Polymerized Toner Initiation via Bifunctional Peroxy Ester
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Solution Overview
Problem
The existing methods for producing toners by suspension polymerization face challenges such as polymerization inhibition by colorants, residual unreacted monomers, and decomposition products from polymerization initiators, leading to image quality degradation and triboelectric charging instability.
Innovation Solution
A method using a bifunctional peroxy ester organic peroxide as a polymerization initiator with a specific structure, represented by General Formula (1), is employed to optimize the polymerization process, reducing polymerization inhibition and enhancing the utilization efficiency of the initiator, thereby minimizing residual decomposition products and improving triboelectric charging stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional polymerization initiator is used in suspension polymerization, then the polymerization reaction can proceed, but polymerization inhibition occurs due to colorants and decomposition products remain in the toner particles
Solution Approach 1:
The patent changes the chemical structure parameters of the polymerization initiator by specifying that R1 and R2 are aliphatic hydrocarbon groups with 1-6 carbon atoms and R3 is an aliphatic hydrocarbon group with 3-12 carbon atoms. This structural modification reduces polymerization inhibition by colorants and minimizes decomposition product residues, resolving the contradiction between achieving complete polymerization and avoiding harmful residues.
Solution Approach 2:
The patent applies local quality by making different parts of the initiator molecule have different properties: the R1 and R2 groups (with 1-6 carbon atoms) provide one set of characteristics while the R3 group (with 3-12 carbon atoms) provides another. This differentiated structure allows the initiator to function effectively while reducing harmful decomposition products.
2Manufacturing precision
If the polymerization reaction is enhanced to reduce unreacted monomer, then more polymerization initiator is needed, but this increases decomposition product residues
Solution Approach 1:
The patent optimizes the initiator structure parameters to achieve high monomer conversion rates without proportionally increasing decomposition products. The specific carbon atom ranges for R1, R2, and R3 groups create an initiator that is highly efficient at promoting polymerization while maintaining low residue levels, resolving the contradiction between conversion rate and residue formation.
3Productivity
If conventional initiators are used, then production can proceed, but unreacted monomer remains leading to charge amount nonuniformity and fogging
Solution Approach 1:
The patent modifies the initiator structure parameters (R1-R3 group definitions) to achieve near-complete monomer conversion, which ensures uniform charge distribution on toner particles and prevents fogging. This structural optimization maintains production efficiency while significantly improving charge uniformity and image quality.
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 method effectively suppresses polymerization inhibition, reduces residual unreacted monomers and decomposition products, and enhances the triboelectric charging stability of toner particles, resulting in improved long-term image quality and reduced contamination risks.
Implementation Method 1
a polymerization initiator having a specific structure is used, thereby effects of the polymerization inhibiting substances are suppressed and utilization efficiency of the polymerization initiator is improved
Implementation Method 2
utilization efficiency of the polymerization initiator is improved
Data Source
AI summary
The present invention provides a method for producing a toner that can suppress the production of the decomposition products derived from a polymerization initiator, and can suppress the remaining presence, in the toner particles, of the unreacted polymerizable monomer and decomposition product residues. On the basis of this method, the present invention provides a toner that is excellent in triboelectric charging stability and can yield stable images over a long term. The present invention provides a method for producing a polymerized toner including a step of producing a polymerized toner particle by dispersing in an aqueous medium a polymerizable monomer composition including at least a polymerizable monomer and a colorant and by polymerizing the polymerizable monomer by using a polymerization initiator in the aqueous medium, the method being characterized in that the polymerization initiator has a structure represented by the following General Formula:(wherein R1 and R2 each independently represent an optionally branched or substituted aliphatic hydrocarbon group having 1 to 6 carbon atoms, and R3 represents an optionally branched aliphatic hydrocarbon group having 3 to 12 carbon atoms).