Monoester Wax Toner Offset Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional toners with high wax content face issues with insufficient fixability and releasability due to poor wax dispersion, leading to offset problems and contamination during the printing process.
Innovation Solution
A toner prepared by wet granulation methods using a monoester wax with 36 to 46 carbon atoms, where the wax is finely dispersed and controlled using hexane extraction to limit wax exposure on the surface, ensuring optimal fixability and preventing offset.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a large amount of wax is added to improve offset prevention, then offset prevention capability is improved, but wax dispersion becomes poor leading to insufficient fixability and contamination
Solution Approach 1:
The patent changes the chemical parameters of the wax by specifying a carbon atom number range of 36-46 and using monoester wax with particular chemical structure. This parameter optimization enables the wax to achieve both high concentration incorporation (up to 10% by weight) and uniform dispersion, resolving the contradiction between offset prevention and dispersion uniformity
Solution Approach 2:
The patent creates a composite toner system combining polyester resin with specifically selected monoester wax (carbon atoms 36-46). This composite material approach allows the wax and resin to be compatible at molecular level, achieving uniform dispersion while maintaining high wax content for offset prevention
2Object-affected harmful factors
If wax concentration is increased to improve offset prevention, then offset prevention is improved, but releasability deteriorates due to excessive wax exposure on surface
Solution Approach 1:
The patent optimizes the carbon atom number parameter of the monoester wax to 36-46, which controls the wax's melting point and surface activity. This parameter control ensures that while sufficient wax is present for offset prevention, the surface exposure is limited to optimal levels that maintain releasability
Solution Approach 2:
The patent creates non-uniform wax distribution with higher concentration in the interior and controlled lower exposure on the surface. This local quality differentiation allows the bulk wax to provide offset prevention while surface wax exposure is limited to maintain releasability
3Object-affected harmful factors
If non-polar wax with low melt viscosity is used to prevent offset, then offset prevention is improved, but compatibility with polar binder resin decreases making dispersion difficult
Solution Approach 1:
The patent selects monoester wax with carbon atoms 36-46, which has optimal polarity and melting point parameters. This parameter selection balances the non-polar characteristics needed for offset prevention with sufficient polarity for compatibility with polyester resin, enabling uniform dispersion
Solution Approach 2:
The patent achieves homogeneous mixing of wax and polyester resin by selecting monoester wax with appropriate polarity parameters. The selected wax composition is compatible with the polar polyester resin at molecular level, creating a homogeneous dispersion without phase separation
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 solution effectively prevents wax exposure on the toner surface, enhancing fixability and releasability while maintaining high wax content, thus improving image quality and reducing contamination risks.
Implementation Method 1
dissolving a release agent in n-hexane
Implementation Method 2
separated by hexane extraction from the toner
Implementation Method 3
having a DSC endothermic energy amount originating from the wax
Data Source
AI summary
A toner is prepared by wet granulation methods, including a monoester wax having carbon atoms of from 36 to 46 on average as a release agent. The toner has a DSC endothermic energy amount (ΔH1) originating from the wax of from 10 to 12 mJ/mg and a DSC endothermic energy amount (ΔH2) originating from the wax of from 0.6 to 0.9 times as much as ΔH1 after a part of the wax is separated by hexane extraction from the toner. The hexane extraction includes mixing 1 g of the toner in 7 ml of n-hexane to prepare a mixture; stirring the mixture at 120 rpm for 1 min by a pot mill to prepare a dispersion; and subjecting the dispersion to suction filtration.