Rosin-Based Polyester Toner for Renewable Resource Fusing
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Solution Overview
Problem
There is a need for improved resins and toner compositions that are derived from renewable resources, do not contain bisphenol-A, and offer good fusing and electrical performance, with concurrent requirements for high yield, small particle size, controlled morphology, and a narrow particle size distribution, particularly for emulsion aggregation toners.
Innovation Solution
The development of polyester resins derived from rosin-based materials, including rosin diacids, rosin acid esters, and rosin diols, which are either esters of functionalized rosins or dimerized rosins, used in toner compositions for emulsion aggregation processes, allowing for the creation of toners with specific properties such as core-shell structures and controlled particle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional petroleum-based resins are used in toner compositions, then good fusing and electrical performance can be achieved, but the toners are not derived from renewable resources and may contain bisphenol-A
Solution Approach 1:
The patent changes the chemical composition parameters by using rosin-based polyester resins with specific molecular weight ranges (Mn: 5,000-50,000; Mw: 50,000-300,000) and controlled polydispersity (Mw/Mn: 1.05-2.0). This maintains the necessary fusing and electrical performance while transitioning from petroleum-based to renewable resource-based materials.
Solution Approach 2:
The patent creates composite resin systems by combining rosin-based polyesters with other compatible resins and additives in specific ratios. This composite approach ensures that the toner composition achieves the required performance characteristics while being derived from renewable resources and free from bisphenol-A.
2Productivity
If emulsion aggregation process is used to prepare toners, then high yield and controlled particle morphology can be achieved, but narrow particle size distribution and small particle size require precise control
Solution Approach 1:
The patent optimizes emulsion aggregation process parameters including resin molecular weight (Mn: 5,000-50,000), polydispersity (Mw/Mn: 1.05-2.0), and process conditions to achieve the desired particle size distribution (GSD: 1.05-1.30) and morphology while maintaining high yield production.
Solution Approach 2:
The patent performs preliminary resin synthesis with controlled molecular characteristics before the emulsion aggregation step. By pre-controlling the resin's Mn, Mw, and Mw/Mn ratio, the process ensures that subsequent aggregation yields particles with narrow size distribution and consistent morphology, reducing the need for extensive post-processing.
3Reliability
If rosin-based polyester resins are synthesized with specific molecular weight and polydispersity, then good fusing performance is achieved, but the synthesis process requires precise control
Solution Approach 1:
The patent establishes specific parameter ranges for rosin-based polyester synthesis: Mn (5,000-50,000), Mw (50,000-300,000), and Mw/Mn ratio (1.05-2.0). These parameter specifications ensure optimal fusing performance while providing clear manufacturing targets for quality control.
Solution Approach 2:
The patent implements quality control mechanisms that monitor and adjust synthesis parameters during resin production. By measuring molecular weight and polydispersity and providing feedback to the synthesis process, the system maintains consistent resin properties that deliver reliable fusing performance.
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 rosin-based polyester resins provide toners with enhanced fusing performance, electrical properties, and controlled particle morphology, meeting the requirements of high yield and narrow particle size distribution, while being derived from renewable sources and avoiding bisphenol-A.
Implementation Method 1
a polyester resin comprising the polycondensation product of: (a) at least one diacid, acid ester, or diester; and (b) at least one diol
Data Source
AI summary
Disclosed is a polyester resin comprising the polycondensation product of (a) at least one diacid, acid ester, or diester; and (b) at least one diol; wherein either (i) at least one diacid, acid ester, or diester comprises a rosin diacid, rosin acid ester, or rosin diester; or (ii) at least one diol comprises a rosin diol, and wherein at least one of the rosin diacid, rosin acid ester, rosin diester, or rosin diol is either (A) an ester of a functionalized rosin or an ester of a reduced functionalized rosin, or (B) a dimerized rosin. Also disclosed is a toner composition comprising particles which comprise the disclosed polyester resin and an optional colorant.