Bio-based Polyester Toner Compositions for Environmental Sustainability

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Solution Overview

Problem

Current toner compositions, particularly polyester-based ones, rely on fossil fuels and contain carcinogenic/endocrine-disrupting chemicals like bisphenol A, leading to environmental concerns and potential regulatory restrictions, necessitating the development of cost-effective, environmentally friendly alternatives.

Innovation Solution

The use of biodegradable semi-crystalline and amorphous polyester resins derived from bio-based materials such as polyhydroxyalkanoates, polylactide, and polyesters from D-Isosorbide, combined with optional colorants, waxes, and coagulants, in an emulsion aggregation process to form toner compositions that are free from organic solvents and harmful chemicals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If fossil fuel-based polyester resins are used in toner compositions, then manufacturing cost and process maturity are maintained, but environmental sustainability deteriorates due to greenhouse gas emissions and accumulation of non-degradable materials

Engineering Contradiction:

Improvemanufacturing cost and process maturityVSAvoidenvironmental sustainability

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the fundamental parameter of resin origin from fossil fuel-based to bio-based sources. It specifies polyesters derived from renewable resources including polyhydroxyalkanoates, polylactide, polyesters from D-Isosorbide, fatty dimer diol, and dimer diacid, transforming the toner composition from non-sustainable to environmentally friendly while maintaining functional performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite resin system combining multiple bio-based polyester components. It specifies compositions containing polyhydroxyalkanoate, polylactide, and other bio-based polyesters in specific weight ratios (e.g., 20-80 wt% PHA, 20-80 wt% PLA), forming a composite material that achieves both environmental sustainability and desired toner properties

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If bisphenol A-containing polyester resins are used in toner compositions, then manufacturing cost and performance are maintained, but health safety deteriorates due to carcinogenic and endocrine-disrupting properties

Engineering Contradiction:

Improvemanufacturing cost and performanceVSAvoidhealth safety

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent explicitly removes bisphenol A and other harmful chemicals from the toner composition. It specifies that the bio-based polyesters shall be free from bisphenol A, thereby extracting the harmful substance while maintaining the functional performance through alternative bio-based resin systems

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the limitation of removing harmful chemicals into a benefit by highlighting that bio-based polyesters naturally provide the desired functionality without carcinogenic or endocrine-disrupting properties, turning a restrictive requirement into a safety advantage

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If conventional polyester resins are used in toner compositions, then current manufacturing processes and performance standards are maintained, but future regulatory compliance deteriorates due to anticipated restrictions on harmful chemicals

Engineering Contradiction:

Improvecurrent manufacturing efficiencyVSAvoidregulatory compliance

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent performs preliminary action by proactively adopting bio-based polyester resins before regulatory restrictions are enacted. It specifies compositions using renewable resource-derived polyesters now, preparing the product line for future environmental regulations and avoiding potential redesign costs when restrictions take effect

Inventive Principle:

Principle #10Preliminary action

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 results in toner compositions that are environmentally friendly, cost-effective, and free from harmful chemicals, offering improved environmental sustainability and compliance with future regulatory standards while maintaining effective printing performance.

Implementation Method 1

emulsion aggregation processes for preparing toner compositions

Methodology Applied

Scientific EffectCoagulation: Coagulation

Implementation Method 2

heating the resin, using an emulsion polymerization

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS8187780B2Toner compositions and processes

Publication Date: 2012.05.29 XEROX CORP

AI summary

Environmentally friendly toner particles are provided which may, in embodiments, include a biodegradable semi-crystalline polyester resin and a biodegradable amorphous polyester resin.