Toner Composition Using Segmented Amorphous Polyesters
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Solution Overview
Problem
Current toner compositions and processes lack cost-effectiveness and ecological friendliness, and fail to provide optimal blocking performance without over plasticizing the amorphous resin, while also requiring improved gloss and fusing performance.
Innovation Solution
A toner composition comprising a combination of a lower molecular weight unbranched amorphous polyester, a higher molecular weight branched amorphous polyester, a crystalline polyester, and a wax, with specific weight percentages and generation methods, allowing for reduced wax usage and enhanced compatibility between amorphous and crystalline resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single amorphous polyester resin is used to reduce blocking, then blocking performance is improved, but fine tuning of gloss and fusing performance is not possible
Solution Approach 1:
The invention divides the single resin system into two distinct amorphous polyester resins with different molecular weights and structures. The first resin (lower molecular weight, unbranched) provides blocking resistance, while the second resin (higher molecular weight, branched) enables fine tuning of gloss and fusing performance. This segmentation allows each resin to specialize in specific functions that cannot be achieved with a single resin type.
Solution Approach 2:
Each resin is designed with specific local qualities: the first resin has low molecular weight and unbranched structure optimized for blocking performance, while the second resin has high molecular weight and branched structure optimized for gloss and fusing. This local quality differentiation enables each component to perform its specific function optimally within the overall toner system.
2Reliability
If wax content is increased to improve gloss and fusing, then gloss and fusing performance are improved, but toner cost increases and ecological friendliness decreases
Solution Approach 1:
The invention changes the chemical and physical parameters of the resin system by introducing two amorphous polyesters with different molecular weights and structures. This parameter change in the resin composition allows the system to achieve adequate gloss and fusing performance with reduced wax content, as the resin itself provides the necessary performance characteristics rather than relying heavily on wax additives.
Solution Approach 2:
The invention creates a composite resin system combining two amorphous polyesters with complementary properties. This composite material approach allows the resins to work synergistically, providing the functional performance previously requiring high wax content, thereby reducing the quantity of wax needed in the toner formulation.
3Strength
If crystalline resin is used to improve structure, then structural integrity is improved, but recrystallization from amorphous resin after preparation is not achieved
Solution Approach 1:
The invention introduces dynamics into the resin system by using two amorphous polyesters with different molecular mobilities. The lower molecular weight resin provides chain mobility that enables recrystallization of the crystalline component after toner preparation, while the higher molecular weight resin maintains structural integrity. This dynamic balance allows the system to achieve both strength and recrystallization capability.
Solution Approach 2:
The invention changes the molecular weight and structural parameters of the amorphous resin phase to create a environment conducive to crystalline resin recrystallization. The specific combination of low and high molecular weight amorphous polyesters creates optimal physical conditions (viscosity, chain mobility, glass transition temperature) that allow the crystalline resin to recrystallize from the amorphous matrix after toner preparation, thereby achieving both structural integrity and composition stability.
4Ease of manufacture
If conventional toner composition is used to maintain cost effectiveness, then cost is controlled, but ecological friendliness and performance are insufficient
Solution Approach 1:
The invention changes the compositional parameters by using two amorphous polyesters with optimized molecular weights and structures, allowing reduction of wax and other additives content. This parameter optimization achieves adequate performance with simpler, more eco-friendly materials while maintaining cost effectiveness through reduced formulation complexity and fewer expensive additives.
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 achieves reduced overall toner cost, improved blocking performance, and adequate gloss and fusing performance, while maintaining ecological friendliness and reducing energy requirements during fusing.
Implementation Method 1
the first amorphous polyester is generated by the catalytic polymerization of monomers of an organic diol, an organic diacid, and dodecenyl succinic acid, dodecenyl succinic anhydride
Implementation Method 2
a polyester derived from dodecenyl succinic acid, dodecenyl succinic anhydride
Implementation Method 3
a branching agent derived from a polyacid or polyol component; wherein the second higher molecular weight branched amorphous polyester is generated by the catalytic polymerization
Data Source
AI summary
A toner composition comprising (a) a first lower molecular weight amorphous polyester resin comprising a polyester derived from dodecenyl succinic acid, dodecenyl succinic anhydride, or a combination thereof present in an amount of from about 5 to about 15 weight percent, based on the total weight of the first amorphous polyester; (b) a second higher molecular weight amorphous polyester resin comprising a polyester derived from dodecenyl succinic acid, dodecenyl succinic anhydride, or a combination thereof, and a branching agent derived from a polyacid or polyol component; wherein the dodecenyl succinic acid, dodecenyl succinic anhydride, or combination thereof is present in the second amorphous polyester in an amount of from about 5 to about 15 weight percent, based on the total weight of the second amorphous polyester; (c) a crystalline polyester resin; (d) a wax; and (e) optionally, a colorant.