Emulsion Aggregation Toner Particles with Polysaccharide Fillers

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Solution Overview

Problem

Conventional toner production methods are energy-inefficient, result in particles with irregular shapes and sizes, and rely on petroleum-based resins that are toxic and environmentally harmful, necessitating a shift to sustainable and non-toxic alternatives.

Innovation Solution

The development of emulsion aggregation toner particles that incorporate polysaccharides as fillers to reduce petroleum-based content, using a process that includes resins, optional waxes, and colorants, achieving desirable particle characteristics and print quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional grinding process is used to produce toner particles, then toner particles can be manufactured, but energy consumption is high and particle shape and size distributions are irregular

Engineering Contradiction:

Improvetoner production efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent replaces the conventional mechanical grinding process with an emulsion aggregation process that uses chemical and physical mechanisms to form toner particles. The process involves forming an emulsion of resin and polysaccharide in water, then using a coagulant to induce aggregation into uniform particles, eliminating the need for high-energy mechanical grinding while achieving consistent particle size and shape distributions

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes phase transitions in the emulsion aggregation process. The emulsion is heated to a temperature above the glass transition temperature of the resin to enable particle coalescence and aggregation, then cooled to freeze the particle size distribution. This controlled phase transition allows energy-efficient particle formation with uniform characteristics

Inventive Principle:

Principle #36Phase transitions

2Reliability

If petroleum-based resins are used in toner compositions, then toner can be manufactured with desired properties, but environmental harm and toxicity increase

Engineering Contradiction:

Improvetoner performanceVSAvoidenvironmental toxicity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent creates a composite toner composition combining petroleum-based resin with bio-based polysaccharide materials. This composite approach reduces the proportion of toxic petroleum-based components while maintaining toner performance through the synergistic properties of both materials. The polysaccharide acts as a filler and structural component that compensates for reduced petroleum resin content

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical composition parameters of the toner by incorporating polysaccharides at specific concentrations (e.g., 1-50 wt%). This parameter change reduces the toxicity profile of the toner while maintaining functional properties through careful optimization of the resin-to-polysaccharide ratio and selection of appropriate polysaccharide types

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional toner production methods are used, then toner can be manufactured, but particle shape and size distributions are irregular requiring sorting

Engineering Contradiction:

Improvemanufacturing throughputVSAvoidparticle uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent performs preliminary action by forming uniform emulsion droplets before the aggregation step. The emulsion preparation process includes controlled mixing and homogenization that ensures uniform droplet size distribution prior to coagulation. This preliminary uniformity in the emulsion phase translates to uniform particle size and shape in the final toner product, eliminating the need for post-production sorting

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses water as an intermediary medium in the emulsion aggregation process. The aqueous emulsion provides a controlled environment where resin and polysaccharide can self-assemble into uniform particles through controlled aggregation. This intermediary liquid phase enables precise control over particle formation, producing uniform size and shape distributions without mechanical grinding

Inventive Principle:

Principle #24Intermediary (Mediator)

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 polysaccharides in toner particles enhances bio-content, reduces petroleum reliance, and produces toners with superior print quality, improved particle shape and size distributions, and environmentally friendly properties.

Implementation Method 1

emulsion aggregation toner particles that include polysaccharides as fillers

Methodology Applied

Scientific EffectEmulsion aggregation: Emulsion

Implementation Method 2

emulsion aggregation methods of making such toner compositions

Methodology Applied

Scientific EffectAggregation: Coagulation

Data Source

PatentUS8178269B2Toner compositions and methods

Publication Date: 2012.05.15 XEROX CORP

AI summary

Emulsion aggregation toner particles including a resin, polysaccharide particles, an optional wax, and an optional colorant. The toner particles contain about 1 to about 50 wt % polysaccharide particles based on the total weight of the toner particles.