Bio-Based Polyester Toner Resin Composition

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Solution Overview

Problem

Current toner production methods rely on fossil fuel-based materials, leading to environmental issues and the use of carcinogenic monomers, necessitating the development of bio-based alternatives that are cost-effective and environmentally friendly.

Innovation Solution

The use of bio-based amorphous and crystalline polyester resins derived from renewable sources, such as 2,3-butanediol and dicarboxylic acids, in toner compositions, combined with optional ingredients like colorants and waxes, to create sustainable toner particles through emulsion aggregation processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If fossil fuel-based polymeric materials are used in toner production, then manufacturing cost and process maturity are maintained, but environmental sustainability deteriorates due to greenhouse gas emissions and accumulation of non-degradable materials

Engineering Contradiction:

Improvemanufacturing cost and process maturityVSAvoidenvironmental sustainability

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the polyester resin by incorporating bio-based monomers (50-100% by weight) such as 2,3-butanediol and dicarboxylic acids, transforming the material from fossil fuel-based to bio-based while maintaining the emulsion aggregation process parameters that ensure manufacturability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite resin system combining bio-based amorphous polyester resin with crystalline polyester resin, where the amorphous component provides sustainability and the crystalline component maintains structural properties needed for toner performance and manufacturing

Inventive Principle:

Principle #40Composite materials

2Reliability

If bisphenol A monomer is used in polyester-based toners, then resin performance and manufacturing reliability are maintained, but health safety deteriorates due to carcinogenic and endocrine disrupting properties

Engineering Contradiction:

Improveresin performanceVSAvoidhealth safety

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes the harmful bisphenol A monomer from the resin composition entirely, replacing it with safe bio-based alternatives including 2,3-butanediol and dicarboxylic acids, thereby eliminating the carcinogenic and endocrine disrupting properties while preserving resin functionality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs readily available bio-based monomers that can be produced through fermentation and natural processes, replacing the persistent harmful BPA with renewable, biodegradable alternatives that do not accumulate in the environment or pose health risks

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If 100% bio-based monomers are used in polyester resin, then environmental sustainability is maximized, but manufacturing cost and process control may deteriorate

Engineering Contradiction:

Improveenvironmental sustainabilityVSAvoidmanufacturing cost and process control

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent applies partial bio-based content (50-100% by weight of bio-based monomers) rather than requiring complete substitution, allowing manufacturers to gradually transition to bio-based materials while maintaining process stability and cost-effectiveness, with the option to increase bio-based content as processes mature

Inventive Principle:

Principle #16Partial or excessive action

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 reliance on petrochemicals, sequesters carbon, and produces toners with improved environmental sustainability while maintaining suitable rheological properties for toner fabrication.

Implementation Method 1

Emulsion aggregation (EA) is one such method. Emulsion aggregation techniques may involve the formation of a polymer emulsion by heating a monomer and undertaking a batch or semi-continuous emulsion polymerization

Methodology Applied

Scientific EffectEmulsion aggregation: Coagulation

Implementation Method 2

Polyester EA ultra low melt (ULM) toners have been prepared utilizing amorphous and crystalline polyester resins

Methodology Applied

Scientific EffectPhase transition: Phase Change

Data Source

PatentUS8574802B2Toner compositions and processes

Publication Date: 2013.11.05 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. In embodiments, the bio-based amorphous polyester resin includes a biologically derived diol, such as 2,3-butanediol.