Dry Toner with Crystalline Thermoplastic Elastomer for Bending Resistance
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Solution Overview
Problem
Existing dry toner technologies face challenges in achieving both high bending resistance and low-temperature fixability for packaging printing applications, with UV-curable materials and thermoplastic elastomers either increasing complexity and cost or compromising on durability and flexibility.
Innovation Solution
A dry toner formulation incorporating a binder resin and a thermoplastic elastomer with a crystalline part, where the thermoplastic elastomer is compatible with the binder resin to enhance bending resistance while maintaining low-temperature fixability and storage stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If UV-curable material is incorporated in the toner to improve bending resistance, then bending resistance is improved, but device complexity and cost increase due to requiring UV irradiation apparatus
Solution Approach 1:
The patent extracts the UV-curing step from the toner system by using thermoplastic elastomer that provides bending resistance through thermal fixing alone, eliminating the need for UV irradiation apparatus while maintaining the desired bending resistance property
Solution Approach 2:
The patent replaces expensive UV-curable materials and apparatus with conventional thermoplastic elastomer and standard thermal fixing equipment, achieving comparable or superior bending resistance at lower cost and device complexity
2Strength
If UV-curable material is used to improve bending resistance, then bending resistance is improved, but printing speed decreases due to inadequate UV cure at high speeds
Solution Approach 1:
The patent replaces the UV photopolymerization mechanism with thermal melting and bonding mechanisms of thermoplastic elastomer, which operate effectively at high printing speeds without the curing time limitations of UV processes
Solution Approach 2:
The patent changes the fixing mechanism from UV light-induced crosslinking to heat-induced melting and bonding, allowing the process to occur rapidly during the brief contact time at high printing speeds while still achieving excellent bending resistance
3Strength
If thermoplastic elastomer with high softening point is added to improve bending resistance, then bending resistance is improved, but low-temperature fixability deteriorates
Solution Approach 1:
The patent uses a multi-component binder resin system where each component serves a specific function: one component provides low-temperature fixability while another component ensures high bending resistance, achieving both properties simultaneously through local functional differentiation
Solution Approach 2:
The patent creates a composite binder resin system combining multiple resin components with complementary properties, where the synergistic interaction between components achieves both low-temperature fixability and high bending resistance that cannot be obtained with single-component elastomers
4Strength
If compatibility between binder resin and thermoplastic elastomer is increased to improve bending resistance, then bending resistance is improved, but storage stability decreases due to lowered glass transition temperature
Solution Approach 1:
The patent creates local compatibility between binder resin and thermoplastic elastomer in the fixed image layer to ensure flexibility and bending resistance, while maintaining overall storage stability through controlled interaction that prevents excessive softening and blocking
Solution Approach 2:
The patent optimizes the glass transition temperature and compatibility parameters of the binder resin system to achieve a balance where sufficient compatibility provides bending resistance while controlled parameter values prevent storage instability and blocking
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 achieves excellent bending resistance, low-temperature fixability, and storage stability by ensuring compatibility between the binder resin and thermoplastic elastomer, balancing molecular mobility and crystallinity to inhibit blocking resistance decline.
Implementation Method 1
a crystalline part originating from the thermoplastic elastomer is present in the toner
Implementation Method 2
a portion of the thermoplastic elastomer in the toner is compatible with the binder resin
Data Source
AI summary
An object of the present invention is to provide a toner that produces an excellent bending resistance in the output image and that also exhibits an excellent low-temperature fixability and an excellent storage stability. This toner includes a binder resin and a thermoplastic elastomer having a crystalline part, wherein the binder resin and the thermoplastic elastomer in the toner are compatible with each other and the toner has a crystalline part originating from the thermoplastic elastomer.