Electrostatic Carrier Coating Stirring Control
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Solution Overview
Problem
Existing methods for producing carriers for electrostatic charge image development often result in color dullness due to incomplete crushing of carrier particles and excessive exposure of the core surface, leading to issues with resin peeling and free resin powder generation.
Innovation Solution
A method involving specific stirring conditions in a mixer, where the peripheral speed of the stirring blade is between 0.2 and 2.0 m/s and the stirring workload is between 1×10^3 and 4×10^3, ensures the carrier is crushed to primary particles while reducing shear force and preventing complete solidification of the resin coating layer, thereby minimizing color dullness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the peripheral speed of the stirring blade is lower than 0.2 m/s or higher than 2.0 m/s, or the stirring workload is lower than 1×10³ m or higher than 4×10³ m, then the carrier particles are more easily crushed, but the resin coating layer completely solidifies and peels off, causing color dullness
Solution Approach 1:
The patent applies parameter changes by precisely controlling the peripheral speed of the stirring blade (0.2-2.0 m/s) and stirring workload (1×10³-4×10³ m) during the coating process. This controlled parameter range prevents complete solidification of the resin coating layer while ensuring uniform carrier particle formation, thereby avoiding color dullness in the developed images.
Solution Approach 2:
The patent implements preliminary action by controlling the stirring conditions during the coating process to prevent complete solidification of the resin coating layer before the carrier particles are fully formed. This preliminary control of the resin's solidification state ensures proper coating adhesion and prevents subsequent peeling that would cause color dullness.
2Stability of the object's composition
If the stirring blade speed is increased to improve mixing uniformity, then the resin coating layer solidifies completely and peels off, but if the speed is decreased to prevent peeling, then the mixing uniformity deteriorates
Solution Approach 1:
The patent resolves this contradiction through parameter changes by establishing an optimal range for peripheral speed (0.2-2.0 m/s) and stirring workload (1×10³-4×10³ m). Within this range, the resin coating layer maintains stability without complete solidification, while achieving uniform coating distribution on the carrier particles, preventing both peeling and mixing不均匀ity.
3Quantity of substance
If the stirring workload is increased to ensure complete coating coverage, then free resin powder is generated, but if the workload is decreased to reduce free resin, then coating coverage becomes incomplete
Solution Approach 1:
The patent applies parameter changes by controlling the stirring workload within the specific range of 1×10³-4×10³ m with peripheral speed of 0.2-2.0 m/s. This controlled workload ensures complete coating coverage on carrier particles while preventing excessive mechanical stress that would generate free resin powder, thus resolving the contradiction between coverage and free resin generation.
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 method effectively reduces color dullness and enhances the strength of the resin coating layer, suppressing the generation of free resin powder and maintaining image quality during long-term printing.
Implementation Method 1
the peripheral speed of the stirring blade is between 0.2 and 2.0 m/s and the stirring workload is between 1×10^3 and 4×10^3, ensures the carrier is crushed to primary particles while reducing shear force
Implementation Method 2
preventing complete solidification of the resin coating layer, thereby minimizing color dullness
Data Source
AI summary
A method for producing a carrier for electrostatic charge image development includes coating magnetic particles by adding the magnetic particles and a coating liquid containing a resin and a solvent to a mixer with a stirring blade to form a resin coating layer on surfaces of the magnetic particles and taking a carrier having the resin coating layer out of the mixer. In the coating, the stirring conditions after the solvent is evaporated and dried by heating in the mixer until the carrier is taken out of the mixer satisfy Formula 1 below and Formula 2 below:0.2≤peripheral speed πDn (m/s) of stirring blade≤2.0 Formula 1,1×103≤stirring workload (peripheral speed×stirring time T)≤4×103 Formula 2,where D represents a diameter (m) of the stirring blade, n represents a number of revolutions (rps) of the stirring blade, and T represents a time (s) from a time point at which, after a load power of the stirring blade before drying of the solvent increases with drying until completion of drying, a load power of the stirring blade decreases to 1.3 times or less the load power of the stirring blade before drying to a time point at which stirring in the mixer is stopped.