Self-Emulsifying Granules for Solvent-Free Polyester Toner Production
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Solution Overview
Problem
Current methods for producing polyester toners require solvent-based processes, which are environmentally unfriendly and pose operational challenges due to the use of water, leading to increased production costs and resin property issues.
Innovation Solution
A solvent-free process involving a polyester resin, a highly concentrated surfactant, and a solid neutralizing agent, such as monocyclic or polycyclic compounds with nitrogen atoms, is used to form self-emulsifying granules that can be converted into latex emulsions without water, reducing production stages and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based processes are used to prepare polyester toners, then resin dissolution and emulsion formation are achieved, but environmental harm increases and production costs increase due to solvent distillation requirements
Solution Approach 1:
The invention extracts and eliminates organic solvents from the emulsion preparation process. Instead of using solvent-based dissolution followed by energy-intensive distillation, the process directly forms emulsions from polyester resins using aqueous surfactant solutions, removing the harmful solvent component entirely while maintaining emulsion formation capability
Solution Approach 2:
The invention changes the physical-chemical parameters of the emulsion preparation process by using aqueous-based systems instead of organic solvent systems. This parameter change eliminates the need for solvent distillation, reduces environmental harm, and lowers production costs while achieving the same emulsion formation objective
2Object-affected harmful factors
If water is added to thermally softened resin for solventless emulsification, then latex emulsions are formed without organic solvents, but resin properties deteriorate and operational challenges arise
Solution Approach 1:
The invention introduces a surfactant as an intermediary substance between the polyester resin and water. The surfactant facilitates emulsion formation by reducing surface tension and enabling stable dispersion of resin particles in aqueous medium, thereby preventing direct adverse interactions between water and resin that would otherwise deteriorate resin properties
Solution Approach 2:
The surfactant system enables the emulsion preparation process to be self-sufficient without requiring organic solvents. The surfactant molecules self-assemble at the resin-water interface, providing steric or electrostatic stabilization that maintains resin properties while achieving solventless emulsification
3Reliability
If neutralizing agents and surfactants are added as separate solutions, then resin neutralization and emulsion stabilization are achieved, but process complexity increases and production efficiency decreases
Solution Approach 1:
The invention merges the neutralizing agent and surfactant into a single combined composition. This unified formulation performs both neutralization of carboxylic acid groups and emulsion stabilization simultaneously, eliminating the need for separate addition steps and reducing overall process complexity while maintaining both functions effectively
4Ease of manufacture
If multiple process stages are used for toner production, then resin processing and emulsion formation are achieved, but production time increases and productivity decreases
Solution Approach 1:
The invention performs preliminary preparation of the combined neutralizing agent-surfactant composition before the main emulsion formation process. This pre-prepared composition is then added in a single step to thermally softened resin, consolidating multiple operations into fewer stages and significantly improving production speed and efficiency
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
This process enhances the production efficiency, reduces environmental impact, and maintains the molecular weight properties of the resin, resulting in toners with improved flow properties and stability, while eliminating the need for water in the extrusion process.
Implementation Method 1
contacting a polyester resin with a highly concentrated surfactant, and a solid neutralizing agent selected from the group consisting of monocyclic compounds containing one or more nitrogen atoms, polycyclic compounds containing one or more nitrogen atoms, and combinations thereof, in the absence of water and an organic solvent to form a mixture; melt mixing the mixture; forming a self-emulsifying composite of the melt mixed mixture
Implementation Method 2
A self-emulsifiable granule of the present disclosure includes at least one polyester resin in the absence of an organic solvent and water; a highly concentrated surfactant; and a solid neutralizing agent selected from the group consisting of monocyclic compounds containing one or more nitrogen atoms, polycyclic compounds containing one or more nitrogen atoms, and combinations thereof; and wherein the self-emulsifiable granule forms a latex emulsion upon contact with water
Data Source
AI summary
A process for making a self-emulsifying composite suitable for use in forming latex emulsions includes contacting a resin with a solid or highly concentrated surfactant, a solid neutralizing agent in the absence of water and an organic solvent to form a mixture, melt mixing the mixture, and forming a self-emulsifying composite of the melt mixed mixture such as a granule. Self-emulsifying granules are also provided and configured to form a latex emulsion when added to water, which may then be utilized to form a toner.