Bio-Based Toner Resin for Low-Energy Fusing
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Solution Overview
Problem
Conventional toners used in office copiers and laser printers face challenges with flow and wetting, require high energy for fusing, and are not environmentally sustainable, as they are based on synthetic resins. There is a need for toners that can be charged positively or negatively, with improved pigment dispersion and the ability to deink from office waste paper, using renewable resource-derived resins.
Innovation Solution
A toner composition comprising an amorphous thermoplastic polymer derived from bio-based monomers, such as dianhydrohexitol and dimer acid, with a glass transition temperature between 50°C and 80°C, and a coloring agent, which can be formulated to have a negative or positive tribo-electric charge, and a mean particle size of less than 30 micrometers, allowing for improved flow and fusing characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional synthetic resin-based toners are used, then toning and printing features are maintained, but environmental sustainability is compromised and long-term supply concerns arise
Solution Approach 1:
The patent changes the chemical composition parameters of the resin by using bio-based feedstocks (corn starch, soybeans, vegetable oils) instead of petroleum-based materials. This substitution maintains the functional properties needed for toning and printing while eliminating the environmental harm associated with synthetic resins, directly resolving the contradiction between reliability and environmental sustainability
Solution Approach 2:
The patent employs readily available bio-based feedstocks that are renewable and sustainable, replacing finite petroleum resources. These bio-based resins provide the necessary performance characteristics for toners while being environmentally friendly and ensuring long-term supply availability, thus resolving the contradiction between maintaining performance and improving environmental sustainability
2Reliability
If high fusing temperature is used, then complete melting and bonding of toner particles is achieved, but energy consumption increases
Solution Approach 1:
The patent modifies the thermal properties of the toner resin by incorporating bio-based polymers with lower melting points and appropriate glass transition temperatures. This allows the toner to achieve complete melting and bonding at lower fusing temperatures, maintaining reliable toner bonding while significantly reducing the energy consumption of the fusing process
Solution Approach 2:
The patent uses composite resin formulations combining bio-based polymers with specific additives to optimize both thermal behavior and bonding performance. These composite materials provide the necessary melt flow characteristics at lower temperatures while ensuring complete bonding, thus resolving the contradiction between reliable toner bonding and reduced energy consumption
3Reliability
If petroleum-derived resins are used, then consistent performance is achieved, but long-term supply security is compromised
Solution Approach 1:
The patent replaces finite petroleum-derived resins with renewable bio-based feedstocks such as corn starch, soybeans, and vegetable oils. These renewable resources provide consistent performance characteristics while ensuring long-term supply security by eliminating dependence on depleting fossil fuel reserves, directly resolving the contradiction between performance consistency and supply security
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 toner achieves effective charging, improved flow and wetting, reduced energy consumption for fusing, and enhanced pigment dispersion, while being environmentally sustainable by utilizing renewable resources, thereby addressing the limitations of conventional synthetic resin-based toners.
Implementation Method 1
The polymer provides negative tribo-electric charging of about 10 to about 40 microCoulomb/g
Implementation Method 2
a thermoplastic polymer... the polymer has a Tg between 50°C and 80°C
Implementation Method 3
resins that flow at lower fusing temperature to minimize the energy consumption to operate a copier
Implementation Method 4
a coloring agent dispersed in the amorphous thermoplastic polymer
Data Source
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AI summary
A series of resins were synthesized using a range of bio-based materials to control the molecular architecture, and therefore the properties, of the inventive resins. The resins were formulated into toner formulations such as those useful in printers and copiers.