Bio-based Branched Polyester Resin for Toner
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Solution Overview
Problem
Current polyester-based toners rely on petroleum-derived monomers, posing health and environmental risks, necessitating the development of bio-based alternatives with reduced negative impact.
Innovation Solution
A bio-based, branched polyester resin is created using a condensation product of cyclic polyhydroxyl acceptors, such as rosin acid, and hydroxyl donors like glycerine carbonate, resulting in a resin with greater than 90% bio-based content, which is biodegradable and exhibits enhanced properties like improved fusing range and reduced hot offset.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If petroleum-derived monomers are used to manufacture polyester-based toners, then the toner production process is well-established and reliable, but health risks and negative environmental impact increase
Solution Approach 1:
The patent changes the chemical composition parameters by substituting petroleum-derived monomers with bio-based monomers (specifically glycerine carbonate and rosin acid). This parameter change maintains the polyester resin structure and manufacturing process while eliminating the harmful factors associated with petroleum products, achieving both environmental benefits and manufacturing feasibility
Solution Approach 2:
The patent employs biodegradable reagents that can break down naturally, replacing persistent petroleum-based materials. The bio-based monomers and resulting polyester resin are designed to be environmentally degradable, allowing the product to fulfill its function and then decompose without long-term environmental harm, effectively treating the material as a sustainable, short-living alternative
2Object-affected harmful factors
If bio-based reagents are used to create sustainable polyester resins, then environmental impact is reduced, but the resin must maintain adequate performance properties for toner application
Solution Approach 1:
The patent adjusts key parameters of the polyester resin including molecular weight (Mn: 500-1500, Mw: 400-125,000), glass transition temperature (Tg: 10-50°C), and softening point (85-120°C) by controlling the ratio and selection of bio-based monomers. These parameter optimizations ensure the resin maintains adequate viscosity, flow properties, and fusing characteristics required for reliable toner performance while remaining environmentally sustainable
Solution Approach 2:
The patent creates a composite polyester resin system combining multiple bio-based components: glycerine carbonate (providing hydroxyl groups), rosin acid (providing carboxyl groups and branching), and optional additional monomers. This composite approach allows synergistic optimization where each component contributes specific properties, ensuring both environmental sustainability and reliable toner performance through balanced composition
3Object-affected harmful factors
If high bio-based content (>90%) is achieved in the polyester resin, then sustainability is maximized, but manufacturing complexity may increase
Solution Approach 1:
The patent simplifies manufacturing by optimizing the stoichiometric ratios of bio-based monomers (glycerine carbonate to rosin acid molar ratio: 0.8-1.2:1) and controlling reaction parameters (temperature: 150-250°C, time: 1-24 hours). These parameter optimizations enable high bio-based content (>90%) resins to be produced using standard polyesterification processes without requiring complex manufacturing infrastructure
Solution Approach 2:
The patent employs readily available, inexpensive bio-based starting materials (glycerine carbonate from glycerol carbonation, rosin acid from pine resin) that can be procured from renewable sources. These materials replace costly and complex petroleum-based monomers, simplifying the supply chain and manufacturing process while achieving >90% bio-based content and maximum sustainability
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 bio-based resin provides a sustainable solution with improved toner performance, including a broader fusing range and reduced environmental impact, while maintaining high bio-based content and biodegradability.
Implementation Method 1
a condensation product of a cyclic polyhydroxyl acceptor comprising one or more rings... and a hydroxyl donor... in a ring opening condensation reaction
Implementation Method 2
each of which is available for binding to a carboxylic acid group in an esterification reaction... reacted with a polyacid or polyester reagent in an esterification reaction to yield a polyester polymer
Data Source
AI summary
The present disclosure provides a bio-based, branched polyester resin comprising the condensation product of a hydroxyl donor, including glycerol carbonate, and a cyclic polyhydroxyl acceptor, such as abietic acid, neoabietic acid, palustric acid, levopimaric acid, dihydroabietic acid, pimaric acid, and isopimaric acid, that may be used with a polyacid, including fumaric acid, maleic acid, succinic acid, itaconic acid, dodecylsuccinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, and dodecane diacid, to form a polyester useful in manufacturing toner for imaging devices.