Chemical Bonding of Bio-Based Oils to Polyester Toner
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Solution Overview
Problem
Existing methods for forming polyester toners using emulsion aggregation techniques face challenges with wax distribution and compatibility, leading to uneven wax domains and increased costs due to separate wax emulsification steps, which affect toner performance and image quality in low-oil or oil-less fusing systems.
Innovation Solution
A method involving the chemical incorporation of a bio-based wax into the polyester resin chain through epoxidation and amino-functionalization, eliminating the need for a separate wax emulsion and enhancing wax distribution within the toner particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If wax is added as a separate aqueous emulsion during aggregation and coalescence, then wax may be incorporated into toner particles, but the wax may be rejected by the emulsion or incompatible with other toner components, resulting in uneven distribution of wax domains and high wax content on particle surface
Solution Approach 1:
The patent combines the wax component with the polyester resin to form an integrated polyester-wax resin emulsion. This merging eliminates the separate wax emulsion step and ensures uniform distribution of wax domains throughout the toner particles by incorporating wax at the molecular level within the resin structure during the emulsion polymerization process.
Solution Approach 2:
The patent performs preliminary emulsification of the polyester-wax resin combination before the aggregation step. By preparing the polyester-wax resin emulsion in advance with proper surfactant selection and emulsion stabilization, the wax is pre-distributed uniformly throughout the resin matrix, preventing rejection or uneven distribution during subsequent aggregation and coalescence processes.
2Quantity of substance
If a separate wax emulsion step is used, then wax can be added to toner formulation, but it increases production cost and process complexity
Solution Approach 1:
The patent merges the wax addition step with the polyester resin emulsification step by incorporating wax into the polyester resin structure. This eliminates the need for a separate wax emulsion preparation and addition step, reducing both production cost and process complexity while maintaining effective wax content in the final toner formulation.
Solution Approach 2:
The patent creates a multi-functional polyester-wax resin that simultaneously provides the resin matrix and wax components in a single material. This universal resin emulsion performs multiple functions: it serves as both the binder and the wax source, eliminating the need for separate wax emulsion equipment and processing steps.
3Ease of operation
If oils are used in fusing system to aid toner release, then toner release during fusing is improved, but differential gloss occurs due to oil remaining on surface of fused prints and oil contamination issues arise
Solution Approach 1:
The patent converts the harmful effect of free oils that cause contamination and gloss issues into a beneficial by chemically bonding the wax to the polyester resin. The wax-oil is covalently attached to the resin backbone, preventing it from migrating to the surface and causing contamination, while still providing the necessary release properties during fusing through controlled wax crystallization within the toner particle structure.
Solution Approach 2:
The patent creates a composite polyester-wax resin material where the wax component is chemically integrated into the resin structure. This composite structure provides the dual benefit of improved toner release during fusing (through controlled wax behavior) while preventing oil contamination and differential gloss (through chemical bonding that restricts wax migration).
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 ensures consistent wax distribution, reduces production costs, and maintains toner performance in low-oil or oil-less fusing systems, while minimizing surfactant and solvent usage, thereby improving environmental sustainability.
Implementation Method 1
forming a polyester-wax resin emulsion by epoxidizing unsaturated units of a polyester resin
Implementation Method 2
chemically bonding the amino-functionalized bio-based oil to the epoxidized units of the polyester resin
Implementation Method 3
aggregating and coalescing the pre-toner mixture to form the toner particles
Data Source
AI summary
Methods for making toner particles comprising a polyester-wax resin, wherein the polyester-wax resin includes a bio-based oil that is chemically incorporated into the main chain of the polyester resin. The toner particles may be formed using emulsion aggregation methods. A toner formed from the toner particles may be used in low-oil or oil-less fusing systems.