Phase Change Ink Homogenization via Multi-Stage In-Line Rotor-Stator
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Solution Overview
Problem
Existing methods for preparing phase change or solid inks, such as those used in ink jet systems, lack flexibility and do not provide adequate homogenization capabilities, leading to suboptimal particle size distribution and ink quality.
Innovation Solution
A process utilizing a multiple-stage in-line homogenizer with rotor-stator style blades, installed externally to the mixing vessel, which allows for high-shear dispersion of coloring materials in a medium at temperatures above 100°C, followed by filtration to achieve submicron particle sizes and improved ink quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-stage batch mixer is used, then the device complexity is low, but the manufacturing precision of particle size distribution is insufficient
Solution Approach 1:
The mixing process is divided into multiple stages using a multi-stage homogenizer system. Each stage performs a specific function in the dispersion process, with subsequent stages building upon the previous one to achieve progressively finer particle sizes and more uniform distributions.
Solution Approach 2:
The system performs preliminary dispersion actions in earlier stages before reaching the final stage. Each stage prepares the mixture for the next, progressively breaking down aggregates and distributing particles more uniformly before the final homogenization.
2Adaptability or versatility
If in-tank homogenizers are used, then the device complexity is low, but the adaptability to different vessel geometries is limited
Solution Approach 1:
The homogenizer is extracted from the tank interior and installed externally on the vessel. This external mounting allows the homogenizer to be adapted to various vessel geometries and configurations without being constrained by internal tank structure, while the homogenization function remains separate from the containment structure.
3Manufacturing precision
If high shear mixing is applied, then the manufacturing precision of particle size is improved, but the use of energy increases
Solution Approach 1:
The high-shear mixing process is segmented into multiple stages rather than applying maximum shear continuously. Each stage applies appropriate shear force for that stage's specific dispersion needs, with energy input optimized for each phase of the homogenization process.
Solution Approach 2:
The mixing process uses periodic or cyclic action patterns where the homogenizer operates in alternating phases of high-shear mixing and lower-shear recovery. This allows the system to achieve fine particle sizes through intermittent high-shear events rather than continuous maximum-power operation.
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 approach enables the production of inks with narrower particle size distributions and enhanced stability, ensuring better image quality and long-term storage, as evidenced by successful filtration tests and improved performance in ink jet applications.
Implementation Method 1
mixing the dispersion in an in-line homogenizer at high shear until the particle size of the coloring material is less than 0.2 μm
Implementation Method 2
filtering the dispersion at a molten state with one or more filters
Implementation Method 3
obtaining an extrusion of coloring material from an extruder
Data Source
AI summary
The presently disclosed embodiments are directed to processes for making phase change or solid ink used in ink jet system recording apparatuses (e.g., printer, copying machine, facsimile, word processor, plotter, and the like). More particularly, the embodiments pertain to the preparation of pigment or dye-based solid ink using a rotor-stator style, in-line homogenizer.