Toner Production Using Low Molecular Weight Peroxide Initiators
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Solution Overview
Problem
Toner produced by the electrophotographic process faces issues with high temperature shelf stability, odor emission, and durability under high temperature and humidity conditions due to residual volatile matter and unreacted polymerizable monomers, leading to decreased print quality and environmental impact.
Innovation Solution
A toner is developed using an organic peroxide with a molecular weight of 205 or less and a purity of 90% or more as the polymerization initiator, along with specific conditions for polymerization and stripping to minimize residual ether components and volatile matter, resulting in improved shelf stability and print durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymerization initiators (e.g., t-butylperoxy-2-ethylhexanoate) are used in suspension polymerization to produce toner, then polymerization efficiency is improved, but residual volatile matter and unreacted monomer remain in the toner, causing poor high temperature shelf stability and odor emission
Solution Approach 1:
The patent changes the molecular weight parameter of the polymerization initiator from conventional values (216 for t-butylperoxy-2-ethylhexanoate) to 148 or less (specifically 1,1,3,3-tetramethylbutylperoxy-2-ethylhexanoate with molecular weight 148). This parameter change enables more complete polymerization reaction, reducing residual monomer and volatile matter in the toner, thereby eliminating odor emission and improving high temperature shelf stability while maintaining polymerization efficiency
Solution Approach 2:
The patent employs a polymerization initiator with extremely low molecular weight (148) that decomposes completely during polymerization, leaving no persistent residual harmful substances. The initiator acts as a temporary catalyst that fulfills its function and then disappears completely, unlike conventional initiators that leave behind stable residual compounds causing odor and degradation
2Object-generated harmful factors
If excessive treatment is applied to remove remaining low molecular weight components from toner, then volatile matter content is reduced, but colored polymer particles agglomerate during treatment, causing the toner to drop in print durability
Solution Approach 1:
The patent applies preliminary action by selecting a polymerization initiator (1,1,3,3-tetramethylbutylperoxy-2-ethylhexanoate) that inherently produces minimal residual monomer and volatile matter through its complete decomposition characteristics. This preliminary optimization of the polymerization process eliminates the need for excessive post-polymerization treatment, thereby preventing particle agglomeration and maintaining print durability while achieving low volatile matter content
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 exhibits enhanced high temperature shelf stability, reduced odor emission, and improved durability during continuous printing under high temperature and humidity conditions, ensuring better print quality and environmental safety.
Implementation Method 1
a polymerization initiator which is an organic peroxide, has a molecular weight of 205 or less, and has a purity of 90% or more
Implementation Method 2
colored polymer particles obtained by polymerizing a polymerizable monomer composition
Implementation Method 3
compounds produced as a byproduct of the polymerization initiator
Data Source
AI summary
[PROBLEMS] To provide a toner superior in shelf stability, not giving off an offensive odor and degrading the surrounding environment when used for printing, and superior in durability at the time of use for continuous printing under high temperature, high humidity conditions.[MEANS FOR SOLVING PROBLEMS] A process of production of a toner containing colored polymer particles obtained by polymerizing a polymerizable monomer composition containing a polymerizable monomer and colorant in an aqueous medium in the presence of a polymerization initiator, wherein the polymerization initiator is an organic peroxide having a molecular weight of 205 or less, and a purity of 90% or more.