Bio-based Polyester Toner Core-Shell Particles

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Solution Overview

Problem

Current toner compositions, particularly polyester-based ones, rely on fossil fuels and contain carcinogenic/endocrine disruptors 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 bio-based amorphous and crystalline polyester resins derived from renewable sources, such as fatty dimer diol and D-isosorbide, in combination with other ingredients like colorants and waxes, through an emulsion aggregation process to form toner particles with a core-shell configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If fossil fuel-based polyester resins are used in toner compositions, then manufacturing cost and performance are maintained, but environmental harm and regulatory risk increase

Engineering Contradiction:

Improveenvironmental harmVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent changes the chemical composition parameters of the polyester resin by incorporating bio-based components (at least 5 mol% of a specific monomer unit) while maintaining the functional performance required for toner applications. This parameter change enables environmental improvement without sacrificing manufacturing viability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite polyester resin system combining bio-based monomers with traditional polyester components. This composite approach allows the material to maintain the desired melting properties, charge characteristics, and fusing performance while reducing environmental harm through renewable content

Inventive Principle:

Principle #40Composite materials

2Reliability

If bisphenol A is used in polyester resins, then resin performance and processing are maintained, but health risks and regulatory restrictions increase

Engineering Contradiction:

Improveresin performanceVSAvoidcarcinogenic properties

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and removes bisphenol A from the resin composition by replacing it with alternative monomers that provide similar functional benefits without the harmful properties. The specification explicitly excludes BPA while maintaining resin performance through other chemical components

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs alternative monomers that serve the same functional purpose as BPA but without the long-term health risks. These alternative components can be processed and used in conventional toner manufacturing without requiring special handling or disposal procedures

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Stability of the object's composition

If conventional polyester resins are used, then fusing properties are maintained, but environmental sustainability deteriorates

Engineering Contradiction:

Improvefusing propertiesVSAvoidenvironmental sustainability

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent modifies the molecular structure parameters of the polyester resin by incorporating specific bio-based monomer units in controlled amounts. This maintains the glass transition temperature, melting point, and flow characteristics necessary for proper fusing while improving environmental sustainability through renewable content

Inventive Principle:

Principle #35Parameter changes

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 reduce reliance on fossil fuels, while maintaining excellent fusing properties and improved document offset resistance.

Implementation Method 1

emulsion aggregation processes utilizing a bio-based polyester resin

Methodology Applied

Scientific EffectCoagulation: Coagulation

Implementation Method 2

formation of an emulsion latex of the resin particles

Methodology Applied

Scientific EffectEmulsion: Emulsion

Implementation Method 3

by heating the resin, using an emulsion polymerization

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS8221948B2Toner compositions and processes

Publication Date: 2012.07.17 XEROX CORP

AI summary

Environmentally friendly toner particles are provided which may, in embodiments, include a bio-based amorphous polyester resin, optionally in combination with another amorphous resin and/or a crystalline resin. Toner particles may, in embodiments, have a core-shell configuration, with the shell formed of the bio-based amorphous polyester resin, the amorphous polyester resin, the crystalline polyester resin, or combinations thereof.