Toner Composition with Ester Wax Encapsulation Accelerator
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Solution Overview
Problem
Toner particles with poor dispersibility of low-melting-point wax exhibit uneven distribution, leading to deterioration in heat-resistant storage capability and burn-in on developing rollers.
Innovation Solution
A toner composition featuring styrene-based resin, hydrocarbon-based wax, and ester wax as an encapsulation accelerator, with controlled average dispersion diameters and encapsulation ratios to enhance dispersibility and fixability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a low-melting-point wax is added into toner particles to enhance low-temperature fixability, then fixability is improved, but dispersibility becomes poor leading to uneven distribution on the surface
Solution Approach 1:
The patent introduces a specific resin as an intermediary substance between the low-melting-point wax and the toner particle matrix. This resin acts as a mediator that improves the dispersibility of the wax within the toner particle, preventing uneven distribution on the surface while maintaining the low-temperature fixability enhancement. The resin facilitates compatible integration of the wax into the toner structure.
2Temperature
If low-melting-point wax is exposed on the surface of toner particles to achieve low-temperature fixability, then fixability is improved, but heat-resistant storage capability deteriorates
Solution Approach 1:
The patent applies a nested structure where the low-melting-point wax is encapsulated within the toner particle matrix rather than being exposed on the surface. The wax is embedded inside the resin-based toner structure, creating a protective enclosure. This nested arrangement allows the wax to function for low-temperature fixability while being protected from premature exposure during heat-resistant storage conditions.
3Temperature
If low-melting-point wax is exposed on the surface of toner particles, then low-temperature fixability is achieved, but burn-in on developing roller occurs
Solution Approach 1:
The patent encapsulates the low-melting-point wax within the toner particle structure, preventing its exposure on the surface. The nested arrangement ensures that the wax remains embedded inside the toner particle during the development process, eliminating direct contact with the developing roller and thus preventing burn-in while preserving the low-temperature fixability function.
4Ease of operation
If styrene-based resin is added to impart fluidity to toner, then fluidity is improved, but dispersibility of wax components deteriorates
Solution Approach 1:
The patent employs a composite material system that integrates styrene-based resin for fluidity with specific wax components and dispersing agents. The composite structure combines multiple materials with complementary properties: the styrene-based resin provides fluidity, while the wax components provide low-temperature fixability, and the dispersing agents ensure uniform distribution. This composite approach resolves the contradiction by synergistically combining materials that address both requirements simultaneously.
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 both fixability and heat-resistant storage capability while suppressing burn-in on developing rollers, through improved encapsulation and dispersibility of the wax components.
Implementation Method 1
a styrene-based resin dispersed in the binder resin, a hydrocarbon-based wax dispersed in the styrene-based resin, and an ester wax as an encapsulation accelerator
Data Source
AI summary
A toner with the following configuration includes a toner particle including a binder resin. The toner particle includes a styrene-based resin dispersed in a binder resin, a hydrocarbon-based wax dispersed in the styrene-based resin, and an ester wax as an encapsulation accelerator. The average dispersion diameter of the styrene-based resin is in a range from 200 nm to 900 nm, the average dispersion diameter of the hydrocarbon-based wax is less than the average dispersion diameter of the styrene-based resin and is in a range from 50 nm to 300 nm. The encapsulation ratio, which is the volume ratio of the hydrocarbon-based wax in the dispersed particles of the styrene-based resin, is in a range from 20% to 50%.