Core-Shell Resin Particle Toner with Plant-Derived Monomers

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Solution Overview

Problem

Current toner manufacturing processes have a significant environmental impact and require improvements in energy efficiency, with a need for sustainable binder resins that maintain strength and low temperature fixability.

Innovation Solution

A resin particle with a core-shell structure, where the core contains a plant-derived alcohol monomer accounting for 5-35% of the alcohol component and the shell contains polyethylene terephthalate or polybutylene terephthalate, both potentially as recycled materials, to reduce environmental burden while enhancing toner strength and fixability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional binder resins are used in toner manufacturing, then the manufacturing process is established and reliable, but the environmental impact is significant and energy consumption is high

Engineering Contradiction:

Improveenvironmental impactVSAvoidenergy consumption in manufacturing

Core Design Contradiction:

Object-affected harmful factorsVSUse of energy by stationary object

Solution Approach 1:

The invention changes the chemical composition parameters of the binder resin by incorporating plant-derived alcohol monomers (5-35 mass%) and controlling the content of polyethylene terephthalate or polybutylene terephthalate (10-70 mass%). This parameter optimization enables lower melting point and reduced viscosity, allowing the toner to be manufactured with lower energy input while maintaining performance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite binder resin system combining plant-derived alcohol monomers with conventional polyester components. This composite approach integrates renewable materials with established polymer chemistry, achieving reduced environmental impact while maintaining the mechanical and thermal properties necessary for toner functionality.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If plant-derived binder resins are used to reduce environmental burden, then sustainability is improved, but toner strength and low temperature fixability may deteriorate

Engineering Contradiction:

Improveenvironmental burdenVSAvoidtoner strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The invention optimizes the concentration parameter of plant-derived alcohol monomers within a specific range (5-35 mass%). This controlled parameter change ensures sufficient plant-derived content for environmental benefits while maintaining adequate toner strength through optimal molecular weight and crosslinking density.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention forms a composite resin system where plant-derived alcohol monomers are integrated with polyester backbone structures containing polyethylene terephthalate or polybutylene terephthalate. This composite structure combines the sustainability advantages of plant-derived materials with the strength and thermal stability of conventional polyesters, achieving both environmental and performance goals.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If plant-derived binder resins are used to reduce environmental burden, then sustainability is improved, but fixability at low temperature may worsen

Engineering Contradiction:

Improveenvironmental burdenVSAvoidfixing temperature

Core Design Contradiction:

Object-affected harmful factorsVSTemperature

Solution Approach 1:

The invention modifies the thermal parameters of the binder resin by incorporating plant-derived alcohol monomers that create lower melting point crystalline structures. The controlled composition (5-35 mass% plant-derived alcohol monomer with 10-70 mass% polyethylene terephthalate or polybutylene terephthalate) enables the resin to melt and flow at lower temperatures, improving low-temperature fixability while maintaining sustainability.

Inventive Principle:

Principle #35Parameter changes

4Object-affected harmful factors

If recycled materials are used in binder resin to reduce environmental impact, then sustainability is improved, but manufacturing precision and quality control may deteriorate

Engineering Contradiction:

Improveenvironmental impactVSAvoidquality control

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The invention establishes precise compositional parameters for the binder resin, specifying that plant-derived alcohol monomers constitute 5-35 mass% and polyethylene terephthalate or polybutylene terephthalate constitutes 10-70 mass%. These controlled parameters ensure consistent quality and performance regardless of whether recycled materials are used, enabling reliable manufacturing precision through defined composition ranges.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20230367236A1Resin particle and toner

Publication Date: 2023.11.16 RICOH CO LTD

AI summary

A resin particle contains a core containing a first binder resin containing an alcohol component and a shell containing a second binder resin containing at least one of polyethylene terephthalate and polybutylene terephthalate, wherein the first binder resin contains a plant-derived alcohol monomer accounting for 5 to 35 percent by mass of the entire of the alcohol component and the at least one of polyethylene terephthalate and polybutylene terephthalate accounts for 10 to 70 percent by mass of the entire of the second binder resin.