Toner with Vinyl Resin Matrix and Polyester Domains
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Solution Overview
Problem
Existing toner technologies face challenges in achieving both low-temperature fixability, high-temperature storability, and separability due to issues with the affinity between core and shell layers, leading to poor image quality and separability problems.
Innovation Solution
A toner with a matrix phase of vinyl resin and domain phases of non-crystalline polyester resin, where the domain phases are localized in the surface layer, achieving a specific ratio and size distribution to enhance fixability and storability, and the use of a crystalline polyester resin for improved thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a styrene acrylic resin is used as the core particle resin and a polyester resin is used as the shell layer resin, then low-temperature fixability is improved, but high-temperature storability deteriorates due to lack of affinity between the resins
Solution Approach 1:
An acrylic-modified polyester resin is used as the shell layer resin to serve as an intermediary between the styrene acrylic core particle resin and the polyester shell layer. This modified resin contains both polyester groups (providing affinity with the core) and acrylic groups (providing affinity with the shell layer), thereby resolving the incompatibility issue and enabling uniform shell layer formation.
Solution Approach 2:
The shell layer resin is designed as a composite material - an acrylic-modified polyester resin that combines properties of both polyester and acrylic resins. This composite structure allows the shell layer to simultaneously bond with the styrene acrylic core and maintain its own structural integrity and thermal stability.
2Temperature
If the glass transition point or molecular weight of the binder resin is lowered to reduce melt temperature or melt viscosity, then low-temperature fixability is improved, but high-temperature storability and separability deteriorate
Solution Approach 1:
The binder resin system is designed with local quality differentiation: the core particle uses styrene acrylic resin with lower glass transition point for low-temperature fixability, while the shell layer uses acrylic-modified polyester resin with higher glass transition point for high-temperature storability. Each region has the specific resin properties needed for its function.
Solution Approach 2:
The binder resin is segmented into two distinct functional components: a core resin (styrene acrylic) responsible for low-temperature fixability and a shell layer resin (acrylic-modified polyester) responsible for high-temperature storability and structural stability. This segmentation allows each component to optimize its properties independently.
3Temperature
If a polyester resin shell layer is formed on a styrene acrylic resin core particle, then low-temperature fixability is improved, but shell layer uniformity deteriorates due to lack of affinity
Solution Approach 1:
The acrylic-modified polyester resin acts as an intermediary material that bridges the styrene acrylic core and the polyester shell layer. The acrylic groups in the modified resin provide chemical affinity with the styrene acrylic core, while the polyester groups provide affinity with the shell layer, enabling uniform and adhesion-free shell layer formation.
Solution Approach 2:
The shell layer resin is modified by introducing acrylic functional groups into the polyester resin structure. This parameter change (chemical modification) alters the resin's affinity characteristics, enabling it to bond with both the styrene acrylic core and maintain uniform shell layer structure.
4Reliability
If the shell layer is made thick to improve high-temperature storability, then separability deteriorates due to blocked release agent exudation
Solution Approach 1:
The shell layer is designed with local quality variation: the outer surface maintains polyester resin properties for high-temperature storability, while the inner region near the core contains acrylic-modified polyester resin with lower glass transition point to facilitate release agent exudation. This local differentiation allows both high-temperature storability and separability to coexist.
Solution Approach 2:
The shell layer structure is designed to be porous or contain channels that allow release agent molecules to diffuse through from the core to the surface during heat fixing. The acrylic-modified polyester regions create pathways for release agent exudation while the outer polyester layer maintains structural integrity and thermal stability.
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 achieves low-temperature fixability, high-temperature storability, and sufficient separability by ensuring the non-crystalline polyester resin domain phases are dispersed in the vinyl resin matrix, allowing for effective release agent exudation and maintaining image quality.
Implementation Method 1
domain phases composed of a non-crystalline polyester resin dispersed in the matrix phase
Implementation Method 2
the aggregated microparticles are further fused together under heating
Implementation Method 3
allowing for effective release agent exudation
Data Source
AI summary
The toner according to the present invention comprises a matrix phase composed of a vinyl resin, and domain phases composed of a non-crystalline polyester resin dispersed in the matrix phase, and a number-average domain diameter of the domain phases composed of the non-crystalline polyester resin is 30 to 150 nm. The toner satisfies relation represented by a specific requirement of the total area of the domain phases present in a surface layer area of the toner particle, and the total area of the domain phases present in areas other than the surface layer area, in a given cross-section of the toner particle.