Crystalline Imide Plasticized Toner for Ultra-Low Melt Fusing
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Solution Overview
Problem
Current toner compositions, such as Ultra-Low-Melt 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 desire to lower MFT by an additional 10° C. to 20° C. compared to existing benchmarks.
Innovation Solution
Incorporating small molecule crystalline imides with a molecular weight less than 1,000 g/mol into toner compositions, specifically emulsion aggregation toners, 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 EA toners are used, then baseline crease fix MFT performance is achieved, but further reduction in MFT by 10-20°C is not possible
Solution Approach 1:
The patent changes the molecular weight parameter of the crystalline component from conventional ranges to specifically less than 1,000 g/mol (preferably 50-500 g/mol), and adjusts the plasticizer content to 5-30 wt% of the binder resin. These parameter changes enable the toner to achieve crease fix MFT below -20°C, reducing fuser energy consumption while maintaining toner performance.
Solution Approach 2:
The patent creates a composite toner system combining amorphous binder resin, small molecule crystalline components (less than 1,000 g/mol), and plasticizers in specific ratios. This composite structure allows the toner to achieve ultra-low melt properties with crease fix MFT below -20°C, improving both adhesion quality and fuser energy efficiency simultaneously.
2Temperature
If small molecule crystalline imides are added to reduce MFT, then crease fix MFT decreases by 5-20°C, but toner composition complexity increases
Solution Approach 1:
The patent specifies precise parameter ranges for the crystalline imide components (molecular weight less than 1,000 g/mol, preferably 50-500 g/mol; melting point less than 120°C) and plasticizer content (5-30 wt% of binder resin). These controlled parameter changes achieve the desired MFT reduction while maintaining manageable composition complexity through defined specifications.
3Temperature
If crystalline components with molecular weight less than 1,000 g/mol are used, then glass transition temperature is reduced, but selection of compatible materials becomes more difficult
Solution Approach 1:
The patent establishes specific parameter thresholds for material selection: crystalline components with molecular weight less than 1,000 g/mol (preferably 50-500 g/mol) and melting point less than 120°C, and plasticizer content at 5-30 wt% of binder resin. These parameter specifications reduce glass transition temperature while providing clear guidelines for material compatibility, making manufacturing more straightforward despite the specialized material requirements.
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 imides in toner compositions achieves crease fix MFT comparable to or lower than nominal ULM EA toners, such as the Xerox 700 Digital Color Press toner, by 5° C. to 20° C., thereby reducing energy requirements and extending fuser life.
Implementation Method 1
small molecule crystalline imides which are compatible with toner binder resins to provide low crease fix minimum fusing temperature
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 imide 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 imide 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 imide as determined by differential scanning calorimetry, the enthalpy of fusion for the crystalline imide in the mixture being measured to be less than 10% of the enthalpy of fusion of the crystalline imide 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 imides may include N-alkyl and N-aryl imides, such as N-benzylphthalimide.