Magenta Toner Production via Elevated Temperature Phase Inversion
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Solution Overview
Problem
The production efficiency of magenta toner is low due to low yield, low throughput, high geometric standard deviation (GSD) values resulting from larger amounts of fine and coarse particles, primarily caused by the interaction of red colorants with other toner components in conventional latex emulsion aggregation methods.
Innovation Solution
An improved phase inversion emulsification process involving elevated temperatures above the glass transition temperature (Tg) of resins or the boiling point of solvents to accelerate solvent removal and alter the surface of latex particles, enhancing aggregation and productivity by reducing steric barriers and electrostatic interactions, thereby increasing the yield and throughput of magenta toner production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional solvent distillation is performed at temperatures below the Tg of resins or melting point of crystalline resins, then energy consumption is reduced and resin stability is maintained, but solvent removal efficiency is low and production throughput is reduced
Solution Approach 1:
The patent applies parameter changes by heating the emulsion to temperatures above the Tg of amorphous resins or above the melting point of crystalline resins during solvent distillation. This temperature parameter change accelerates solvent removal and alters the surface of latex particles to enhance aggregation, directly resolving the contradiction between solvent removal efficiency and energy consumption by accepting higher energy input to achieve dramatically improved productivity
Solution Approach 2:
The patent utilizes phase transitions of resins by heating above their Tg or melting point during the distillation process. This causes the resins to transition from a glassy or crystalline state to a more flexible or molten state, which accelerates solvent removal and modifies particle surfaces to reduce steric barriers and electrostatic interactions, thereby enhancing aggregation and overall production efficiency
2Productivity
If conventional PIE process is used with standard distillation temperatures, then resin stability is maintained, but production time is excessive and throughput is low
Solution Approach 1:
The patent implements parameter changes by elevating the distillation temperature above the Tg of amorphous resins or above the melting point of crystalline resins. This parameter modification simultaneously accelerates solvent removal, alters latex particle surfaces to enhance aggregation, and reduces production time, directly addressing the contradiction between production throughput and production duration
Solution Approach 2:
The patent applies preliminary action by pre-heating the emulsion to high temperatures before and during the solvent distillation phase. This preliminary thermal treatment prepares the resin matrix and particle surfaces in advance, facilitating faster solvent removal and subsequent aggregation, thereby reducing overall production time while increasing throughput
3Manufacturing precision
If red colorants are used in conventional toner production, then magenta color is achieved, but interaction with other toner components causes high GSD values and particle size variability
Solution Approach 1:
The patent applies parameter changes by heating the emulsion to temperatures above the Tg of amorphous resins or above the melting point of crystalline resins during solvent distillation. This temperature parameter change alters the surface of latex particles, reducing steric barriers and electrostatic interactions that cause problematic colorant-component interactions, thereby decreasing GSD values and improving particle size uniformity while maintaining magenta color quality
Solution Approach 2:
The patent utilizes phase transitions of resins during heated distillation to modify the surface properties of latex particles. This phase change process reduces steric barriers and electrostatic interactions, minimizing harmful interactions between red colorants and other toner components, resulting in improved particle size uniformity and reduced GSD values
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 process results in a higher yield, increased throughput, and reduced processing time for magenta toner production, with a 25% shorter solvent stripping phase and improved toner quality, specifically reducing coarse particle content and enhancing commercial-scale production efficiency.
Implementation Method 1
solvent is distilled with said first emulsion exposed to a temperature above the Tg of an amorphous resin, the melting point of a crystalline resin or both
Implementation Method 2
solvent is distilled with said first emulsion exposed to a temperature above the Tg of an amorphous resin
Implementation Method 3
exposed to a temperature above the Tg of an amorphous resin, the melting point of a crystalline resin or both when contained in said first emulsion
Data Source
AI summary
A process for making a latex emulsion where distillation occurs at an elevated temperature is used to make resin particles with a conditioned surface which can be used to make magenta toner with increased efficiency.