Toner Composition Using Composite Resins for Fixing and Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing toner manufacturing methods face challenges in achieving small particle size, narrow particle size distribution, wide color gamut, low fixing temperature, and maintaining anti-cohesiveness and charge stability, particularly when using the emulsion and aggregation process, which can result in reduced heat storage ability and image quality issues.
Innovation Solution
A toner composition comprising a crystalline polyester resin, an amorphous polyester resin, a releasing agent, and a colorant, where the resins and releasing agent satisfy specific solubility parameter differences and electrical resistance ratios, forming a core-shell structure to enhance gloss, charge stability, anti-cohesiveness, and low temperature fixability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the emulsion and aggregation process is used to manufacture toner, then small particle size and narrow particle size distribution are achieved, but heat storage ability and anti-cohesiveness are reduced
Solution Approach 1:
The patent uses a composite binder resin system comprising both crystalline polyester resin and amorphous polyester resin. The crystalline polyester resin (5-50 wt%) provides heat storage ability and anti-cohesiveness, while the amorphous polyester resin (50-95 wt%) ensures small particle size and narrow particle size distribution. This composite material approach resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The patent specifies precise parameter ranges for the binder resin composition: crystalline polyester resin content of 5-50 wt%, amorphous polyester resin content of 50-95 wt%, and specific solubility parameter differences (ΔSPα≥3, ΔSPβ≤1, ΔSPγ≥2.5). These parameter controls optimize both particle size distribution and heat storage ability, resolving the technical contradiction through quantitative composition specification.
2Manufacturing precision
If the emulsion and aggregation process is used to manufacture toner, then small particle size is achieved, but controlling morphology of toner particles becomes difficult
Solution Approach 1:
The patent controls toner particle morphology through specific parameter specifications: particle size distribution (span≤0.14), spherical shape requirements, and binder resin composition ratios. These controlled parameters ensure both small particle size and proper morphology, making the manufacturing process predictable and controllable.
3Temperature
If a binder resin with low glass transition temperature is used, then low temperature fixing is achieved, but high temperature storage ability and gloss property are insufficient
Solution Approach 1:
The patent employs a composite binder resin system where crystalline polyester resin provides high temperature storage ability and melting point, while amorphous polyester resin with lower glass transition temperature enables low temperature fixing. The combination resolves the contradiction between low fixing temperature and high temperature storage ability.
Solution Approach 2:
The patent specifies the glass transition temperature of the amorphous polyester resin in the range of 50-80°C and the melting point of the crystalline polyester resin in the range of 60-100°C. These parameter specifications enable the toner to fix at low temperatures while maintaining high temperature storage stability.
4Temperature
If wax is included in the toner to improve low temperature fixability, then fixing temperature is reduced, but heat storage ability and anti-cohesiveness are reduced due to plasticizing effect
Solution Approach 1:
The patent replaces traditional wax-based low temperature fixing agents with a composite binder resin system comprising crystalline and amorphous polyester resins. This composite material system achieves low temperature fixing through the amorphous resin's glass transition temperature while the crystalline resin maintains anti-cohesiveness and heat storage ability, eliminating the plasticizing effect problem.
Data Source
AI summary
A toner for developing an electrostatic image and a method of manufacturing the same are provided. The toner may have a morphological surface characteristic that induces high thermal and physical characteristics. The toner may simultaneously improve gloss, charge stability, anti-cohesiveness, storage ability, and low temperature fixability.