Polyester Toner Network Structure for Low-Temperature Fixing
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Solution Overview
Problem
Conventional toner production methods, such as the kneading pulverizing method, face challenges in achieving small particle diameters, uniform particle size distribution, and high-level low temperature fixing ability, leading to issues like high fixing energy consumption, surface wax deposition, and inadequate heat-resistant storage stability.
Innovation Solution
A toner containing a polyester resin with a specific structure, represented by formulas 1) to 3), which includes a branched structure via urethane or urea bonds, forming a uniform three-dimensional network structure to enhance low temperature fixing ability and heat-resistant storage stability, while preventing surface wax deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the kneading pulverizing method is used to produce toners, then the production process is simple, but the particle diameter cannot be made small, the particle size distribution is broad, and the fixing energy required is high
Solution Approach 1:
The invention changes the fundamental production parameter from mechanical kneading and pulverization to chemical polymerization. This allows precise control over particle diameter and size distribution by adjusting polymerization conditions (monomer ratios, catalysts, temperature, time) rather than relying on mechanical breakdown, thereby achieving small and uniform particles while maintaining ease of manufacture through a standardized chemical process
Solution Approach 2:
The invention replaces the mechanical kneading and pulverization system with a chemical polymerization system. Instead of mechanically breaking down materials into particles, the system uses chemical reactions to directly form particles with controlled size and distribution, eliminating the trade-off between manufacturing simplicity and particle precision
2Reliability
If wax is added to improve fixing ability, then releasing effects are obtained, but the toners are cracked at the interfaces with the wax upon pulverization, so that much of the wax is present on the toner surface causing deposition
Solution Approach 1:
The invention performs preliminary encapsulation of the wax (release agent) within the toner particle core before the polymerization process completes. This preliminary action prevents wax from being exposed on the surface during subsequent handling, thereby maintaining releasing effects while preventing deposition on carriers and photoconductors
Solution Approach 2:
The invention creates a nested structure where the wax (release agent) is enclosed within the toner particle, similar to nested dolls. The polymer matrix forms an outer layer that contains the wax core, preventing wax exposure on the surface while preserving the releasing function when needed
3Temperature
If a crystalline polyester resin is used to lower melting temperature for low temperature fixing, then the fixing temperature is lowered, but the non-crystalline polyester resin does not melt, so the toner is not fixed
Solution Approach 1:
The invention applies local quality by creating a heterogeneous resin composition where crystalline polyester resin particles (which melt at low temperature) are distributed within a non-crystalline polyester resin matrix. The crystalline regions provide low-temperature melting for initial fixation, while the non-crystalline regions provide continuous binding, ensuring complete and reliable fixing
4Manufacturing precision
If the particle diameter is reduced to improve image quality, then the quality of output images improves, but the fixing energy required increases
Solution Approach 1:
The invention uses composite materials by combining multiple resin types (crystalline polyester and non-crystalline polyester) with specific glass transition temperatures and melting points. This composite structure allows small particle diameter for image quality while the specific material composition reduces the fixing energy required by optimizing the thermal behavior of the toner particles
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 results in a toner that achieves high-level low temperature fixing ability, hot offset resistance, high glossiness, and heat-resistant storage stability without causing filming, thereby improving image quality and fixing performance.
Implementation Method 1
a polyester resin having a significantly low glass transition temperature
Implementation Method 2
when both the crystalline polyester resin and the non-crystalline polyester resin melt to some extent
Implementation Method 3
the reactive precursor is non-linear, and thus a network structure is formed, where the network structure contains branched structures in the molecular skeleton, and contains three-dimensional molecular chains
Data Source
AI summary
A toner, including: a polyester resin, wherein the polyester resin has a structure represented by any one of formulas 1) to 3) below: 1) R1-(NHCONH-R2)n-, 2) R1-(NHCOO-R2)n-, and 3) R1-(OCONH-R2)n-, where n is 3 or more, R1 represents an aromatic organic group or an aliphatic organic group, and R2 represents a group derived from a resin that is polyester formed of polycarboxylic acid, polyol, or both thereof; or that is a modified polyester obtained by modifying polyester with isocyanate.