Crystalline Aromatic Ether Toner for Low-Temperature Fusing
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Solution Overview
Problem
Current toner compositions, such as Ultra-Low-Melt (ULM) emulsion aggregation (EA) toners, have a Crease Fix Minimum Fusing Temperature (MFT) that can be improved further to reduce energy consumption and enhance fuser life, with a goal of lowering MFT by an additional 10° C. to 20° C. compared to existing benchmarks.
Innovation Solution
Incorporating small molecule crystalline aromatic ethers with a molecular weight less than 1,000 g/mol into toner compositions, which are compatible with amorphous polymeric resins, reducing the glass transition temperature and enthalpy of fusion, and having a melting point less than 120° C., to achieve lower MFT without significant solid to liquid phase transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional ULM EA toners are used, then crease fix MFT is reduced to approximately -20°C compared to styrene/acrylate EA toners, but further reduction of 10°C to 20°C is desired to achieve even lower energy consumption
Solution Approach 1:
The patent changes the chemical composition parameters of the toner by incorporating small molecule crystalline aromatic ethers with specific molecular weights (less than 1,000 g/mol, preferably less than 500 g/mol) and melting points (less than 120°C). This compositional parameter change enables the toner to achieve crease fix MFT values 10-20°C lower than conventional ULM EA toners, directly reducing the energy required for the fusing process.
Solution Approach 2:
The patent creates a composite toner system by combining amorphous polymeric resins with small molecule crystalline aromatic ethers. This composite material approach allows the toner to leverage the low melting point and compatibility characteristics of the aromatic ether compounds, achieving superior low-temperature fusing performance and energy efficiency compared to conventional single-component toner systems.
2Loss of energy
If small molecule crystalline aromatic ethers are added to reduce MFT, then energy consumption is reduced and fuser life is extended, but the complexity of toner composition increases
Solution Approach 1:
The small molecule crystalline aromatic ethers act as intermediary substances that facilitate low-temperature fusing by mediating between the toner particles and the fuser heating element. These aromatic ether compounds serve as a bridge, enabling energy-efficient transfer and fixation of toner to substrate while maintaining compatibility with the polymeric resin matrix, thus reducing energy consumption without requiring fundamental changes to the fusing system.
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 use of small molecule crystalline aromatic ethers in toner compositions achieves a Crease Fix MFT comparable to or lower than existing ULM EA toners, such as the Xerox® 700 Digital Color Press toner, by 5° C. to 20° C., thereby reducing energy consumption and extending fuser life.
Implementation Method 1
reducing the glass transition temperature and enthalpy of fusion
Implementation Method 2
having a melting point less than 120° C., to achieve lower MFT without significant solid to liquid phase transitions
Data Source
AI summary
A toner includes a polymeric resin, optionally a colorant, and a small molecule crystalline aromatic ether having a molecular weight less than 1,000 g/mol. The polymeric resin may be an amorphous resin and a mixture of the amorphous resin and the crystalline aromatic ether may be characterized by a reduction in glass transition temperature from that of the resin and by the lack of a melting point for the crystalline aromatic ether as determined by differential scanning calorimetry, the enthalpy of fusion for the crystalline aromatic ether in the mixture being measured to be less than 10% of the enthalpy of fusion of the crystalline aromatic ether in pure form. Furthermore, the toner may be configured to have a crease fix minimum fusing temperature (MFT) less than or equal to the crease fix MFT of a benchmark ultra-low-melt emulsion aggregation toner. Suitable crystalline aromatic ethers may include benzyl 2-naphthyl ether.