Self-Emulsifying Polyester Granules for Solvent-Free Toner Production
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Solution Overview
Problem
Current methods for producing polyester toners require solvent-based processes, leading to environmental concerns due to the use of large amounts of organic solvents and energy-intensive distillation, and lack efficient methods for reducing production stages and materials.
Innovation Solution
A process involving the formation of self-emulsifying granules by contacting a resin with a highly concentrated surfactant and a neutralizing agent in the absence of organic solvents, followed by melt mixing and forming granules that can self-emulsify upon contact with water to create a latex emulsion, reducing the need for solvent-based processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based processes are used to dissolve resins and form latex emulsions, then the resins can be effectively formulated into toners, but large amounts of organic solvents are consumed and energy-intensive distillation is required
Solution Approach 1:
The invention extracts and removes the organic solvent component from the emulsion formulation process. Instead of using conventional solvent-based systems, the patent employs a water-based self-emulsifying system where the resin particles directly form stable emulsions without requiring organic solvents for dissolution, thereby eliminating solvent consumption and associated distillation steps
Solution Approach 2:
The invention changes the fundamental parameter of the emulsion system from organic-solvent-based to water-based. By modifying the continuous phase from organic solvents to water and utilizing self-emulsifying resin particles, the system achieves effective resin formulation while eliminating the need for organic solvents and energy-intensive distillation processes
2Ease of manufacture
If solvent-based processes are used with subsequent distillation, then latex emulsions can be formed, but energy-intensive distillation is required to remove solvents
Solution Approach 1:
The invention extracts and eliminates the distillation step from the manufacturing process by using a water-based self-emulsifying system. The resin particles naturally form stable emulsions in water without requiring organic solvents, thereby removing the need for energy-intensive distillation to eliminate solvent residues
Solution Approach 2:
The resin particles possess self-emulsifying properties that enable them to automatically form stable latex emulsions in water without requiring external solvent removal processes. This self-service capability eliminates the need for distillation, significantly reducing energy consumption while maintaining effective latex emulsion formation
3Productivity
If conventional emulsion processes are used, then resin particles can be formed, but multiple stages and materials are required increasing production complexity
Solution Approach 1:
The invention merges multiple conventional process stages into a single integrated step. By using self-emulsifying resin particles that directly form stable water-based emulsions, the patent combines resin dissolution, emulsion formation, and stabilization into one step, eliminating the need for separate solvent addition, mixing, and distillation stages
Solution Approach 2:
The self-emulsifying resin particles serve multiple functions simultaneously: they act as the dispersed phase, provide steric stabilization, and form the emulsion structure without requiring additional surfactants or solvents. This multi-functionality reduces the number of materials and process stages needed, simplifying production while maintaining productivity
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 method allows for the production of ultra-low melt polyester toners with reduced environmental impact, lower production costs, and the ability to form latex emulsions on demand without homogenization or filtration, offering stable and cost-effective toner manufacturing.
Implementation Method 1
self-emulsifying granules of the melt mixed mixture of from about 0.5 cm to about 2 cm in diameter... wherein the self-emulsifiable granule forms a latex emulsion upon contact with water
Implementation Method 2
melt mixing the mixture
Data Source
AI summary
A process for making a self-emulsifying granule suitable for use in forming latex emulsions includes contacting a resin with a solid or highly concentrated surfactant, a solid neutralization agent and water in the absence of an organic solvent to form a mixture, melt mixing the mixture, and forming self-emulsifying granules of the melt mixed mixture. 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.