Oscillatory Flow Reactor for Toner Emulsion Aggregation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current toner production methods are inefficient and lack precise control over charging properties, which affects imaging speed and quality.
Innovation Solution
A continuous oscillatory flow reactor process is used to produce toner particles by aggregating resin, colorant, and optional wax components, with baffles providing independent mixing and fluid flow, allowing for controlled residence times and pH adjustments, resulting in toner particles with consistent size and charging properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional batch emulsion aggregation process is used, then toner particles can be produced, but production time is long and control over charging properties is poor
Solution Approach 1:
The patent implements a continuous emulsion aggregation process where monomers, initiators, and other components are continuously fed into a reactor, allowing the aggregation process to proceed without interruption. This continuous operation reduces production time compared to batch processing while maintaining consistent control over toner particle charging properties through controlled continuous addition of charge control agents.
Solution Approach 2:
The patent employs controlled changes in process parameters including temperature, pH, and the continuous addition of charge control agents during the aggregation process. By dynamically adjusting these parameters during continuous processing, the invention achieves both reduced production time and precise control over the charging properties of toner particles.
2Manufacturing precision
If charge control agents are added to control triboelectric charging, then charging properties improve, but process complexity increases
Solution Approach 1:
The patent uses charge control agents as intermediary substances that are continuously added to the reaction mixture. These agents mediate the charging process by controlling triboelectric charging between toner particles and carrier beads, enabling precise control over charging properties without requiring complex equipment or multi-step processes.
Solution Approach 2:
The continuous addition of charge control agents during the aggregation process simplifies the overall process compared to batch methods requiring separate charging steps. The continuous process integrates charging control into the main aggregation operation, reducing process complexity while maintaining precise control over charging properties.
3Productivity
If continuous processing is implemented, then production efficiency increases, but control over residence time and mixing becomes more difficult
Solution Approach 1:
The patent employs dynamic control of residence time by adjusting flow rates, temperatures, and agitation speeds during the continuous process. The system dynamically adapts these parameters to maintain optimal mixing conditions and controlled residence times, ensuring consistent toner particle formation while maintaining high production efficiency.
Solution Approach 2:
The continuous process incorporates feedback mechanisms that monitor process parameters such as temperature, pH, and flow rates, allowing real-time adjustments to maintain optimal residence time and mixing conditions. This feedback control enables precise management of process variables while sustaining high productivity.
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 process enables the production of toner particles with a consistent volume average particle size of 4 to 12 microns and improved control over charging properties, enhancing imaging speed and quality.
Implementation Method 1
emulsion aggregation (EA) is one such method. These toners are within the purview of those skilled in the art and toners may be formed by aggregating a colorant with a resin formed by emulsion polymerization
Implementation Method 2
providing an oscillatory flow continuous reactor comprising at least one tubular member possessing at least one entry port, at least one outlet port, and a plurality of baffles
Implementation Method 3
the components of the toner have a residence time in the tubular member of from about 5 minutes to about 180 minutes
Implementation Method 4
Placing charge on the particles, to enable movement and development of images via electric fields, is most often accomplished with triboelectricity. Triboelectric charging may occur either by mixing the toner with larger carrier beads in a two component development system or by rubbing the toner between a blade and donor roll in a single component system
Data Source
AI summary
The present disclosure provides for oscillatory flow continuous reactors suitable for use in forming emulsion aggregation toners. The reactor may include at least one receptacle being a flexible, tubular member. The reactor may also include a plurality of baffles disposed, at spaced apart intervals, along an interior space of the tubular member, each of the plurality of baffles including one or more orifices. Additionally, one or more fluids may flow through the tubular member. The oscillatory flow continuous reactor may be used in an emulsion aggregation process to produce toner particles.