Bio-based Amorphous Polyester Toner Resin for Sustainable Electrophotography

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Solution Overview

Problem

Current polyester-based toners rely on fossil fuels and contain carcinogenic/endocrine-disrupting monomers, leading to environmental concerns and the need for more sustainable, cost-effective alternatives.

Innovation Solution

Development of bio-based amorphous polyester resins incorporating camphoric acid, along with other renewable monomers like D-isosorbide and naphthalene dicarboxylate, for use in toner compositions, which are produced through emulsion aggregation processes, reducing reliance on petrochemicals and enhancing environmental sustainability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If fossil fuel-based polyester resins are used in toner production, then cost-effective manufacturing is achieved, but environmental sustainability deteriorates due to greenhouse gas emissions and accumulation of non-degradable materials

Engineering Contradiction:

Improvemanufacturing cost-effectivenessVSAvoidenvironmental 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 (D-isosorbide, naphthalene dicarboxylate, azelaic acid, cyclohexane-1,4-dicarboxylic acid, succinic acid) to replace fossil fuel-based materials. This substitution maintains the resin's functional properties while improving environmental sustainability and reducing greenhouse gas emissions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite polyester resin system combining multiple bio-based monomers with specific functional properties. The resin includes D-isosorbide for structural stability, naphthalene dicarboxylate for thermal properties, and other bio-based components, achieving both environmental sustainability and desired toner performance characteristics.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

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

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidhealth safety

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes the harmful bisphenol A monomer from the polyester resin composition. It replaces BPA with safe bio-based alternatives including D-isosorbide, naphthalene dicarboxylate, azelaic acid, cyclohexane-1,4-dicarboxylic acid, and succinic acid, eliminating carcinogenic and endocrine-disrupting properties while maintaining manufacturing feasibility.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical identity of the monomer components by substituting bisphenol A with bio-based monomers that have fundamentally different chemical structures and safety profiles. This parameter change eliminates health hazards while preserving the polyester resin's functional characteristics for toner application.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If conventional polyester resins are used, then production processes remain simple, but environmental impact worsens due to reliance on non-renewable petrochemical resources

Engineering Contradiction:

Improveprocess complexityVSAvoidresource sustainability

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the resource origin parameter of the polyester resin from petrochemical (non-renewable) to bio-based (renewable) sources. The resin is synthesized from bio-based monomers including D-isosorbide, naphthalene dicarboxylate, azelaic acid, cyclohexane-1,4-dicarboxylic acid, and succinic acid, reducing dependence on depleting fossil fuel resources while maintaining process simplicity.

Inventive Principle:

Principle #35Parameter changes

4Object-affected harmful factors

If semi-crystalline biodegradable polyester resins are used, then biodegradability is improved, but toner performance may deteriorate due to crystalline structure limitations in electrophotographic applications

Engineering Contradiction:

ImprovebiodegradabilityVSAvoidelectrophotographic performance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent creates an amorphous polyester resin composite incorporating multiple bio-based monomers (D-isosorbide, naphthalene dicarboxylate, azelaic acid, cyclohexane-1,4-dicarboxylic acid, succinic acid) that achieve both biodegradability and optimal electrophotographic performance. The amorphous structure provides superior charging, development, and transfer characteristics compared to semi-crystalline alternatives.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the structural state parameter of the polyester resin from semi-crystalline to amorphous. This parameter change enables the resin to exhibit desirable glass transition temperature, low moisture content, and excellent electrophotographic performance while maintaining biodegradability through bio-based monomer composition.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9857708B2Toner compositions and processes

Publication Date: 2018.01.02 XEROX CORP

AI summary

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