Nozzle Array for Toner Manufacturing via Droplet Solidification
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Solution Overview
Problem
Existing toner manufacturing methods, particularly polymerization methods, face challenges with long processing times, high water and energy consumption, and widened particle size distribution due to coalescence of liquid droplets during the drying process, while injection granulation methods struggle to maintain narrow particle size distribution without overlapping nozzles.
Innovation Solution
An apparatus employing a liquid droplet discharge device with multiple nozzles arranged to prevent overlap relative to airflow direction, utilizing liquid column resonance to form uniform droplets, which are then solidified by airflow, ensuring a narrow particle size distribution and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple nozzles are arranged in parallel with the direction of feed of airflow in injection granulation methods, then the manufacturing efficiency is improved, but the discharged liquid droplets containing fine particle constituents are likely to intersect and coalesce with each other before reaching the drying area
Solution Approach 1:
The patent changes the arrangement dimension of multiple nozzles from parallel (one-dimensional alignment) to non-overlapping spatial distribution (two-dimensional or three-dimensional arrangement). This dimensional change prevents droplet intersection and coalescence while maintaining high manufacturing efficiency through parallel processing capability.
2Ease of manufacture
If liquid droplets are discharged from nozzles in injection granulation methods, then the processes for washing and drying toner particles can be eliminated, but some liquid droplets may coalesce with each other before being dried and the coalesced particles may be dried into toner particles
Solution Approach 1:
The patent applies spatial arrangement in additional dimensions to prevent droplet coalescence. By distributing nozzles in non-overlapping positions, the system maintains the simplified one-step drying process while ensuring uniform particle size distribution through prevention of droplet merging.
3Productivity
If multiple nozzles are arranged to discharge liquid droplets, then the productivity is improved, but the discharged liquid droplets are likely to intersect and coalesce before reaching the drying area
Solution Approach 1:
The patent resolves the contradiction by arranging nozzles in a multi-dimensional non-overlapping configuration. This spatial arrangement allows multiple droplets to be discharged simultaneously (maintaining productivity) while preventing their intersection and coalescence (maintaining particle size precision).
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 apparatus effectively prevents coalescence of liquid droplets, resulting in toner particles with a very narrow particle diameter distribution and improved productivity, reducing energy consumption and processing time.
Implementation Method 1
employing injection granulation using liquid column resonance
Implementation Method 2
The liquid droplet solidification device is adapted to solidify the liquid droplets by an airflow
Data Source
AI summary
An apparatus for manufacturing fine particles is provided. The apparatus includes a liquid droplet discharge device and a liquid droplet solidification device. The liquid droplet discharge device has multiple nozzles. The liquid droplet discharge device is adapted to discharge a liquid from the multiple nozzles to form the liquid into liquid droplets. The liquid comprises a solvent in which constituents of the fine particles are dissolved or dispersed or a melt of constituents of the fine particles. The liquid droplet solidification device is adapted to solidify the liquid droplets by an airflow. The multiple nozzles are arranged in a manner such that each of the nozzles does not overlap each other relative to a direction of the airflow.