Color Toner Production via Phase Inversion Emulsification
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Solution Overview
Problem
Conventional methods for producing latex-based toner particles require the costly and energy-intensive dispersion of hydrophobic pigments in water, increasing production costs and cycle times.
Innovation Solution
The process integrates hydrophobic colorants directly into the organic solvent with polyester resin during phase inversion emulsification, eliminating the need for surfactant-based dispersion and enhancing pigment loading and latex production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional methods disperse hydrophobic pigments in water using surfactants, then homogeneous dispersion is achieved, but production cost and energy demand increase
Solution Approach 1:
The patent extracts the hydrophobic pigment from the aqueous dispersion system and incorporates it directly into the organic solvent phase during latex synthesis. This eliminates the need for separate pigment dispersion steps and surfactant-based processing, thereby reducing production costs while maintaining homogeneous color distribution in the final latex particles.
Solution Approach 2:
The pigment is incorporated into the organic solvent mixture before the phase inversion process begins. This preliminary incorporation ensures that the pigment is already in the correct phase and position when the latex forms, eliminating the need for subsequent dispersion steps and reducing overall manufacturing complexity and cost.
2Quantity of substance
If conventional methods disperse hydrophobic pigments in water, then colorant is incorporated, but cycle time increases
Solution Approach 1:
The patent merges the pigment incorporation step with the latex synthesis process itself. By adding the hydrophobic pigment to the organic solvent phase at the beginning and utilizing the phase inversion process, both the latex formation and pigment incorporation occur simultaneously, eliminating separate processing steps and reducing cycle time.
Solution Approach 2:
The pigment is pre-mixed with the organic solvent and resin before the phase inversion process. This preliminary preparation ensures that when the phase inversion occurs, the pigment is already positioned correctly and incorporated into the latex particles as they form, eliminating the need for time-consuming post-synthesis dispersion steps.
3Ease of manufacture
If hydrophobic colorants are integrated during phase inversion emulsification, then manufacturing cost decreases, but pigment dispersion homogeneity must be maintained
Solution Approach 1:
The patent extracts the pigment from the aqueous phase and places it in the organic solvent phase during synthesis. This ensures the pigment remains in a homogeneous environment throughout the process, eliminating the need for separate dispersion steps while maintaining uniform distribution. The phase inversion process then carries this homogeneous distribution into the final latex particles.
Solution Approach 2:
The patent changes the phase environment of the pigment from aqueous to organic during synthesis. By dissolving the hydrophobic pigment in the organic solvent at appropriate concentrations and utilizing the phase inversion process, the system maintains homogeneous pigment distribution while reducing manufacturing complexity and cost.
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 reduces manufacturing costs, increases toner production efficiency, and avoids the need for pigment dispersions, resulting in more efficient and cost-effective production of colored polyester resin particles for toner production.
Implementation Method 1
dissolving a hydrophobic colorant, such as, a pigment, in an organic solvent along with a polyester resin
Implementation Method 2
water is added to convert the dispersion into stable oil-in-water (O/W) latex
Data Source
AI summary
A process for making colored polyester latex by phase inversion emulsification is described.