Bio-based Polyester Toner Encapsulation via Solvent Evaporation
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Solution Overview
Problem
Existing methods for producing toners using bio-based polyester resins face challenges in incorporating insoluble materials like pigments and waxes, as they can be rejected during the emulsion-aggregation process, leading to color changes and incomplete incorporation.
Innovation Solution
A process involving the formation of a polyester latex by contacting a bio-based polyester resin with an organic solvent immiscible with water, mixing it with a water phase containing insoluble components such as wax or pigment dispersions, and evaporating the solvent to encapsulate these components, which are then aggregated and coalesced to form toner particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If bio-based polyester resins are used in emulsion aggregation processes, then environmental sustainability is improved, but incorporation of insoluble materials like pigments and waxes deteriorates
Solution Approach 1:
The patent applies preliminary action by dissolving the bio-based polyester resin in an organic solvent before emulsification, creating a pre-formed resin solution that facilitates subsequent incorporation of insoluble materials. This preliminary dissolution step ensures the resin is in a state that can effectively encapsulate pigments and waxes during the emulsion aggregation process, thereby improving incorporation while maintaining environmental sustainability
Solution Approach 2:
The patent employs parameter changes by controlling the solvent-to-resin ratio and the rate of solvent evaporation during the emulsion aggregation process. By adjusting these parameters, the resin forms a matrix that effectively traps insoluble materials, achieving high incorporation rates (90-98%) while using environmentally friendly bio-based resins
2Device complexity
If conventional emulsion aggregation is used, then process simplicity is maintained, but pigment rejection occurs leading to color inconsistency
Solution Approach 1:
The patent introduces an organic solvent as an intermediary medium that facilitates the incorporation of insoluble materials. The solvent acts as a bridge between the hydrophobic insoluble materials and the hydrophilic emulsion system, allowing pigments and waxes to be uniformly distributed and encapsulated within the resin matrix during emulsion aggregation, thereby ensuring color consistency without complicating the overall process
3Ease of manufacture
If insoluble materials are added during emulsion aggregation, then toner formulation is simplified, but incorporation efficiency deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-dissolving the resin in organic solvent and pre-dispersing the insoluble materials in the emulsion phase before aggregation. This preliminary preparation ensures that when the emulsion is formed and solvent is evaporated, the insoluble materials are already positioned to be efficiently incorporated into the resin matrix, achieving 90-98% incorporation efficiency while maintaining formulation simplicity
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 method effectively encapsulates and incorporates insoluble materials into toner particles, reducing pigment rejection and ensuring consistent color, with high incorporation rates of up to 90-98% of the initial pigment or wax, resulting in high-quality toner particles.
Implementation Method 1
evaporating the organic solvent to form a latex including the resin and the insoluble component
Data Source
AI summary
A process for making a latex emulsion suitable for use in a toner composition includes co-emulsifying a bio-based resin with an insoluble component, such as a pigment or wax, whereby the resin encapsulates the insoluble component. The resulting latex, including the insoluble component encapsulated in the resin, may then be utilized to form a toner. The insoluble component may thus be included in toner particles, which might otherwise be difficult to achieve, using emulsion aggregation processes.