Polyester Resin Binder Composition for Polypropylene Film Toner Adhesion
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Solution Overview
Problem
Conventional toners developed for paper media struggle to fuse effectively onto polypropylene (PP) films due to differences in polarity and surface conditions, leading to poor adhesion and image quality.
Innovation Solution
A resin binder composition for toners is developed, incorporating a polyester-based resin and a polypropylene-based wax with a controlled endothermic amount ratio and particle size distribution, which enhances the fusing properties and transparency of the toner on PP films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional toners designed for paper media are used, then they can achieve good adhesion and image quality on paper, but they fail to fuse effectively on polypropylene films due to polarity and surface condition differences
Solution Approach 1:
The patent modifies the chemical composition parameters of the toner by incorporating specific polyester resins with controlled hydroxyl values and polypropylene-based waxes with specific melting points. This changes the polarity and surface interaction characteristics of the toner, enabling it to adapt to both polar paper surfaces and non-polar polypropylene surfaces while maintaining reliable fusing performance across different media types
Solution Approach 2:
The patent creates a composite binder system combining polyester resin (providing adhesion to polar surfaces) with polypropylene-based wax (providing compatibility with non-polar surfaces). This composite material approach allows the toner to achieve universal adaptability to different printing media while maintaining consistent fusing reliability through the synergistic interaction of the two material components
2Reliability
If the endothermic amount ratio of polypropylene-based wax is not controlled, then the fusing properties on PP films are poor, but controlling it requires precise measurement and formulation
Solution Approach 1:
The patent establishes specific parameter ranges for the endothermic amount ratio (ΔHCW/ΔHW) of polypropylene-based wax to polyester-based resin, along with corresponding hydroxyl value ranges and wax content ranges. By defining these parameter boundaries, the patent enables reliable fusing properties through controlled variation within specified limits, making the formulation process more manageable while ensuring consistent performance on PP films
3Strength
If wax particle size is not optimized, then dispersion in polyester resin is poor leading to poor adhesion, but achieving optimal dispersion requires complex processing
Solution Approach 1:
The patent specifies optimal particle size ranges for polypropylene-based wax (D50: 1-10 μm, D10: 0.1-1 μm, D90: 10-20 μm) to achieve effective dispersion in polyester resin without requiring complex processing equipment. This parameter optimization enables strong adhesion through improved interfacial contact between wax and resin while keeping the dispersion process simple and manufacturable
Solution Approach 2:
The patent performs preliminary size reduction and classification of polypropylene-based wax before dispersion into the polyester resin. By pre-processing the wax to achieve the target particle size distribution, the patent simplifies the subsequent dispersion step and ensures optimal adhesion properties without requiring complex in-situ dispersion equipment or multi-stage processing
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 resin binder composition improves the adhesion and image quality of toners on PP films by optimizing the crystallization and dispersion of the wax within the polyester resin, resulting in enhanced fusing properties and transparency of the printed material.
Implementation Method 1
the resin binder composition has an endothermic amount ratio ΔHCW/W of not less than 0.10 and not more than 0.80... ΔHCW is an endothermic amount of a melting endothermic peak per 1 g of the polypropylene-based wax (W-1) as measured with respect to the resin binder composition
Implementation Method 2
ΔHCW is an endothermic amount of a melting endothermic peak per 1 g of the polypropylene-based wax (W-1) as measured with respect to the resin binder composition; and ΔHW is an endothermic amount of a melting endothermic peak per 1 g of the polypropylene-based wax (W-1) as measured with respect to the polypropylene-based wax (W-1) singly
Implementation Method 3
a volume-median particle size (D50) of a small particle size component of the wax as measured by a dynamic light scattering method using a dispersion S of the small particle size component of the wax which is prepared by the following Method 2 is not less than 20 nm and not more than 400 nm; and a content of the small particle size component of the wax is not less than 20% by mass and not more than 90% by mass
Data Source
AI summary
The present invention provides a toner for development of electrostatic images including a polyester-based resin and a polypropylene-based wax, which is excellent in fusing properties on a polypropylene film. The present invention relates to [1] a resin binder composition for toners for development of electrostatic images which has an endothermic amount ratio ΔHCW/W of not less than 0.10 and not more than 0.80, [2] a resin binder composition for toners for development of electrostatic images in which a volume-median particle size (D50) of a wax as a whole contained therein is not less than 1 μm and not more than 50 μm; a volume-median particle size (D50) of a small particle size component of the wax is not less than 20 nm and not more than 400 nm; and a content of the small particle size component in the wax is not less than 20% by mass and not more than 90% by mass, [3] a process for producing a resin binder composition for toners for development of electrostatic images in which a polypropylene-based wax is added to a reaction system prior to addition polymerization upon production of a composite resin as a resin binder; and [4] a toner for development of electrostatic images including the resin binder composition as described in the above [1] or [2].