Emulsion Aggregation Toner for Flexible Packaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional toner processes for flexible packaging result in high toner pile heights, leading to wavy rolls that are unusable for subsequent packaging operations, and there is a need for smaller emulsion aggregation toners suitable for low melt applications.
Innovation Solution
The development of small particle-sized low melt emulsion aggregation toners with a core-shell configuration, using unsaturated polyester resins and photoinitiators, optimized for particle size, aggregating agent, and solids content, which can be cured using UV light or infrared emitters for low fixing temperatures and improved document offset properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional toner processes are used for flexible packaging, then high surface coverage is achieved, but toner pile height becomes very high (12-14 microns) causing wavy rolls
Solution Approach 1:
The patent changes the particle size parameter from conventional larger sizes to specifically 3-4 microns, which fundamentally alters the pile height characteristic. This parameter change enables the toner to achieve high surface coverage while maintaining low pile height (1-6 microns), eliminating the wavy roll problem in flexible packaging applications
2Length of moving object
If smaller particle size toners (3-4 microns) are used for flexible packaging, then low pile height is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent optimizes the emulsion aggregation process parameters including emulsion particle size, aggregating agent type and amount, and solids content to specifically produce 3-4 micron toner particles. This systematic parameter optimization achieves the desired low pile height while maintaining manufacturability through controlled emulsion aggregation rather than requiring ultra-precision manufacturing
3Temperature
If emulsion aggregation toners with photoinitiators are used, then low melt applications and low fixing temperatures are achieved, but UV curing requirements are introduced
Solution Approach 1:
The patent incorporates photoinitiators into the toner composition, enabling UV-induced curing at low temperatures. This chemical modification allows the toner to be cured using UV light rather than high-temperature heating, achieving low melt applications suitable for flexible packaging while using a relatively simple UV curing mechanism
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 toners achieve a low toner pile height of 1-6 microns, allowing for flexible packaging applications with improved temperature resistance, solvent resistance, and reduced document offset, while maintaining high temperature document offset properties and resistance to organic solvents.
Implementation Method 1
a photoinitiator capable of initiating crosslinking of said unsaturated polymeric resin
Implementation Method 2
a fuser member for fusing said toner to said flexible substrate via light at a wavelength of from 200 nm to 4000 nm
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2~3
AI summary
Processes for producing emulsion aggregation toners are provided. In embodiments, methods of the present disclosure may be utilized to produce toners suitable for low melt applications, including use in flexible packaging applications, where low pile height is desired for low cost and flexibility. In embodiments, the EA toners may be prepared by optimizing the particle size of the emulsion, the choice of and amount of aggregating agent utilized, and the solids content of the emulsion.