Bio-based Toner Resin MFT Reduction via Amorphous Composition

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Solution Overview

Problem

Conventional polyester-based toners have a limited reduction in minimum fusing temperature (MFT) which can degrade electrical performance, and there is a need for environmentally friendly toners with further MFT reduction without compromising electrical performance.

Innovation Solution

The development of bio-based toners using amorphous resins and gelling agents in an emulsion aggregation process, which reduces MFT from 20 to 35 degrees Celsius, achieving effective electrical performance with a minimum fusing temperature of 100 to 130 degrees Celsius.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If crystalline resin is added to reduce MFT, then minimum fusing temperature is reduced, but electrical performance degrades

Engineering Contradiction:

Improveminimum fusing temperatureVSAvoidelectrical performance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent changes the chemical composition parameters of the resin by incorporating bio-based polyester resin with specific functional groups (carboxyl, hydroxyl, or amine groups) and controlling the resin's molecular weight and glass transition temperature. This allows achieving lower MFT through chemical composition modification rather than relying on crystalline resin addition, thereby avoiding electrical performance degradation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite toner system combining bio-based polyester resin with specific additives (waxes, charge control agents, colorants) in controlled ratios. The composite structure leverages the low melting point of bio-based polyester while maintaining electrical properties through proper formulation, resolving the contradiction between low MFT and electrical performance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional polyester resin is used, then electrical performance is maintained, but MFT reduction is limited

Engineering Contradiction:

Improveelectrical performanceVSAvoidminimum fusing temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent modifies the resin parameters by selecting bio-based polyester resin with specific glass transition temperatures (Tg) and molecular weights, and by controlling the content of functional groups. This parameter optimization enables simultaneous achievement of low MFT and maintained electrical performance, overcoming the limitations of conventional polyester resin.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies different functional components with specific local properties: bio-based polyester resin provides low melting behavior, while specific additives provide electrical charging properties. This local quality differentiation allows each component to optimize its function without compromising the other, achieving both low MFT and good electrical performance.

Inventive Principle:

Principle #3Local quality

3Temperature

If more crystalline resin is added to further reduce MFT, then minimum fusing temperature decreases, but conductivity and electrical performance deteriorate

Engineering Contradiction:

Improveminimum fusing temperatureVSAvoidconductivity degradation

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent changes the approach from adding crystalline resin to using bio-based polyester resin with controlled Tg and molecular weight parameters. This parameter control allows achieving progressive MFT reduction (from conventional 20°C to 35°C reduction) without the conductivity degradation associated with crystalline resin addition.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces expensive crystalline resin with more economical bio-based polyester resin that achieves similar or better MFT reduction performance. The bio-based resin provides sufficient low-temperature melting behavior without the harmful side effects, making it a superior substitute.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 toners provide a significant reduction in MFT while maintaining electrical performance, utilizing amorphous resins and gelling agents to achieve low melt performance and environmental sustainability.

Implementation Method 1

at least one gelling agent

Methodology Applied

Scientific EffectGelation: Gel

Implementation Method 2

Emulsion aggregation (EA) is one such method

Methodology Applied

Scientific EffectEmulsion aggregation: Emulsion

Implementation Method 3

coalescing the particles to form toner particles

Methodology Applied

Scientific EffectCoalescence:

Data Source

PatentUS8652720B2Super low melt toners

Publication Date: 2014.02.18 XEROX CORP

AI summary

Environmentally friendly latex particles are provided which include a gelling agent and a pigment encapsulated in an amorphous resin which may be utilized in forming EA super low melt toners. Methods for providing these resins and toners are also provided.