Toner Binder Resin Gel Segmentation for Offset and Gloss
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Solution Overview
Problem
Current toner technologies face challenges in achieving both high gloss and excellent offset properties, with existing methods failing to adequately coexist these qualities, especially with the advancement of full-color capabilities in copiers and printers.
Innovation Solution
A toner formulation with specific ratios of THF-insoluble matter A and THF-insoluble matter B, where THF-insoluble matter A is not more than 10 mass % and THF-insoluble matter B ranges from 5 to 50 mass %, utilizing a binder resin with a dendritic crosslinking agent to control viscoelasticity and surface roughness, ensuring high gloss and improved offset properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high-molecular-weight component (gel) is formed by crosslinking the binder resin to suppress offset, then offset property is improved, but gloss is degraded
Solution Approach 1:
The invention divides the gel structure into two distinct size categories: microgels (0.01-1 μm) that maintain gloss and larger gels (1-10 μm) that suppress offset. This segmentation allows each gel size to perform its specific function without the negative effects of the other, resolving the contradiction between offset suppression and gloss maintenance.
Solution Approach 2:
The invention applies different gel sizes to different functional requirements: microgels are used where gloss is critical (providing smooth surface), while larger gels are used where offset suppression is critical (providing higher viscoelasticity). This local quality differentiation allows simultaneous optimization of both gloss and offset properties.
2Shape
If microgel is used in the toner to maintain gloss, then gloss is improved, but offset property is insufficient
Solution Approach 1:
The invention merges two previously separate solutions (microgels for gloss and larger gels for offset suppression) into a single composite gel system. By combining microgels and larger gels in specific proportions within the same toner particle, the invention achieves both high gloss and excellent offset suppression that neither component could achieve alone.
3Reliability
If high crosslink density microgel is used to improve offset property, then offset property is improved, but gloss is insufficient
Solution Approach 1:
The invention segments the gel population by size, recognizing that crosslink density alone is insufficient to resolve the contradiction. By creating a bimodal distribution of gel sizes, the invention allows high crosslink density in larger gels for offset suppression while maintaining low crosslink density in microgels for gloss preservation.
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 maintains high gloss while exhibiting excellent offset properties, balancing the need for both qualities through controlled viscoelasticity and surface roughness, enhancing the durability and image quality of printed images.
Implementation Method 1
the formation of a high-molecular-weight component (also referred to as a gel) achieved by the crosslinking of all or a portion of the binder resin in the toner
Implementation Method 2
an amount of a tetrahydrofuran THF-insoluble matter A that can be collected when a THF dispersion of the binder resin is passed through a first filter having an average pore diameter of 8 μm, is not more than 10 mass % of the binder resin
Data Source
AI summary
The toner contains a toner particle that has a binder resin, wherein an amount of a tetrahydrofuran THF-insoluble matter A collected when a THF dispersion of the binder resin is passed through a first filter having an average pore diameter of 8 μm, is not more than 10 mass % of the binder resin, and an amount of a THF-insoluble matter B collected when the THF dispersion that has been passed through the first filter is passed through a second filter having an average pore diameter of 0.8 μm, is from 5 mass % to 50 mass % of the binder resin.