Bio-based Polyester Toner Using Furan Derivatives
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Solution Overview
Problem
There is a need for toner production methods that reduce health risks and environmental impact associated with petroleum-based reagents, particularly in emulsion aggregation processes, while maintaining the performance of conventional toner resins.
Innovation Solution
The development of a bio-based polyester resin using a polyacidic furan moiety, such as 2,5-furan dicarboxylic acid, which is synthesized from renewable sources and integrated into toner compositions to minimize the use of petroleum-based monomers like TPA, BPA, or IPA, and to enhance the bio-based content of toner resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If petroleum-based monomers (TPA, BPA, IPA) are used in emulsion aggregation toner production, then manufacturing performance and resin properties are maintained, but health risks and environmental impact increase
Solution Approach 1:
The patent substitutes petroleum-based monomers with bio-based alternatives (furan derivatives replacing TPA/BPA/IPA), changing the chemical composition parameters while maintaining the functional properties required for toner performance. This parameter substitution resolves the contradiction by eliminating harmful petroleum-based substances while preserving necessary toner characteristics through carefully selected bio-based compounds.
Solution Approach 2:
The invention creates composite resin systems combining bio-based furan derivatives with other compatible polymers and additives to achieve the desired balance between environmental sustainability and performance reliability. The composite approach allows integration of multiple bio-based components that collectively provide both eco-friendliness and functional adequacy for toner application.
2Object-affected harmful factors
If bio-based polyester resin is used to replace petroleum-based resin, then environmental sustainability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs pre-synthesized bio-based polyester resin components that are prepared in advance through controlled polymerization of furan derivatives. By performing the complex chemical synthesis beforehand and producing ready-to-use resin materials, the actual toner manufacturing process is simplified, resolving the contradiction between environmental benefits and manufacturing complexity.
Solution Approach 2:
The invention uses emulsion aggregation as an intermediary process that simplifies the integration of bio-based resin into toner production. The emulsion technique acts as a mediator that handles the complexity of bio-based material processing, allowing straightforward aggregation and toner formation without requiring complex manufacturing modifications.
3Quantity of substance
If furan-based polyester resin is synthesized from renewable sources, then bio-based content is increased, but production cost increases
Solution Approach 1:
The patent utilizes furan derivatives that serve multiple functions: they provide high bio-based content, act as effective polymer building blocks, and enable standard emulsion aggregation processing. This multi-functionality reduces overall production costs by eliminating the need for specialized processing equipment or additional manufacturing steps, despite using renewable feedstocks.
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 bio-based polyester resin exhibits properties similar to conventional materials, including good viscosity transition and glass transition temperature, enabling the production of toners with improved environmental sustainability and reduced health risks, while maintaining performance characteristics.
Implementation Method 1
a bio-based polyol with a polyacidic furan, optionally, in the presence of a catalyst, to form a bio-based polyester resin
Implementation Method 2
optionally adding a flocculent to the composition; aggregating the particles
Implementation Method 3
coalescing the particles
Data Source
AI summary
Methods of making a bio-based polyester resin by polycondensing a polyol with a polyacidic furan are described. The polyol can be a rosin diol obtained by reacting a rosin acid and a glycerol carbonate. The polyacidic furan is obtained from a bio-based product. The resin may be used in manufacturing toner for imaging devices.