Core/Shell Toner Manufacturing via Single-Step Coagulation
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Solution Overview
Problem
Existing methods for producing electrostatic charge image developing toners with a core/shell structure require complex and time-consuming processes, leading to issues with toner offsetting during image formation and storage stability, especially at low temperatures.
Innovation Solution
A manufacturing method that forms a core/shell structure by coagulating resin particles with a hydrophilic resin and a hydrophobic resin, where the hydrophilic resin is localized on the surface and the hydrophobic resin is inside, using a single coagulation and fusing process, simplifying the process and reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a core/shell structure is formed by adding resin particles to prepare the shell after formation of the core portion, then good fixability at low temperature and no occurrence of toner off-setting are achieved, but the manufacturing process becomes complicated and the manufacturing duration increases
Solution Approach 1:
The patent combines the core formation and shell formation processes into a single coagulation step. By mixing hydrophilic resin particles and hydrophobic resin particles before coagulation, both core and shell structures are formed simultaneously, eliminating the need for separate shell preparation and attachment steps, thus simplifying the manufacturing process while maintaining the core/shell structure
Solution Approach 2:
The patent prepares both hydrophilic resin particles and hydrophobic resin particles in advance with predetermined properties (glass transition temperatures, particle sizes) before the coagulation process. This preliminary preparation ensures that during the single coagulation step, the particles self-organize into the desired core/shell structure without requiring subsequent processing steps
2Reliability
If a core/shell structure is formed by adding resin particles to prepare the shell after formation of the core portion, then good fixability at low temperature and no occurrence of toner off-setting are achieved, but the manufacturing time increases
Solution Approach 1:
The patent merges multiple sequential operations (core coagulation, shell preparation, shell attachment) into a single simultaneous coagulation process, directly reducing manufacturing duration while achieving the same functional result of forming a stable core/shell structure
Solution Approach 2:
The patent maintains continuous useful action throughout the process by having both hydrophilic and hydrophobic resin particles coagulate simultaneously in one continuous operation, eliminating idle time between separate processing steps and thereby reducing overall manufacturing time
3Use of energy by moving object
If low temperature fixing technique is used to minimize electric power consumption, then energy saving is achieved, but toner off-setting and coagulation during storage occur
Solution Approach 1:
The patent applies local quality by creating a core/shell structure where the shell layer has different properties (higher glass transition temperature) than the core. This localized differentiation allows the toner to maintain stability during storage while enabling low-temperature fixing, as the shell provides structural integrity and prevents off-setting
Solution Approach 2:
The patent uses composite materials by combining hydrophilic resin and hydrophobic resin with different glass transition temperatures in a core/shell configuration. This composite structure enables the toner to exhibit both low-temperature fixability (due to the core's lower Tg) and storage stability (due to the shell's higher Tg), resolving the contradiction between energy saving and reliability
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 toners with improved fixability at low temperatures, reduced offsetting, and enhanced storage stability, while also simplifying the manufacturing process and reducing the need for large-scale apparatus.
Implementation Method 1
a manufacturing method of an electrostatic charge image developing toner, wherein a core/shell structure is formed by coagulating resin particles including at least a hydrophilic resin and a hydrophobic resin
Implementation Method 2
coagulating resin particles including at least a hydrophilic resin and a hydrophobic resin, wherein a core/shell structure is formed by coagulating resin particles including at least a hydrophilic resin and a hydrophobic resin
Data Source
AI summary
Disclosed is a toner having a core/shell structure and including a hydrophilic resin and a hydrophobic resin, and a manufacturing method thereof.