Polymerized Toner Stripping via Gas Injection and Vacuum

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Solution Overview

Problem

Existing methods for producing polymerized toners using the polymerization method struggle to efficiently remove residual monomer and VOC, leading to issues like aggregation, degradation of ingredients, and reduced print durability, especially under varying temperature and humidity conditions.

Innovation Solution

A method involving the injection of air or inert gas under reduced pressure with specific flow rates and stirring conditions in an evaporator to strip residual monomer and VOC from the aqueous dispersion medium, while controlling temperature and bubble levels, is employed to produce toners with improved durability and environmental safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If residual monomer and VOC are removed by heating the aqueous dispersion medium after polymerization, then residual monomer and VOC can be removed, but colored polymer particles aggregate and ingredients degrade

Engineering Contradiction:

Improveresidual monomer and VOCVSAvoidtoner quality

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The patent changes the physical state parameter from liquid (aqueous dispersion medium) to gas (vapor phase) by heating, enabling removal of residual monomer and VOC through evaporation and stripping while controlling the process to prevent aggregation and degradation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts residual monomer and VOC from the colored polymer particles by passing vapor through the aqueous dispersion medium, separating these harmful substances from the toner particles through vapor-phase stripping

Inventive Principle:

Principle #2Taking out (Extraction)

2Loss of substance

If heating time and temperature are increased to remove residual monomer and VOC, then removal efficiency improves, but colored polymer particles aggregate and ingredients degrade

Engineering Contradiction:

Improveresidual monomer and VOCVSAvoidparticle aggregation control

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The patent implements feedback control by monitoring the removal efficiency of residual monomer and VOC while adjusting heating parameters in real-time to prevent aggregation and degradation, stopping the process when removal efficiency decreases

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent uses periodic vapor generation and passage through the aqueous dispersion medium, alternating between vapor generation phases and non-vapor phases to continuously remove residual monomer and VOC while preventing constant high-temperature exposure that causes aggregation

Inventive Principle:

Principle #19Periodic action

3Loss of substance

If conventional stripping methods are used, then residual monomer and VOC can be removed, but the process is complex and energy-consuming

Engineering Contradiction:

Improveresidual monomer and VOCVSAvoidstripping process complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent merges the polymerization process and stripping process into a single integrated step, where vapor generated during polymerization is directly used to strip residual monomer and VOC from the colored polymer particles, eliminating the need for separate stripping equipment

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent enables the system to serve itself by using the vapor generated during polymerization to perform the stripping function, eliminating the need for external stripping agents or complex stripping systems

Inventive Principle:

Principle #25Self-service

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 stably and efficiently produces polymerized toners with low residual monomer and VOC, enhancing print durability and environmental safety across different temperature and humidity environments.

Implementation Method 1

a stripping step of injecting a gas comprised of air or an inert gas into the dispersion liquid of the colored polymer particles while stirring the dispersion liquid in an evaporator

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

removing the residual monomer and residual VOC from the colored polymer particles

Methodology Applied

Scientific EffectMass transfer: Diffusion

Data Source

PatentUS7709176B2Method for producing polymerized toner

Publication Date: 2010.05.04 ZEON CORP

AI summary

A method for producing a polymerized toner comprising a step of polymerizing a polymerizable monomer composition in an aqueous dispersion medium in the presence of a polymerization initiator to obtain a dispersion liquid of colored polymer particles and a stripping step of injecting a gas comprised of air or an inert gas into the dispersion liquid of the colored polymer particles while stirring the dispersion liquid in an evaporator and the flow rate of the gas injected per weight of the colored polymer particles being 0.05 to 4 L/(hr·kg), the pressure of the vapor phase of the evaporator being 5 to 80 kPa.