Composite Toner Resin Low-Temperature Fixing Stability
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Solution Overview
Problem
Current toner production methods, such as the kneading-pulverizing method, fail to achieve high-quality output images due to irregular particle shapes and large particle sizes, leading to high energy consumption for fixing and poor heat-resistant storage stability, while polymerization methods do not adequately meet the demand for high low-temperature fixing ability and hot offset resistance.
Innovation Solution
A toner composition featuring a binder resin with a crystalline polyester resin and a non-crystalline polyester resin containing urethane or urea bonds, where the non-crystalline resin has a specific glass transition temperature range and a sufficient amount of isocyanate monomers, ensuring both low-temperature fixing ability and heat-resistant storage stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the kneading-pulverizing method is used to produce toner, then the production process is simple, but the particle size is large and irregular, leading to poor image quality and high energy consumption for fixing
Solution Approach 1:
The invention uses a polymerization process that segmentally builds toner particles through controlled chain growth, where monomers polymerize in a regulated manner to form particles with uniform size and spherical shape, avoiding the irregular cracking and size variation inherent in mechanical pulverization methods
Solution Approach 2:
The invention changes the fundamental production parameter from mechanical force (kneading and pulverization) to chemical reaction control (polymerization kinetics), allowing precise control over particle size, shape, and molecular weight distribution to achieve uniform spherical particles with diameters of 3-7 μm
2Ease of manufacture
If the kneading-pulverizing method is used to produce toner, then the production process is straightforward, but the particle shape is irregular, resulting in high energy consumption for fixing
Solution Approach 1:
The polymerization process segments the particle formation into controlled stages, producing uniform spherical particles that pack and transfer efficiently, reducing the energy required for melting and fixing compared to irregular particles from mechanical methods
Solution Approach 2:
By changing from mechanical particle size reduction to controlled polymerization, the invention produces particles with optimal size and shape parameters that require less energy for the fixing process, as spherical particles melt and transfer more efficiently
3Temperature
If wax is added to improve fixing ability, then the releasing effect is enhanced, but the toner deposits on the carrier and photoconductor
Solution Approach 1:
The invention creates a composite resin system combining polyester resin with polyurethane or polyurea components, forming a multi-phase structure where different resin phases work synergistically to provide both releasing effect and prevent deposition, eliminating the need for excessive wax addition
Solution Approach 2:
The resin composition is designed with local quality variations through the sea-island structure, where dispersed polyurethane/polyurea phases provide specific functional properties in localized regions, enabling controlled releasing behavior without overall deposition issues
4Temperature
If a crystalline polyester resin is used to achieve low temperature fixing, then the fixing temperature is reduced, but the hot offset resistance is insufficient
Solution Approach 1:
The invention combines crystalline polyester resin with polyurethane or polyurea resins in a composite system, where the crystalline phase provides low-temperature melting capability while the amorphous polyurethane/polyurea phase maintains structural integrity and prevents hot offset at higher temperatures
Solution Approach 2:
The resin system exhibits local quality differentiation with crystalline regions providing low-temperature fixing and amorphous regions providing hot offset resistance, creating a multi-functional material that addresses both temperature requirements simultaneously
5Temperature
If the glass transition temperature and molecular weight of non-crystalline polyester resin are reduced to improve low temperature fixing, then the low temperature fixing ability is enhanced, but the heat resistant storage stability is degraded
Solution Approach 1:
The invention creates a composite resin system where low glass transition temperature components enable low-temperature fixing while high molecular weight polyurethane or polyurea components provide heat resistant storage stability, achieving both requirements through material composition rather than compromising single-component properties
Solution Approach 2:
The invention changes the approach from modifying single resin parameters (Tg and molecular weight) to controlling the composition ratio and molecular characteristics of multiple resin components, allowing independent optimization of low-temperature fixing and heat-resistant stability through compositional design
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
The toner achieves excellent low-temperature fixing ability, stable fixing in high-temperature ranges, and improved heat-resistant storage stability, addressing the limitations of existing methods.
Implementation Method 1
low temperature fixing ability because a crystalline polyester resin is sharply melted compared to a non-crystalline polyester resin
Implementation Method 2
the non-crystalline polyester resin, which is present as sea that constitutes a large part of the toner particle, is not melted
Data Source
AI summary
A toner containing colorant, releasing agent, and binder resin containing crystalline polyester resin, and non-crystalline polyester resin containing urethane bond, urea bond, or both, the non-crystalline polyester resin containing first and second non-crystalline polyester resins, both containing urethane bond, or urea bond, or both, wherein monomers constituting the first non-crystalline polyester resin contains isocyanate monomer for forming the urethane bond, the urea bond, or the both, in an amount of 0.5 mol % or greater to total amount of the monomers, monomers constituting the second non-crystalline polyester resin contain isocyanate monomer for forming the urethane bond, the urea bond, or the both, in an amount of 0.5 mol % or greater to total amount of the monomers, the first non-crystalline polyester resin has Tg of −60° C. or higher but lower than 10° C., and the second non-crystalline polyester resin has Tg of 30° C. or higher but lower than 70° C.