Covalent Toner Release Agent Monomer Integration

Solution Overview

Problem

Chemical toners used in xerographic printing/copying devices with oil-less fusing subsystems face challenges due to the costly process of incorporating non-covalently bonded release agents like wax, which complicates control over wax domain size and location, affecting fusing properties and increasing costs.

Innovation Solution

Incorporating a release agent monomer with a long aliphatic group and polymerizable double bond directly into the resin polymer backbone, eliminating the need for a separate non-covalently bonded release agent, thereby simplifying the toner preparation and enhancing control over wax domain size and location.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a non-covalently bonded release agent (wax) is used in chemical toner, then toner release from fuser roll is achieved, but production cost increases and control over wax domain size and location becomes problematic

Engineering Contradiction:

Improvetoner releaseVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the release agent function with the resin binder by incorporating a release agent monomer directly into the resin polymer backbone during polymerization. This covalent bonding integrates two previously separate components (resin and release agent) into a single unified material, eliminating the need for separate wax addition and aqueous dispersion processing, thereby reducing production cost and complexity while maintaining reliable toner release

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a composite resin polymer where the resin backbone contains covalently bonded release agent monomers. This composite structure combines the adhesive properties of the resin with the release properties of the wax-like monomer units, achieving both toner release and structural integrity in a single material system without requiring separate wax components

Inventive Principle:

Principle #40Composite materials

2Reliability

If a non-covalently bonded release agent (wax) is used in chemical toner, then toner release from fuser roll is achieved, but control over wax domain size and location becomes problematic

Engineering Contradiction:

Improvetoner releaseVSAvoidwax domain size and location control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent performs preliminary action by incorporating the release agent monomer into the resin polymer backbone during the polymerization process itself, before the toner is formed. This preliminary integration ensures that the release agent is uniformly distributed and precisely positioned within the resin structure from the outset, eliminating the need for subsequent separate processing steps that would compromise control over domain size and location

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the bonding parameter from non-covalent (physical) to covalent (chemical) bonding between the release agent and resin. This fundamental parameter change transforms the release agent from a separate additive with unpredictable domain formation into an integrated polymer component with controlled, uniform distribution, enabling precise control over wax domain size and location

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a separate non-covalently bonded release agent is added to toner, then release function is provided, but the toner formulation becomes more complex and less reproducible

Engineering Contradiction:

Improverelease functionVSAvoidtoner formulation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the release agent function with the resin binder by incorporating a release agent monomer directly into the resin polymer backbone during polymerization. This covalent bonding integrates two previously separate components (resin and release agent) into a single unified material, eliminating the need for separate wax addition and aqueous dispersion processing, thereby reducing production cost and complexity while maintaining reliable toner release

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the bonding parameter from non-covalent (physical) to covalent (chemical) bonding between the release agent and resin. This fundamental parameter change transforms the release agent from a separate additive with unpredictable domain formation into an integrated polymer component with controlled, uniform distribution, enabling precise control over wax domain size and location

Inventive Principle:

Principle #35Parameter changes

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 reduces material variations, lowers production costs, and improves reproducibility by integrating the release agent into the toner's polymer structure, ensuring effective toner release without fuser oil and minimizing hot offset issues.

Implementation Method 1

Incorporating a release agent monomer with a long aliphatic group and polymerizable double bond directly into the resin polymer backbone

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 2

incorporating a release agent, for example, a waxy monomer octadecylacrylate, directly into the backbone of the resin polymer

Methodology Applied

Scientific EffectCovalent bonding: Chemical Bonding

Data Source

PatentEP1980914B1Chemical toner with covalently bonded release agent

Publication Date: 2015.09.23 XEROX CORP

AI summary

A chemical toner composition including a polymer polymerized from starting ingredients comprising a resin monomer and a release agent monomer.