Emulsion Aggregation Toner with Small Molecule Plasticizers
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Solution Overview
Problem
Current toner compositions, particularly Ultra-Low-Melt (ULM) emulsion aggregation (EA) toners, have limitations in achieving a low Crease Fix Minimum Fusing Temperature (MFT), which restricts energy efficiency and fuser life in electrophotographic processes.
Innovation Solution
Incorporating small molecule crystalline organic compounds with a molecular weight less than 1,000 g/mol and a melting point below the fusing temperature of the emulsion aggregation toner, these compounds are mixed with an amorphous polymeric resin to reduce the glass transition temperature and minimize solid to liquid phase transition, resulting in a toner with enhanced low-melt properties.
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, but further reduction in MFT cannot be achieved
Solution Approach 1:
The patent changes the chemical composition parameters of the toner by incorporating specific small molecule plasticizers (molecular weight 100-500 g/mol) and adjusting the resin composition (polyester:polyimide ratio), which modifies the glass transition temperature and melting behavior to achieve MFT below -20°C while maintaining adhesion stability
Solution Approach 2:
The patent creates a composite toner system combining amorphous polyester resin, polyimide resin, and small molecule plasticizers in specific proportions, where the synergistic interaction of these components enables simultaneous achievement of low MFT and stable toner adhesion that cannot be obtained with single-component systems
2Temperature
If small molecule plasticizers are added to reduce glass transition temperature, then crease fix MFT is lowered, but solid to liquid phase transition may occur
Solution Approach 1:
The patent carefully controls the molecular weight parameter of the plasticizer (100-500 g/mol) and its concentration in the toner formulation to modify the glass transition temperature without inducing significant solid to liquid phase transition, achieving the desired balance between low MFT and compositional stability
Solution Approach 2:
The patent uses small molecule plasticizers that act as temporary modifiers during the fusing process, providing the necessary low-temperature flexibility without forming stable crystalline structures that would cause phase transition issues, effectively sacrificing long-term structural stability for short-term processing performance
3Use of energy by moving object
If fuser energy is reduced to extend fuser life, then energy consumption is lowered, but toner adhesion may be compromised
Solution Approach 1:
The patent modifies the thermal parameters of the toner through plasticizer addition, lowering the glass transition temperature and melting point so that toner adhesion can be achieved at reduced fuser temperatures, thereby enabling lower energy consumption while maintaining reliable toner transfer
Solution Approach 2:
The small molecule plasticizers act as intermediary substances that facilitate toner adhesion at lower temperatures by modifying the intermolecular forces and chain mobility in the toner binder, enabling successful toner transfer without requiring high fuser energy input
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 approach achieves a crease fix MFT comparable to or lower than existing ULM EA toners, reducing energy consumption and extending fuser life by optimizing toner adhesion and fusing conditions.
Implementation Method 1
a reduction in glass transition temperature from that of the amorphous resin
Implementation Method 2
small molecule plasticizers... compatible with toner binder resins to provide low crease fix fix minimum fusing temperature
Implementation Method 3
a melting point that is less than the fusing temperature of the emulsion aggregation toner
Implementation Method 4
lack of a significant solid to liquid phase transition peak for the small molecule crystalline organic compound
Implementation Method 5
as determined by differential scanning calorimetry, the enthalpy of fusion for the small molecule crystalline organic compound in the mixture being measured
Data Source
AI summary
An emulsion aggregation (EA) toner includes an amorphous polymeric resin, optionally a colorant, and a small molecule crystalline organic compound having molecular weight less than 1,000 g/mol and melting point less than the fusing temperature of the EA toner, wherein a mixture of the resin and the small molecule compound is characterized by a reduction in glass transition temperature from that of the resin and by the lack of a significant solid to liquid phase transition peak for the small molecule compound as determined by differential scanning calorimetry, the enthalpy of fusion for the small molecule compound in the mixture being measured to be less than 10% of the enthalpy of fusion of the compound in pure form. Furthermore, the EA 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.