Toner Composition Reactive Coalescing Agent
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Solution Overview
Problem
Existing toner production methods using triboelectricity for charging result in nonuniform charge distribution and instability, making it difficult to control and maintain the charging of small toner particles, which affects print quality and reliability.
Innovation Solution
A method involving the use of a latex, an aqueous colorant dispersion, and an optional wax dispersion to form a blend, followed by heating below the glass transition temperature, adding a reactive coalescing agent like glycol esters of vegetable oil fatty acids to coalesce toner particles, resulting in core-shell toner particles with uniform size and charging characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If triboelectric charging is used to charge toner particles, then the toner can be moved and developed via electric fields, but the charge distribution becomes nonuniform and unstable, especially for small particles
Solution Approach 1:
The patent introduces a liquid carrier as an intermediary medium to transfer charge uniformly to toner particles. Instead of direct triboelectric charging which causes nonuniform charge distribution, the liquid carrier acts as a mediator that distributes charge evenly across the toner particles through its fluid properties and contact mechanisms, thereby improving charge uniformity while maintaining charging stability
Solution Approach 2:
The patent changes the charging mechanism from solid-to-solid triboelectric contact to liquid-mediated charging. By changing the physical state and charging parameters from direct particle-to-particle or particle-to-carrier contact to liquid carrier-mediated charge transfer, the system achieves more uniform and stable charge distribution on toner particles
2Manufacturing precision
If small toner particles (about 5 micron diameter) are used to achieve offset print quality, then print quality improves, but long-term stability and reliability decrease
Solution Approach 1:
The liquid carrier serves as a stabilizing intermediary for small toner particles. It provides a consistent charging environment that compensates for the inherent instability of small particles, ensuring reliable charge distribution and maintaining system stability while enabling the use of small 5-micron particles for high-quality offset printing
3Ease of manufacture
If triboelectric charging is used, then charging can be achieved, but the charging becomes unpredictable due to material sensitivity
Solution Approach 1:
The liquid carrier acts as a buffering intermediary that decouples the charging process from direct material-to-material contact. This intermediary layer reduces sensitivity to material variations and environmental conditions, making the charging process more predictable and controllable while maintaining ease of manufacture
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
This process produces toner particles with a narrow size distribution, optimal surface area, and robust triboelectric charging, reducing production time and manufacturing costs while improving print quality and stability.
Implementation Method 1
heating the blend at a temperature below the glass transition temperature of the latex to form aggregated toner particles
Implementation Method 2
adding a reactive coalescing agent to the toner particles thereby coalescing the toner particles
Implementation Method 3
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
Processes for producing toner are provided which utilize reactive coalescing agents in forming the toner particles, as well as toners produced by such processes.