of traditional fossil fuel-based monomers including bisphenol A. This substitution maintains the resin's functional properties while eliminating carcinogenic components and reducing environmental impact.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite resin system combining multiple bio-based components (amorphous and crystalline polyester resins derived from different monomers) to achieve the desired balance of properties including charging characteristics, stability across humidity conditions, and thermal/rheological properties necessary for toner performance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If traditional polyester resins are used, then established manufacturing processes can be utilized, but charging characteristics and stability across varying humidity conditions are insufficient

Engineering Contradiction:

Improvecharging characteristics and humidity stabilityVSAvoidresin composition complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a composite resin formulation combining amorphous polyester resin (providing charging characteristics) and crystalline polyester resin (providing stability across humidity conditions). This multi-component system achieves superior reliability by leveraging the complementary properties of each resin type.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent assigns different functional roles to different resin components: the amorphous polyester resin primarily provides charging characteristics, while the crystalline polyester resin primarily provides humidity stability. This functional differentiation allows each component to optimize its contribution to overall toner performance.

Inventive Principle:

Principle #3Local quality

3Object-affected harmful factors

If bio-based polyester resins are used to eliminate carcinogenic monomers, then environmental sustainability improves, but manufacturing cost may increase

Engineering Contradiction:

Improveuse of carcinogenic monomersVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent changes the raw material parameters by substituting bio-based monomers for fossil fuel-based monomers. While bio-based materials can be more expensive, the patent optimizes the formulation to achieve cost-effectiveness through efficient use of materials and improved toner performance that reduces waste and rework.

Inventive Principle:

Principle #35Parameter changes

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 reduces environmental impact, eliminates the use of carcinogenic monomers, and produces toners with excellent charging properties and stability across varying humidity conditions, while maintaining thermal and rheological properties.

Implementation Method 1

aggregating small particles in the mixture to form a plurality of larger aggregates

Methodology Applied

Scientific EffectAggregation:

Implementation Method 2

coalescing the larger aggregates possessing the shell to form toner particles

Methodology Applied

Scientific EffectCoalescence:

Implementation Method 3

contacting the larger aggregates with a shell resin to form a shell over the larger aggregates

Methodology Applied

Scientific EffectCoating: Coatings

Data Source

PatentUS8318398B2Toner compositions and processes

Publication Date: 2012.11.27 XEROX CORP

AI summary

Environmentally friendly toner particles are provided which may include a bio-based amorphous polyester resin, optionally in combination with another amorphous resin and/or a crystalline resin. Methods for providing these toners are also provided.