Naphthalenic Polyester Toner for Oil-less Fusing
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Solution Overview
Problem
Current polyester-based toners derived from Bisphenol A pose environmental concerns due to its endocrine-disrupting properties, and toners made from alternative resins like terephthalic-glycol have poor electrical performance and high relative humidity sensitivity, necessitating the development of environmentally friendly toners with improved carbon/oxygen ratios and stable charge characteristics for use in oil-less fusing applications.
Innovation Solution
The development of toners using polyester resins derived from naphthalenic materials, 2,2-ethyl-butyl-1,3-propanediol, and 2-alkyl succinic materials, which are synthesized through melt polycondensation or emulsion aggregation processes, ensuring a carbon/oxygen ratio of 4 to 9, stable charge, and low relative humidity sensitivity, while eliminating the need for fusing oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If toners are made from alternative resins like terephthalic-glycol to eliminate Bisphenol A, then environmental safety is improved, but electrical performance deteriorates and relative humidity sensitivity increases
Solution Approach 1:
The patent changes the chemical composition parameters of the polyester resin by using specific monomers (terephthalic acid, glycol, and/or styrene) in controlled ratios to achieve a carbon/oxygen ratio of at least 4.0, which simultaneously improves electrical performance and reduces humidity sensitivity while maintaining environmental safety
Solution Approach 2:
The patent creates a composite resin system combining multiple monomers (terephthalic acid, glycol, and styrene) in specific proportions to achieve both environmental compatibility and superior electrical properties, resolving the trade-off between eco-friendliness and performance
2Reliability
If carbon/oxygen ratio is increased to at least 4.0 to improve electrical performance, then charge stability is improved, but resin composition complexity increases
Solution Approach 1:
The patent systematically adjusts the carbon/oxygen ratio parameter by selecting specific monomer combinations and their ratios, achieving charge stability through a clear quantitative guideline (C/O ratio ≥ 4.0) without requiring complex multi-parameter optimization
3Reliability
If glass transition temperature is controlled to 50-65°C to prevent hot offset, then toner performance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent establishes a clear target range for glass transition temperature (50-65°C) and provides specific monomer ratio guidelines to achieve this range consistently, balancing performance improvement with manufacturable precision requirements
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 resulting toners exhibit improved electrical characteristics, stable charge, and low relative humidity sensitivity, making them suitable for high-speed printing applications without the need for costly fuser oils, thus addressing environmental and performance issues of previous toner technologies.
Implementation Method 1
aggregating said resulting mixture of amorphous polyester resin particles, crystalline polyester resin particles, and colorant including from about 25 to about 45 weight percent solids dispersion and wax dispersion with a coagulant at a pH of from about 2.5 to about 4
Implementation Method 2
shearing the resulting mixture with a homogenizer at from about 2,000 to about 10,000 rpm
Implementation Method 3
heating the resulting aggregate composite to a temperature below the onset melting point of the crystalline resin to enable coalescence
Implementation Method 4
freezing said aggregate size by the addition of alkaline base at a pH of from about 6.3 to about 9
Data Source
AI summary
Embodiments include a toner having a) a polyester resin derived from a naphthalenic material, a 2-alkyl succinic material, and 2,2-ethyl-butyl-1,3-propanediol, b) a wax, and c) an optional colorant.