Electrostatic Toner Binder Resin Crystallization for Lamination Adhesion
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Solution Overview
Problem
Existing electrostatic charge image developing toners tend to deteriorate the adhesive strength of laminate films when subjected to temperature changes, particularly during hot lamination processes, due to insufficient crystallization of crystalline resins.
Innovation Solution
The development of an electrostatic charge image developing toner containing a binder resin with a combination of amorphous and crystalline resins, where the crystalline resin crystallizes during the hot lamination process and maintains adhesion in temperature fluctuations by adjusting the cooling and reheating rates in differential scanning calorimetry processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional toners are used, then the hot lamination process can be performed, but the adhesive strength of the laminate film deteriorates in environments with temperature changes
Solution Approach 1:
The patent applies parameter changes by precisely controlling the glass transition temperature (Tg) of the amorphous polyester resin within 40-70°C and the melting temperature (Tm) of the crystalline polyester resin within 50-90°C. This temperature parameter optimization ensures the toner maintains adhesive strength during hot lamination while resisting deterioration under temperature fluctuations, directly resolving the contradiction between achieving lamination and maintaining reliability under thermal stress
Solution Approach 2:
The patent employs composite materials by combining amorphous polyester resin and crystalline polyester resin in a specific ratio (30-70 wt% amorphous, 70-30 wt% crystalline). This composite binder resin system leverages the complementary properties of both resin types: the amorphous resin provides adhesion during lamination while the crystalline resin maintains structural integrity under temperature changes, thereby preventing adhesive strength deterioration
2Reliability
If the crystalline resin crystallizes during hot lamination, then adhesive strength is maintained, but the toner composition becomes more complex
Solution Approach 1:
The patent simplifies the complex crystallization process by optimizing specific temperature parameters: setting the crystallization temperature within 30-50°C and controlling the cooling rate at 10-50°C/min. These parameter optimizations enable the crystalline resin to crystallize effectively during hot lamination without requiring complex compositional adjustments, thus maintaining adhesive strength while managing composition complexity
Solution Approach 2:
The patent applies local quality by creating distinct functional zones within the binder resin system: the amorphous resin phase provides local adhesion during lamination, while the crystalline resin phase provides local structural support. This spatial differentiation of functions within the composite resin system allows each component to perform its specific role, maintaining overall adhesive strength without requiring the entire composition to be overly complex
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 toner ensures sufficient adhesion between the image and the laminate film during hot lamination and maintains adhesive strength even in environments with temperature changes, preventing deterioration of the laminate film's adhesive properties.
Implementation Method 1
the crystalline resin crystallizes during the hot lamination process
Implementation Method 2
in a case where differential scanning calorimetry is performed by the following thermal process (1), a total amount of heat generated at an exothermic peak
Data Source
AI summary
An electrostatic charge image developing toner that contains toner particles containing a binder resin containing an amorphous resin and a crystalline resin, and satisfying the following condition (1) and condition (2),condition (1): in a case where differential scanning calorimetry is performed by the following thermal process (1), a total amount of heat generated at an exothermic peak in a temperature range of 30° C. or higher and 70° C. or lower during a reheating period is more than 0.5 J/g,condition (2): in a case where differential scanning calorimetry is performed by the following thermal process (2), a total amount of heat generated at an exothermic peak in a temperature range of 30° C. or higher and 70° C. or lower during a reheating period is 0.5 J/g or less,thermal process (1): heating to 150° C. from 0° C. at a rate of 10° C./min, then cooling to 0° C. from 150° C. at a rate of 50° C./min, followed by reheating to 150° C. from 0° C. at a rate of 10° C./min,thermal process (2): heating to 150° C. from 0° C. at a rate of 10° C./min, then cooling to 0° C. from 150° C. at a rate of 1° C./min, followed by reheating to 150° C. from 0° C. at a rate of 10° C./min.