Belt Filter for Toner Moisture Reduction
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Solution Overview
Problem
Conventional methods for producing toner using wet methods, such as suspension polymerization, face challenges in reducing the moisture content of wet cakes efficiently, leading to increased workload and decreased productivity due to uneven washing and complex sealing mechanisms.
Innovation Solution
A method utilizing a filter cloth continuous running type belt filter with a specified separation-washing mechanism and pressure-ventilation mechanism to achieve low moisture content in toner wet cakes, involving continuous operation, controlled ventilation, and pressure application to reduce moisture levels effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a filter cloth intermittent motion type belt filter is used for solid-liquid separation, then the moisture content of wet cake can be reduced, but the washing uniformity deteriorates and productivity decreases
Solution Approach 1:
The filter cloth is changed from intermittent motion to continuous motion, making the system dynamic rather than static. This continuous motion allows uniform washing while maintaining high productivity, resolving the contradiction between moisture reduction and production efficiency
Solution Approach 2:
The filtering operation is made continuous rather than intermittent. The filter cloth continuously moves through the washing and filtering zones, ensuring uniform washing action throughout the process while maintaining constant productivity, eliminating the need to compromise between moisture content and production rate
2Quantity of substance
If a sealing mechanism is added to reduce moisture content, then the moisture content of wet cake improves, but the device complexity increases
Solution Approach 1:
The sealing mechanism is completely removed from the system. Instead of adding a separate sealing device, the patent uses the continuous moving filter cloth itself to achieve both washing and filtering functions, simplifying the overall device structure while maintaining effective moisture reduction
Solution Approach 2:
The filter cloth is given multiple functions: it serves as both the filtering medium and the washing surface. By making the filter cloth continuous and moving, it simultaneously performs solid-liquid separation and uniform washing without requiring separate sealing or washing mechanisms, reducing device complexity while improving moisture content control
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 approach significantly reduces the moisture content of toner wet cakes, thereby decreasing the workload in the drying process and enhancing productivity by ensuring uniform washing and simplifying the process.
Implementation Method 1
a series of steps including solid-liquid separation, filtration and dehydration of a toner particle dispersion liquid
Implementation Method 2
a ventilation means for dehydration by ventilation to decrease the percentage of moisture content of the wet cake
Implementation Method 3
a sealing means for sealing the gas subjected to ventilation to decrease the percentage of moisture content of the wet cake obtained thereby
Data Source
AI summary
The present invention is to provide a method for producing a toner capable of sufficiently decreasing the percentage of moisture content of a wet cake in the process of obtaining colored resin particles in wet state (wet cake), capable of reducing the workload in the following drying process, and thus excellent in productivity. A method for producing a toner comprising the steps of: a process of obtaining an aqueous dispersion of colored resin particles by forming colored resin particles by a wet method; a process of obtaining the colored resin particles in wet state (wet cake) by supplying the aqueous dispersion of the colored resin particles to a belt filter and performing solid-liquid separation; and a process of drying the wet cake, wherein a filter cloth continuous running type belt filter is used as the belt filter in the process of obtaining the wet cake, and the filter cloth continuous running type belt filter has a separation-washing mechanism, in which the aqueous dispersion of the colored resin particles is supplied on a lower filter cloth of the belt filter, the colored resin particles are separated followed by washing, and thus the wet cake is formed, and a pressure-ventilation mechanism, in which the wet cake is covered with an upper filter cloth, the wet cake, disposed between the upper and lower filter cloths, is ventilated while pressure is applied to the wet cake, and thus the wet cake having low percentage of moisture content is obtained.