Abstract
We developed new polyester resin particles for use in toner that are prepared by an advanced dissolution suspension method. The new resin particles have excellent characteristics, such as a narrow particle size distribution, a uniform and non-spherical particle shape and high melt elasticity at high temperature with low-temperature meltability. The narrow particle size distribution, which has a coefficient of variation (CV) under 20%, is obtained by using nanoscale styrene-acrylic particles during the particle formation of the dissolution suspension process. The styrene-acrylic particles are prepared by emulsion polymerization and act as a particle size control agent in the formation of the polyester particles by adsorption on the surface of the polyester solution droplets through the hetero-coagulation effect. The particle shape is controlled from spherical to non-spherical forms, such as spindle or dimple shapes, during the solvent removal process. Moreover, a melting property suitable for toner application is achieved by the elongation reaction of the polyester prepolymer proceeding simultaneously during the particle formation process. This review introduces the outlines of the technical features and the key processes. Novel polyester resin particles useful for toner with characteristics such as a narrow particle size distribution, a uniform and non-spherical particle shape, and high melt elasticity at high temperature with low-temperature meltability were developed. These characteristics were achieved by the application of three key technologies to the conventional dissolution suspension method, and they contribute to energy savings and high image quality for toner.
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