Loop-Type Flash Dryer Toner Particle Fusion Prevention
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Solution Overview
Problem
The loop-type flash dryer used in toner manufacturing is prone to toner particle fusion with the drying pipe due to high-speed drying gas, which can be mitigated by reducing gas speed but results in insufficient drying efficiency.
Innovation Solution
A method utilizing a loop-type flash dryer with specific gas flow speed and temperature settings, including multiple blowing ports positioned strategically to control gas flow and prevent particle collisions, ensuring efficient drying without fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high speed drying gas is used in the loop-type flash dryer, then drying efficiency is improved, but toner particles are likely to collide with the drying pipe and fuse
Solution Approach 1:
The invention divides the single gas blowing port into multiple blowing ports (first blowing port and second blowing port) positioned at different locations in the drying pipe. This segmentation allows the gas flow to be distributed and controlled at multiple points, preventing localized high-speed gas streams from causing particle collisions and fusion while maintaining overall drying efficiency.
Solution Approach 2:
The invention applies different gas flow speeds at different locations by using multiple blowing ports with potentially different flow rates. The first blowing port supplies gas at speed A (4.5≤A≤14.5 m/s) and the second blowing port supplies gas at speed B (19.0≤B≤38.5 m/s), creating locally optimized flow conditions that prevent fusion while maintaining drying efficiency.
2Object-affected harmful factors
If the speed of drying gas is reduced to prevent particle collisions, then toner particle fusion is suppressed, but drying efficiency is lowered
Solution Approach 1:
The invention combines the effects of multiple gas blowing ports to achieve both fusion prevention and efficient drying. By merging the gas flows from the first blowing port (upstream) and second blowing port (downstream), the system creates a controlled gas circulation that suppresses particle fusion while maintaining sufficient drying capability through the combined heat and flow effects.
Solution Approach 2:
The loop-type flash dryer maintains continuous circulation of drying gas through the loop configuration, with multiple blowing ports ensuring continuous effective drying action throughout the system. This continuous action ensures that drying efficiency is maintained without requiring excessively high gas speeds that would cause fusion.
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 suppresses toner particle fusion while maintaining high drying efficiency by optimizing gas flow speeds and temperatures within the loop-type flash dryer.
Implementation Method 1
a gas stream circulating in a loop-type drying pipe
Implementation Method 2
gas stream circulating in a loop-type drying pipe
Implementation Method 3
drying gas for a shorter period of time
Implementation Method 4
a heat medium is generally used for removing the dispersion medium
Data Source
AI summary
A method of manufacturing toner particles, including a step of drying wet toner particles with a drying unit, the wet toner particles being obtained from an aqueous dispersion medium, wherein the drying unit includes a loop-type flash dryer in which the wet toner particles to be dried are supplied to a gas stream circulating in a loop-type drying pipe, the loop-type flash dryer includes: (i) a loop-type drying pipe; (ii) an inlet port for supplying wet toner particles to the loop-type drying pipe; (iii) an outlet port for discharging dried toner particles from the loop-type drying pipe; (iv) a first blowing port for blowing gas into the loop-type drying pipe; and (v) second blowing ports for blowing gas into the loop-type drying pipe.