PET-Structured Toner Binder Balancing Fixing and Separability
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Solution Overview
Problem
Existing toners using recycled PET bottles face issues with low-temperature fixability, separability from fixing members, and curling resistance in high-speed printing apparatuses due to compatibility and viscosity challenges with amorphous and crystalline polyesters, and hydrocarbon waxes.
Innovation Solution
A toner formulation with an amorphous resin containing a polyethylene terephthalate structure and specific alkyl or alkenyl groups, combined with a crystalline polyester and metal elements like calcium, magnesium, sodium, or barium, to enhance compatibility, dispersibility, and elasticity, ensuring low-temperature fixability and curling resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an amorphous polyester containing polyethylene terephthalate structure is used as binder resin, then low-temperature fixability is improved, but separability from fixing member deteriorates
Solution Approach 1:
The patent modifies the chemical structure parameters of the amorphous polyester by introducing specific units (formulae 1-4) with long-chain hydrocarbon groups to reduce polarity and improve compatibility with hydrocarbon wax release agents, thereby maintaining separability while preserving low-temperature fixability
Solution Approach 2:
The patent creates a composite binder resin system combining modified amorphous polyester with crystalline polyester in specific ratios, where the crystalline polyester provides structural integrity for separability while the modified amorphous polyester enables low-temperature fixation
2Temperature
If polyethylene terephthalate structure is introduced into amorphous polyester, then low-temperature fixability is improved, but compatibility with crystalline polyester deteriorates
Solution Approach 1:
The patent changes the chemical parameters of amorphous polyester by incorporating units with long-chain hydrocarbon groups (formulae 1-4) that reduce the polarity of polyethylene terephthalate structure, improving compatibility with crystalline polyester while maintaining low-temperature fixability
Solution Approach 2:
The patent introduces specific functional units (formulae 1-4) at controlled proportions (5-50 mol%) within the amorphous polyester structure to locally modify polarity characteristics and improve compatibility without compromising overall low-temperature fixation capability
3Temperature
If amorphous polyester with polyethylene terephthalate structure is used, then low-temperature fixability is improved, but rigidity decreases leading to poor separability
Solution Approach 1:
The patent forms a composite system where crystalline polyester (30-70 parts) provides rigidity and structural strength for separability, while modified amorphous polyester (70-30 parts) contributes low-temperature fixation, achieving both requirements simultaneously
Solution Approach 2:
The patent modifies the amorphous polyester structure to reduce excessive softness by incorporating units with long-chain hydrocarbon groups, balancing rigidity for separability while preserving low-temperature fixability
4Reliability
If hydrocarbon wax is used as release agent, then separability is improved, but compatibility with amorphous polyester containing polyethylene terephthalate structure deteriorates
Solution Approach 1:
The patent reduces the polarity parameters of amorphous polyester by introducing units with long-chain hydrocarbon groups (formulae 1-4), improving compatibility with low-polarity hydrocarbon wax release agents and enhancing separability
Data Source
AI summary
A toner includes toner particles containing a binder resin and a release agent. The binder resin contains an amorphous resin A and a crystalline polyester C. The amorphous resin A is a polyester and has, as a structure that forms a polyester backbone, (i) a polyethylene terephthalate structural moiety and (ii) a unit having a specified structure. An SP value of the amorphous resin A is represented by SPA, an SP value of the crystalline polyester C is represented by SPC, and a formula 1.00≤SPA-SPC≤1.35 is satisfied. The toner contains at least one metal element selected from the metal element group consisting of calcium, magnesium, sodium, and barium and contains aluminum.