Toner Resin Particle with Polyhydroxycarboxylic Acid Skeleton
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Solution Overview
Problem
Conventional toner manufacturing processes, particularly those using pulverization, face challenges in uniformly dispersing colorants and charge controlling agents in thermoplastic binder resins, resulting in poor fluidity, developability, durability, and image quality, while also relying on petroleum-based materials that contribute to global warming.
Innovation Solution
A toner composition featuring a resin particle with a polyhydroxycarboxylic acid skeleton and a polyester resin covering layer, where the polyester resin has a specific weight average molecular weight range and is obtained through a dissolution suspension process using an organic solvent, enhancing uniform dispersion and image quality while reducing environmental impact by using plant-derived materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pulverization process is used to manufacture toner, then manufacturing simplicity is improved, but uniform dispersion of colorants and charge controlling agents deteriorates
Solution Approach 1:
The patent changes the manufacturing parameters by switching from pulverization process to suspension polymerization process, and specifically uses L-form polylactic acid with controlled molecular weight (1,000-10,000) to achieve both good dispersion and manufacturability
Solution Approach 2:
The patent creates a composite binder resin system by combining L-form polylactic acid (for biodegradability and crystallinity) with specific additives and using it in a multi-component toner formulation that includes colorants, charge controlling agents, and other functional materials
2Reliability
If petroleum-based binder resins are used, then toner performance is improved, but environmental harm increases
Solution Approach 1:
The patent changes the chemical composition parameter by replacing petroleum-based resins with L-form polylactic acid, a biodegradable polymer derived from renewable resources, while maintaining the necessary performance characteristics through controlled molecular weight and crystallinity
Solution Approach 2:
The patent adopts a biodegradable binder resin that can be disposed of environmentally friendly, aligning with the concept of using materials that can be safely discarded after use, thereby reducing long-term environmental accumulation and harm
3Object-generated harmful factors
If L-form polylactic acid is used as binder resin, then biodegradability is improved, but solubility in organic solvents deteriorates
Solution Approach 1:
The patent optimizes the molecular weight parameter of L-form polylactic acid to the range of 1,000-10,000, which balances crystallinity (for biodegradability) with sufficient solubility in organic solvents for the suspension polymerization process
Solution Approach 2:
The patent introduces specific functional groups or additives locally to the polylactic acid structure or surface to enhance solubility while maintaining the bulk properties of biodegradability and crystallinity
4Strength
If high crystallinity polylactic acid is used, then mechanical strength is improved, but solubility in organic solvents deteriorates
Solution Approach 1:
The patent precisely controls the molecular weight parameter (1,000-10,000) to achieve the optimal balance where sufficient crystallinity provides mechanical strength while maintaining enough amorphous regions for organic solvent solubility
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 solution improves the uniform dispersion of colorants and waxes, leading to enhanced image density and haze reduction, while transitioning to plant-based materials addresses the depletion and global warming issues associated with petroleum-derived binder resins.
Implementation Method 1
a resin particle (A) or covering layer (P) that is adhered to a surface of the resin particle (B)
Implementation Method 2
a step of removing the organic solvent
Data Source
AI summary
A toner including a resin particle (C) is provided. The resin particle (C) includes a resin particle (B) and; a resin particle (A) or covering layer (P) that is adhered to a surface of the resin particle (B). The resin particle (B) includes a resin (b) having a polyhydroxycarboxylic acid skeleton. The resin particle (A) or covering layer (P) includes a resin (a). The resin (a) is a polyester resin having a polybasic acid unit and a polyol unit and has a weight average molecular weight within a range from 9,500 to 100,000.