Toner Compositions Phase Inversion Emulsification Charge Control
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Solution Overview
Problem
Current toner production methods face challenges in efficiently controlling the charging properties of toner particles, leading to unstable triboelectric charging and reduced imaging quality, particularly due to poor incorporation of charge control agents during the emulsion aggregation process.
Innovation Solution
A process involving the formation of resin emulsions by contacting polyester resin with charge control agents and organic solvents, followed by phase inversion to create a disperse phase emulsion, which improves the incorporation and distribution of charge control agents within the toner particles, enhancing triboelectric charging characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If charge control agents are applied to toner particle surfaces by a blending process, then the toner can be formed, but the incorporation of charge control agents is poor leading to unstable triboelectric charging
Solution Approach 1:
The charge control agent is incorporated into the resin emulsion before toner particle formation occurs. This preliminary incorporation ensures uniform distribution of the charge control agent throughout the toner particles, eliminating the poor incorporation and unstable charging associated with post-formation blending processes.
Solution Approach 2:
The charge control agent is merged with the resin emulsion phase, creating a unified composition where the charge control agent is intimately mixed with the resin at the molecular level. This merging ensures consistent distribution and stable triboelectric charging properties throughout the toner particles.
2Productivity
If conventional emulsion aggregation processes are used, then toner production can proceed, but production time is excessive and charge control is difficult
Solution Approach 1:
The resin emulsion containing the charge control agent is prepared in advance before the emulsion aggregation step. This preliminary preparation eliminates the need for time-consuming post-processing to add charge control agents, significantly reducing overall production time while maintaining precise charge control.
Solution Approach 2:
The invention changes the physical state and timing of charge control agent incorporation from post-formation surface application to pre-formation emulsion incorporation. This parameter change streamlines the process, reducing both production time and the complexity of charge control operations.
3Reliability
If charge control agents are used in small amounts (0.01-5 wt%), then the toner composition remains simple, but the control of charge polarity and distribution is insufficient
Solution Approach 1:
The charge control agent is distributed uniformly throughout the toner particle matrix through emulsion incorporation, ensuring that even small amounts of charge control agent are effectively utilized. This uniform local distribution maximizes the charging efficiency and polarity control achieved by the charge control agent.
Solution Approach 2:
The method changes from surface-level charge control agent application to bulk emulsion incorporation, which dramatically improves the effectiveness of charge control agents at low concentrations. The emulsion process ensures optimal distribution and interaction between the charge control agent and toner matrix, enhancing charge polarity control without requiring increased amounts of charge control agent.
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 process results in toners with improved charging characteristics and reduced loss of charge control agents, leading to enhanced imaging speed and quality by ensuring stable triboelectric charging.
Implementation Method 1
contacting at least one polyester resin with at least one charge control agent and at least one organic solvent to form a resin mixture
Implementation Method 2
heating the resin mixture to a desired temperature
Implementation Method 3
adding water, in embodiments dropwise, to the diluted mixture until phase inversion occurs to form a phase inversed mixture
Implementation Method 4
removing the solvents from the phase inversed mixture to form an emulsion including the at least one polyester and the charge control agent in the disperse phase
Implementation Method 5
Placing charge on the particles, to enable movement and development of images via electric fields, is most often accomplished with triboelectricity
Data Source
AI summary
The present disclosure provides polyesters suitable for use in forming toners. In embodiments, a polyester may be subjected to phase inversion emulsification, in which charge control agents are added so that the polyester emulsion includes charge control agents therein. The resulting polyester emulsion with charge control agents may then be utilized to form toner particles.