Core-Shell Toner with Segmented Shell Layers
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Solution Overview
Problem
Existing toners face challenges in achieving excellent low-temperature fixability, heat-resistant preservability, and anti-fogging performance due to limitations in shell layer composition and structure.
Innovation Solution
A toner with a core-shell structure, where the toner core is coated with a first shell layer composed of a low-Tg thermoplastic resin and a second shell layer partially covering the first shell layer, using a hydrophobic thermoplastic resin with a higher glass transition point, enhancing fixability and preservability while inhibiting charge decay from moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a single shell layer with low-Tg resin is used to achieve low-temperature fixability, then low-temperature fixability is improved, but heat-resistant preservability deteriorates
Solution Approach 1:
The shell layer is segmented into two distinct layers: a first shell layer containing low-Tg resin (35-66°C) for low-temperature fixability, and a second shell layer containing high-Tg resin (71-105°C) for heat-resistant preservability. This segmentation allows each layer to perform its specific function without interfering with the other, resolving the contradiction between low-temperature fixability and heat-resistant preservability.
Solution Approach 2:
Different regions of the shell structure are assigned different material properties: the inner first shell layer uses low-Tg resin to enable low-temperature fixation, while the outer second shell layer uses high-Tg resin to provide heat resistance. This local differentiation of material properties allows simultaneous achievement of both low-temperature fixability and heat-resistant preservability.
2Object-affected harmful factors
If hydrophobic resin is added to improve anti-fogging performance, then anti-fogging performance is improved, but low-temperature fixability may deteriorate
Solution Approach 1:
The hydrophobic resin is localized specifically in the second shell layer rather than being distributed throughout the entire shell structure. This local placement ensures that the hydrophobic effect is provided at the outer surface for anti-fogging performance, while the low-Tg resin in the first shell layer remains available to provide low-temperature fixability.
Solution Approach 2:
The shell is segmented into functional zones: the first shell layer handles low-temperature fixation, while the second shell layer handles both heat resistance and anti-fogging through the hydrophobic resin. This functional segmentation allows hydrophobic resin to be added without compromising low-temperature fixability.
3Stability of the object's composition
If charge control agents are added to improve charge stability, then charge stability is improved, but dispersibility may deteriorate
Solution Approach 1:
The first shell layer acts as an intermediary between the toner core and the external environment, providing a controlled interface that facilitates uniform dispersibility. The low-Tg resin in this layer ensures good surface properties for dispersion, while the charge control agents can be effectively distributed throughout the structure without aggregation.
Solution Approach 2:
By controlling the glass transition temperature parameters of the resins in each shell layer (low-Tg in first layer, high-Tg in second layer), the patent optimizes both charge stability and dispersibility. The specific Tg ranges ensure that charge control agents are properly stabilized while maintaining good surface dispersibility.
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 exhibits improved low-temperature fixability, heat-resistant preservability, and anti-fogging performance by preventing contact between low-Tg resin domains and maintaining hydrophobicity, thus preventing charge decay and improving image stability.
Implementation Method 1
The first thermoplastic resin has a glass transition point of at least 35° C. and no greater than 66° C.
Implementation Method 2
The second thermoplastic resin has a glass transition point of at least 71° C. and no greater than 105° C.
Implementation Method 3
The third thermoplastic resin is more hydrophobic than the first thermoplastic resin and the second thermoplastic resin
Data Source
AI summary
A toner includes toner particles. The toner particles each include a toner core containing a binder resin, a first shell layer covering a surface of the toner core, and a second shell layer partially covering a surface of the first shell layer. The first shell layers include first domains composed of a first thermoplastic resin and second domains composed of a second thermoplastic resin. The first thermoplastic resin has a glass transition point of at least 35° C. and no greater than 66° C. The second thermoplastic resin has a glass transition point of at least 71° C. and no greater than 105° C. The second shell layers contain a third thermoplastic resin that is more hydrophobic than the first thermoplastic resin and the second thermoplastic resin. The third thermoplastic resin has a higher glass transition point than the first thermoplastic resin.