Toner Composition with Crystalline Polyester Resin for Low-Temperature Fixing
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Solution Overview
Problem
Conventional toner production methods, such as the kneading-pulverizing method, result in toners with large particle diameters, broad particle size distribution, and poor energy efficiency for image fixing, while the polymerization method struggles to achieve optimal heat-resistant storage stability and low-temperature fixing ability simultaneously.
Innovation Solution
A toner composition containing a mixture of crystalline and non-crystalline polyester resins, with specific endothermic and exothermic value ratios, is developed to optimize particle size distribution and thermal properties, ensuring stable heat-resistant storage stability and low-temperature fixing ability.
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 and easy to manufacture, but the toner particle diameter becomes large and the particle size distribution becomes broad
Solution Approach 1:
The invention segments the toner production process into two distinct stages: first forming toner particles with desired size distribution through polymerization, then classifying them by particle size. This segmentation allows each stage to optimize for its specific function, achieving both ease of manufacture and precise particle size control.
Solution Approach 2:
The invention introduces a classification process as an intermediary step between toner formation and final product. This intermediary mechanism separates toner particles by size, ensuring that the final product has sharp particle size distribution while maintaining the simplicity of the polymerization production method.
2Manufacturing precision
If the polymerization method is used to produce toner with small particle diameter, then the particle size distribution becomes sharp, but the heat-resistant storage stability and low-temperature fixing ability cannot be optimized simultaneously
Solution Approach 1:
The invention applies local quality by using different resin types in different proportions within the toner composition. Specifically, it combines crystalline polyester resin (providing heat-resistant storage stability) with non-crystalline polyester resin (providing low-temperature fixing ability) in a specific ratio range (7:3 to 3:7), allowing each resin type to contribute its unique properties to the overall toner performance.
Solution Approach 2:
The invention uses composite materials by combining two different polyester resin types with complementary properties. The crystalline polyester resin provides thermal stability for heat-resistant storage, while the non-crystalline polyester resin provides fusibility for low-temperature fixing. This composite approach allows the toner to achieve both heat-resistant storage stability and low-temperature fixing ability simultaneously.
3Temperature
If crystalline polyester resin is used to improve low-temperature fixing ability, then the fixing temperature can be reduced, but the heat-resistant storage stability may be impaired
Solution Approach 1:
The invention changes the compositional parameters of the binder resin by combining crystalline and non-crystalline polyester resins in specific proportions. This parameter adjustment allows the toner to achieve a balance between low-temperature fixing ability (provided by crystalline resin) and heat-resistant storage stability (provided by non-crystalline resin), resolving the trade-off between these two properties.
4Reliability
If non-crystalline polyester resin is used to improve heat-resistant storage stability, then the storage stability is enhanced, but the low-temperature fixing ability deteriorates
Solution Approach 1:
The invention adjusts the compositional parameters by incorporating crystalline polyester resin alongside non-crystalline polyester resin. This parameter change ensures that while the non-crystalline resin provides heat-resistant storage stability, the crystalline resin simultaneously provides low-temperature fixing ability, preventing the deterioration of fixing properties.
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 achieves balanced low-temperature fixing ability and heat-resistant storage stability, reducing energy consumption and preventing toner adhesion issues, while maintaining sharp particle size distribution and improved fixing efficiency.
Implementation Method 1
the crystalline polyester resin contained in the toner has crystallinity, the resultant toner has thermofusion properties that the viscosity of the toner dramatically decreases at around the fixing onset temperature (fusion onset temperature)
Implementation Method 2
shows dramatic viscosity reduction (sharp melt) at the fusion onset temperature so as to be fixed
Implementation Method 3
an endothermic value A of the crystalline polyester resin at a first temperature increase in a differential scanning calorimetry of the toner
Data Source
AI summary
A toner containing toner particles, each toner particle containing: a releasing agent; a colorant; and a binder resin containing at least a crystalline polyester resin and a non-crystalline polyester resin, wherein in the case where a volume average particle diameter of the toner is defined as Dv, the toner contains a group of the toner particles having 4/5 Dv, and a group of the toner particles having 6/5 Dv, and wherein an endothermic value A of the crystalline polyester resin at a first temperature increase in DSC of the toner, an endothermic value B of the crystalline polyester resin at a first temperature increase in DSC of the group of the toner particle having 4/5 Dv, and an endothermic value C of the crystalline polyester resin at a first temperature increase in DSC of the group of the toner particles having 6/5 Dv satisfy the relation represented by the following formulas:50<(B/A)×100<90, and110<(C/A)×100<150.