Toner Formulation Using Sulfuric Acid Catalyst for Low-Temperature Fixing
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Solution Overview
Problem
The existing toner production methods face challenges in achieving sufficient dispersibility of releasing agents, leading to aggregation and offset issues, particularly on transparent image forming materials like OHP sheets, and require high-energy polycondensation reactions that consume resources and result in background fogging at high temperatures.
Innovation Solution
A toner formulation incorporating a polycondensation resin and condensation compound produced with a sulfur acid catalyst in an aqueous medium, which enhances dispersibility through electrostatic repulsive forces and reduces metallic catalyst residues, allowing for low-temperature processing and improved image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a vinyl polymer with high molecular weight is used as binder resin, then fixing temperature can be reduced, but energy saving is compromised due to requirement of high temperature fixing
Solution Approach 1:
The patent changes the chemical composition parameters by using polyester resin instead of vinyl polymer, and adjusts the molecular weight parameter to achieve low-temperature fixing while maintaining image quality and reducing energy consumption
2Reliability
If conventional polycondensation reaction is used to produce polyester resin, then high reactivity and prevention of coloration are achieved, but energy consumption increases and reaction time extends
Solution Approach 1:
The patent changes the reaction temperature parameter from conventional high temperature (>200°C) to low temperature (100-150°C), and uses sulfuric acid as a catalyst to maintain reaction efficiency while reducing energy consumption and reaction time
3Ease of manufacture
If releasing agent is dispersed in toner, then image forming is enabled, but aggregation and offset occur due to insufficient dispersibility
Solution Approach 1:
The patent changes the chemical environment parameters by using sulfuric acid catalyst and aqueous medium, which improves the dispersibility of releasing agent in toner and prevents aggregation and offset issues
4Speed
If metallic compound catalyst is used for polycondensation reaction, then high reactivity is achieved, but metallic element residues cause background fogging at high temperatures
Solution Approach 1:
The patent uses sulfuric acid as an intermediary catalyst instead of metallic compounds, which achieves high reaction rate while avoiding metallic element residues that cause background fogging
Solution Approach 2:
The patent replaces the metallic catalyst system with a sulfuric acid catalyst system, substituting one catalytic mechanism with another that has beneficial properties (no metallic residues, lower operating temperature)
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 proposed solution improves the dispersibility of releasing agents within the toner, reduces energy consumption, and minimizes background fogging, resulting in enhanced image quality and reduced offset issues on transparent materials.
Implementation Method 1
a polycondensation resin obtained by polycondensing a polycondensation monomer in the presence of a polycondensation catalyst, the releasing agent containing a condensation compound obtained by condensing a condensation monomer in the presence of a condensation catalyst
Implementation Method 2
enhances dispersibility through electrostatic repulsive forces
Data Source
AI summary
A toner for developing an electrostatic image comprises: a binder resin; and a releasing agent, wherein the binder resin comprises a polycondensation resin obtained by polycondensing a polycondensation monomer in the presence of a polycondensation catalyst, the releasing agent comprises a condensation compound obtained by condensing a condensation monomer in the presence of a condensation catalyst, the toner contains a metallic element derived from the polycondensation catalyst and the condensation catalyst in an amount of from 0 to 10 ppm, and the toner contains a sulfur component in an amount of from 100 to 20,000 ppm.