Toner Composition with Crystalline Polyester for Low Temperature Fixing
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Solution Overview
Problem
Existing toner production methods fail to achieve stable low temperature fixing ability and hot offset resistance while maintaining heat resistance storage stability, often resulting in poor image quality and increased energy consumption due to large particle sizes and uneven wax distribution.
Innovation Solution
A toner composition containing a non-crystalline polyester resin and crystalline polyester resin, with a specific melting point and wax distribution, is developed using a method involving dispersion in an aqueous medium, followed by solvent removal and annealing to achieve optimal compatibility and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the kneading-pulverizing method is used to produce toner, then the production process is simple, but the toner has large particle size, irregular shape, and poor low temperature fixing ability
Solution Approach 1:
The invention changes the fundamental production parameter from mechanical kneading-pulverizing to chemical polymerization. This allows precise control of particle size through polymerization conditions (monomer ratio, temperature, time) rather than relying on mechanical force, achieving both ease of manufacture and precise particle size control (0.5-5 μm diameter)
Solution Approach 2:
The invention uses composite material structure by incorporating crystalline polyester (2-20 parts by mass) into the binder resin system. This composite approach provides specific particle size distribution and shape control during polymerization while maintaining manufacturing simplicity, resolving the contradiction between process simplicity and particle size precision
2Ease of manufacture
If the kneading-pulverizing method is used, then production is easier, but the toner requires high energy for fixing due to wax releasing effect
Solution Approach 1:
The invention changes the production method parameter from mechanical to chemical, resulting in toner particles with uniform wax distribution throughout the polymer matrix rather than concentrated at surfaces. This eliminates the excessive wax releasing effect, reducing fixing energy consumption while keeping production easy through polymerization
Solution Approach 2:
The composite binder resin system (non-crystalline polyester 78-95 parts + crystalline polyester 2-20 parts) creates a structured material where wax is properly encapsulated. This composite structure maintains production ease while controlling wax release to reduce fixing energy requirements
3Temperature
If crystalline polyester is introduced to improve low temperature fixing ability, then fixing ability improves, but storage stability deteriorates
Solution Approach 1:
The invention optimizes the crystalline polyester content parameter to 2-20 parts by mass relative to 100 parts of non-crystalline polyester. This precise parameter control allows low temperature fixing ability improvement while preventing storage stability deterioration by avoiding excessive crystalline content that would cause instability
Solution Approach 2:
The invention applies local quality by distributing crystalline polyester specifically within the binder resin matrix at controlled concentrations. This creates local crystalline regions that improve low temperature fixing without overwhelming the entire toner structure, preserving storage stability
4Manufacturing precision
If particle diameter is reduced to improve image quality, then image quality improves, but powder flow ability and storage stability worsen
Solution Approach 1:
The invention changes the particle formation mechanism through polymerization, enabling small particle diameters (0.5-5 μm) with uniform size distribution. The polymerization process naturally produces spherical particles with consistent dimensions, improving image quality while the uniformity maintains powder flow ability
Solution Approach 2:
The composite binder resin system produces toner particles with optimized surface properties even at small sizes. The combination of non-crystalline and crystalline polyester creates a surface structure that maintains flow ability despite reduced particle diameter, resolving the contradiction between size reduction and flow performance
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 provides a toner with stable low temperature fixing ability, hot offset resistance, and heat resistance storage stability, improving image quality and reducing energy requirements by controlling particle size and wax distribution effectively.
Implementation Method 1
A toner containing: a binder resin containing a non-crystalline polyester resin and a crystalline polyester resin; wherein the crystalline polyester resin has a melting point of 60°C to 80°C
Implementation Method 2
the method further comprises annealing at temperature that is an onset temperature ± 5°C, where the onset temperature is calculated from a DSC curve of the crystalline polyester resin
Implementation Method 3
PTL6 discloses a preparation method of a dispersion liquid using a solvent for phase separation
Data Source
Figure 1
AI summary
To provide a toner containing: a binder resin containing a non-crystalline polyester resin and a crystalline polyester resin; a colorant; and wax, wherein the toner satisfies the following formula 1, and has loss tangent of 1 or smaller at 80°C or higher, B?A < 20 Formula 1 where A represents a melting point of the crystalline polyester resin and B represents a temperature at which the toner has storage modulus G' of 20,000 Pa.