Core-Shell Resin Particles for Toner Fixability
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Solution Overview
Problem
Current toner production methods face challenges in achieving high-quality image outputs due to large particle sizes, irregular shapes, and poor low-temperature fixability, heat-resistant storage stability, and charging characteristics, leading to energy inefficiencies and toner deposition issues.
Innovation Solution
Resin particles with a core-shell structure comprising amorphous polyester resins, crystalline polyester resin, and a release agent, where the amorphous polyester resin includes a sulfonic acid salt group-containing polyester resin with a solubility parameter of 10 to 13, providing a core-shell structure for enhanced low-temperature fixability, adhesion, and heat-resistant storage stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a kneading and pulverization method is used to produce toner, then production is feasible, but the toner particles have large sizes, irregular shapes, and broad size distribution leading to poor image quality
Solution Approach 1:
The invention changes the fundamental production parameter from mechanical kneading and pulverization to polymerization reaction. This parameter change enables precise control over particle size and shape during the formation process, producing spherical particles with narrow size distribution and eliminating the need for subsequent pulverization steps.
Solution Approach 2:
The invention utilizes phase transition by controlling the polymerization reaction to form particles in a specific phase state. The polymerization process allows particles to form and solidify in a controlled manner, achieving uniform spherical shapes and sizes directly during production without requiring mechanical breaking down.
2Reliability
If wax is added to produce toner by kneading and pulverization method, then release effect is exhibited, but a large amount of wax accumulates at particle surfaces causing toner deposition on carriers and photoconductors
Solution Approach 1:
The invention applies preliminary action by incorporating the release agent into the polymerization process from the beginning. The release agent is mixed with the monomers before polymerization starts, ensuring uniform distribution throughout the particle matrix during formation, which prevents surface accumulation and subsequent deposition issues.
Solution Approach 2:
The invention changes the parameter of release agent concentration and distribution by using polymerization method. The release agent is uniformly distributed at molecular level during polymerization, creating optimal concentration throughout the particle rather than accumulating at surfaces, thus maintaining release effect while preventing deposition.
3Use of energy by moving object
If conventional toner particles are used, then production is straightforward, but low-temperature fixability is poor leading to high energy consumption
Solution Approach 1:
The invention changes the particle uniformity parameter through controlled polymerization, producing particles with narrow size distribution and uniform spherical shapes. This uniformity ensures consistent melting and fixing behavior, enabling low-temperature fixability and reducing energy consumption during the fixing process.
Solution Approach 2:
The invention uses composite materials by combining specific resin components with release agents in controlled ratios during polymerization. This composite structure optimizes both the melting characteristics for low-temperature fixing and the particle uniformity, achieving energy efficiency without sacrificing manufacturing precision.
4Temperature
If polymerization method is used to produce small diameter toner particles, then low-temperature fixability improves, but heat-resistant storage stability and charging characteristics are not sufficiently achieved
Solution Approach 1:
The invention applies local quality by creating a multi-component resin system where different resin components perform different functions. Some resin components provide low melting point for low-temperature fixing, while others maintain structural integrity for heat-resistant storage stability and proper charging characteristics, achieving local optimization of properties within the same particle.
Solution Approach 2:
The invention uses composite materials by formulating a multi-component resin system that combines resins with different thermal and electrical properties. This composite structure allows the toner to exhibit low-temperature fixability from low-melting components while maintaining storage stability and charging characteristics through other stable components.
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 resin particles achieve excellent low-temperature fixability, adhesion, and heat-resistant storage stability, improving energy efficiency and reducing toner deposition, while maintaining desired charging characteristics.
Implementation Method 1
amorphous polyester resin including a sulfonic acid salt group-containing polyester resin
Implementation Method 2
amorphous polyester resin including a sulfonic acid salt group-containing polyester resin
Implementation Method 3
core-shell structure including a core layer and a shell layer
Data Source
AI summary
Resin particles, each include amorphous polyester resins, a crystalline polyester resin, and a release agent. The amorphous polyester resins include (i) an amorphous polyester resin including a sulfonic acid salt group-containing polyester resin and (ii) an amorphous polyester resin different from the amorphous polyester resin including the sulfonic acid salt group-containing polyester resin. The sulfonic acid salt group-containing polyester resin has a solubility parameter of from 10 to 13. Each of the resin particles has a core-shell structure including a core layer and a shell layer. The shell layer includes the (i) amorphous polyester resin including the sulfonic acid salt group-containing polyester resin.