Bio-based Polyester Resins for Emulsion Aggregation Toners
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Solution Overview
Problem
Current emulsion aggregation toner technologies rely on fossil-based resources, leading to environmental concerns and economic instability due to the depletion of global fossil reserves and volatile oil prices, necessitating the development of sustainable, bio-based alternatives.
Innovation Solution
The use of bio-based amorphous polyester resins derived from renewable resources such as 1,4:3,6-dianhydro-D-sorbitol (isosorbide), nonanedioic acid (azelaic acid), and butanedioic acid (succinic acid) for the production of emulsion aggregation toners, allowing for the adjustment of polymer properties like acid value and glass transition temperature through varying monomer ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fossil-based resources are used for emulsion aggregation toner production, then current technology and manufacturing processes can be maintained, but environmental sustainability deteriorates and economic stability worsens due to depletion of global fossil reserves and volatile oil prices
Solution Approach 1:
The patent changes the fundamental parameter of resource origin from fossil-based to bio-based materials. Specifically, it uses renewable resources such as vegetable oils, fats, and starches as feedstocks for producing polyester resins, thereby eliminating dependence on depleting fossil reserves and reducing vulnerability to oil price volatility while maintaining toner production capabilities
Solution Approach 2:
The patent employs composite material structures by combining bio-based polyester resins with traditional toner components. The bio-based polyester resins are synthesized from multiple renewable feedstocks (vegetable oils, fats, starches) and combined with colorants, charge control agents, and other toner ingredients to create a functional composite toner product that achieves both sustainability and performance
2Reliability
If bio-based monomers are used to produce amorphous polyester resins, then environmental sustainability and economic resilience improve, but manufacturing precision and property consistency may deteriorate due to variability in renewable feedstocks
Solution Approach 1:
The patent uses composite material approaches by combining multiple bio-based components (polyester resins from vegetable oils, fats, and starches) with traditional toner ingredients. This composite strategy allows the variability of individual bio-based feedstocks to be balanced and compensated through formulation design, achieving consistent toner properties while maintaining environmental benefits
Solution Approach 2:
The patent applies parameter changes by systematically adjusting the composition ratios of different bio-based monomers and controlling polymerization conditions (temperature, catalysts, reaction time) to standardize the properties of amorphous polyester resins. This enables consistent control of glass transition temperature, molecular weight, and acid value despite using renewable feedstocks
3Reliability
If amorphous polyester resins with tailored properties are produced through emulsion aggregation, then toner performance improves, but process complexity increases due to multiple synthesis and aggregation steps
Solution Approach 1:
The patent applies segmentation by dividing the toner production process into distinct modular stages: (1) synthesis of amorphous polyester resins from bio-based monomers, (2) formation of emulsion latex, (3) aggregation with colorants and additives, and (4) drying and finishing. This segmented approach allows each step to be optimized independently and facilitates property tailoring at each stage
4Adaptability or versatility
If multiple monomer ratios are used to achieve different polymer properties, then adaptability and versatility improve, but manufacturing precision and quality control become more difficult
Solution Approach 1:
The patent systematically applies parameter changes by establishing defined ranges for monomer ratios (e.g., different proportions of dicarboxylic acids, diols, and starch-derived monomers) that correspond to specific toner applications. Each monomer ratio range is optimized to produce resins with targeted glass transition temperatures, molecular weights, and acid values, allowing quality control through parameter specification rather than requiring complex real-time adjustments
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 reduces the carbon footprint, decreases plastic waste, and provides a stable source of income for domestic agriculture while producing toners with tailored properties such as gloss levels and charging characteristics, enhancing environmental sustainability and economic resilience.
Implementation Method 1
the amorphous polyesters may be obtained from the mixture of three different monomers: 1,4:3,6-dianhydro-D-sorbitol (isosorbide), nonanedioic acid (azelaic acid), and butanedioic acid (succinic acid)
Implementation Method 2
The colorant dispersion is added to the emulsion latex mixture, and an aggregating agent or complexing agent is then added and/or aggregation is otherwise initiated to form aggregated toner particles
Implementation Method 3
The aggregated toner particles are heated to enable coalescence/fusing, thereby achieving aggregated, fused toner particles
Data Source
AI summary
Disclosed are amorphous polyesters that contain only renewable resources designed for emulsion aggregation toner fabrication. The amorphous polyesters may be obtained from the mixture of three different monomers: 1,4:3,6-dianhydro-D-sorbitol (isosorbide), nonanedioic acid (azelaic acid), and butanedioic acid (succinic acid). Different polymer properties may be achieved depending on the ratio of these three monomers. By altering the ratio, polymers of high to low acid value can be obtained, as well as different ranges of glass transition temperatures.