Toner Manufacturing with Modified Hydrocarbon Wax
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Solution Overview
Problem
Current toner manufacturing methods face challenges in achieving a balance between low-temperature fixing properties and high-temperature storage, leading to issues like cold offset, image quality degradation, and poor gloss, especially in high-speed image forming apparatuses, due to limitations in thermal energy and the trade-off between low and high-temperature performance.
Innovation Solution
A method involving the melting, mixing, and kneading of a releasing agent and a coloring agent with a polyester binder resin in an aqueous medium, where the releasing agent is a hydrocarbon-based wax modified by a carboxylic acid or anhydride, with specific melting point, acid value, and viscosity ranges, to ensure uniform dispersion and improved storage and anti-spent properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a toner is designed with low melting point components to improve low-temperature fixing property, then fixing performance at low temperature is improved, but the toner deteriorates when stored in high-temperature environments, resulting in solidification
Solution Approach 1:
The patent applies parameter changes by carefully controlling the melting point of the releasing agent within a specific range (70-110°C) and regulating the acid value (3-20 mgKOH/g) and viscosity (5-50 cP at 90°C) to achieve optimal balance between low-temperature fixing and high-temperature storage stability
Solution Approach 2:
The patent uses composite materials by combining a polyester binder resin with a modified hydrocarbon-based wax releasing agent, where the releasing agent is grafted with carboxylic acid or anhydride groups to create a composite structure that provides both low-temperature fixing capability and high-temperature storage stability
2Loss of energy
If thermal energy provided to the toner is reduced to improve environmental performance, then energy consumption is reduced, but the toner is not heated sufficiently, leading to insufficient melting and cold offset
Solution Approach 1:
The patent changes the thermal parameters of the toner by using a releasing agent with specific melting point (70-110°C) and viscosity characteristics, enabling the toner to melt and fix properly at reduced thermal energy input while preventing cold offset through the controlled rheological properties of the releasing agent
3Temperature
If the melting point of the releasing agent is lowered to improve low-temperature fixing, then fixing property is improved, but the toner becomes unstable during high-temperature storage
Solution Approach 1:
The patent optimizes the melting point parameter of the releasing agent to fall within 70-110°C, which is high enough to prevent high-temperature storage instability but low enough to enable effective low-temperature fixing, achieving a precise balance between these conflicting requirements
Solution Approach 2:
The patent applies local quality by modifying the releasing agent with carboxylic acid or anhydride groups to create regions with different thermal properties, where the base wax provides low melting point for fixing while the grafted groups enhance thermal stability for storage
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 method results in a toner with excellent high-temperature offset resistance, low-temperature fixing properties, and improved image quality, including better color reproduction and storage stability, even in high-temperature and high-moisture environments.
Implementation Method 1
melting, mixing, and kneading a releasing agent and a coloring agent with at least part of a polyester binder resin
Implementation Method 2
suspending and granulating an oil phase comprising the binder resin, the coloring agent, and the releasing agent in an aqueous medium
Implementation Method 3
the thermal energy that can be provided to the toner per unit of time at the fixing device is limited
Data Source
AI summary
A method of manufacturing toner including melting, mixing, and kneading a releasing agent and a coloring agent with at least part of a polyester binder resin, and suspending and granulating an oil phase comprising the binder resin, the coloring agent, and the releasing agent in an aqueous medium.