Liquid Column Resonance Chamber for Uniform Toner Production
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Solution Overview
Problem
Existing methods for producing uniformly-shaped particulate materials, such as toner, face challenges including droplet uniting issues during ejection, leading to varied particle sizes and decreased production efficiency, and increased costs due to the need for complex airflow systems.
Innovation Solution
A particulate material production method utilizing a liquid column resonance chamber to generate standing waves for droplet ejection, combined with perpendicular airflow to control droplet flight direction and prevent uniting, resulting in a uniformly-shaped toner production apparatus with a droplet ejector, gas feeder, and solidifying device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If droplet ejection is performed using conventional methods, then production efficiency is reduced due to droplet uniting, but using complex airflow systems to prevent uniting increases device complexity and cost
Solution Approach 1:
The invention applies ultrasonic vibration to the nozzle at a frequency of 20 kHz or higher to generate standing waves in the liquid column, causing periodic ejection of uniform droplets. This mechanical vibration approach replaces complex airflow control systems while achieving precise droplet size control and preventing droplet uniting through consistent ejection timing and spacing.
Solution Approach 2:
The invention changes the operating parameters by using ultrasonic frequencies (20 kHz or higher) and controlling the liquid column resonance conditions to achieve stable droplet ejection. By adjusting vibration frequency, liquid flow rate, and nozzle dimensions, uniform droplets are produced without requiring complex airflow management systems.
2Manufacturing precision
If soap-free polymerization is used to produce uniformly-shaped particulate resin, then particle form is nearly spherical with sharp particle diameter distribution, but production time is long and requires large amounts of water and energy for solvent removal
Solution Approach 1:
The invention performs preliminary action by forming uniform droplets with precise size control before solidification. By using ultrasonic vibration to create monodisperse droplets and immediately solidifying them, the method achieves sharp particle diameter distribution without requiring subsequent lengthy polymerization reactions or extensive washing processes.
Solution Approach 2:
The invention replaces the chemical polymerization process with a physical droplet formation and solidification process. Instead of using soap-free polymerization that requires long reaction times and extensive water removal, the method uses ultrasonic mechanical vibration to form droplets followed by rapid solidification, dramatically reducing production time and energy consumption.
3Reliability
If airflow is supplied vertically from the entrance to prevent droplet uniting, then droplet uniting is reduced, but pressure difference causes air to spread laterally and droplets from adjacent lines unite
Solution Approach 1:
The invention uses ultrasonic vibration of the liquid column at ultrasonic frequencies to achieve precise and stable droplet ejection. This mechanical vibration method provides inherent stability in droplet formation and spacing, eliminating the need for complex vertical airflow systems that cause lateral spreading and adjacent droplet uniting.
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 method enables the production of uniformly-sized toner particles with a sharp particle diameter distribution, improving efficiency and reducing costs by preventing droplet uniting and enhancing production control.
Implementation Method 1
vibrating a particulate material composition liquid in a liquid column resonance chamber having at least one nozzle to form a standing wave in the particulate material composition liquid caused by liquid column resonance
Implementation Method 2
The reshaped droplets are then dried, resulting in formation of a particulate toner
Implementation Method 3
feeding a gas in a direction substantially perpendicular to the droplet ejection direction to change the flight direction of the ejected droplets
Implementation Method 4
solidifying the droplets in the space to produce the particulate material
Data Source
AI summary
The particulate material production method includes vibrating a particulate material composition liquid in a liquid column resonance chamber having at least one nozzle to form a standing wave in the particulate material composition liquid caused by liquid column resonance, so that droplets of the particulate material composition liquid are ejected in a droplet ejection direction from the nozzle so as to fly in a space in a flight direction; feeding a gas in a direction substantially perpendicular to the droplet ejection direction to change the flight direction of the ejected droplets; and solidifying the droplets in the space to produce a particulate material. The particulate material composition liquid includes at least a solvent and a component of the particulate material dissolved or dispersed in the solvent, and the nozzle is located at a location corresponding to an anitnode of the standing wave.