Polymerized Toner Viscosity Control for Uniform Colorant Dispersion
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Solution Overview
Problem
Existing processes for producing polymerized toners in electrophotographic systems face challenges in achieving uniform colorant dispersion, leading to insufficient printing density and reduced production efficiency due to high initial viscosity changes and uneven media particle distribution during the dispersing treatment.
Innovation Solution
A process involving a media type dispersing machine is optimized by controlling the initial viscosity of the polymerizable monomer mixture within specific ranges and using a preliminary dispersion step to adjust the particle size and distribution of the colorant, followed by fine dispersion to achieve a viscosity increase ratio within optimal limits, ensuring uniform colorant distribution and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high shearing force is applied to disperse colorant in monomer composition, then dispersion level of colorant is improved, but viscosity of monomer composition greatly changes and media particles become unevenly distributed, lowering dispersing efficiency
Solution Approach 1:
The patent applies preliminary action by controlling the initial viscosity of the monomer composition before dispersing treatment. By pre-adjusting the viscosity to a specific range (1-100 mPa·s) through additives or monomer selection, the system ensures optimal dispersion conditions from the start, preventing excessive viscosity changes during high-shearing dispersion and maintaining media particle uniformity throughout the process.
2Manufacturing precision
If media type dispersing machine is used to achieve fine dispersion of colorant, then uniformity of colorant distribution is improved, but time required for dispersion becomes long, reducing production efficiency
Solution Approach 1:
The patent applies parameter changes by optimizing the initial viscosity parameter of the monomer composition to a specific range (1-100 mPa·s). This parameter optimization enables the media type dispersing machine to achieve fine and uniform colorant distribution more rapidly, reducing the dispersion time from hours to minutes while maintaining high uniformity standards required for quality toner production.
3Manufacturing precision
If viscosity of monomer composition is increased during dispersing treatment, then colorant dispersion is enhanced, but media particles are unevenly distributed in separation part, lowering dispersing efficiency
Solution Approach 1:
The patent applies preliminary action by pre-controlling the initial viscosity of the monomer composition to a specific range (1-100 mPa·s) before the dispersing treatment. This preliminary viscosity control ensures that during high-shearing dispersion, the viscosity increase remains within acceptable limits (10-1000 times initial viscosity), preventing uneven media particle distribution in the separation part while still achieving effective colorant dispersion.
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 results in a polymerized toner with improved printing density and stability, enabling continuous and efficient production by preventing clogging and maintaining efficient operation of the dispersing machine.
Implementation Method 1
high shearing force is applied to a mixture containing the polymerizable monomer and the colorant to stir the mixture, thereby dispersing the colorant
Implementation Method 2
the fine droplets are then polymerized, thereby producing colored polymer particles
Data Source
AI summary
A process for producing a polymerized toner, comprising the step of polymerizing a polymerizable monomer composition containing a polymerizable monomer and a colorant in the presence of a polymerization initiator in an aqueous dispersion medium to form colored polymer particles, the process comprising the steps of mixing the polymerizable monomer with the colorant to prepare a polymerizable monomer mixture having an initial viscosity of 10 to 3,000 mPa·s or 0.3 to 1 mPa·s as measured at 25° C. by a Brookfield type viscometer, and then feeding the polymerizable monomer mixture to a media type dispersing machine to finely disperse the colorant by the media type dispersing machine, thereby preparing a dispersed polymerizable monomer mixture having a viscosity after the dispersion, the ratio of increase in viscosity of which is 1.0 to 10 times or 100 to 2,000 times as high as the initial viscosity.