Resin Particle Mixing Temperature Control for Toner Uniformity
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Solution Overview
Problem
Existing methods for producing resin particles often result in image unevenness due to segregation of dyes within the resin particles, particularly under high-temperature high-humidity conditions.
Innovation Solution
A method involving mixing a binder resin and a dye at a temperature that satisfies the condition where the melting point of the dye is less than or equal to the temperature, which is also less than or equal to the thermal decomposition temperature of the binder resin, followed by emulsification with a basic compound, water-based solvent, and surfactant to produce resin base particle dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the binder resin and dye are mixed at a temperature below the dye's melting point, then the resin maintains its structural integrity, but the dye does not melt and mix uniformly, causing image unevenness
Solution Approach 1:
The patent applies parameter changes by precisely controlling the mixing temperature to be at or above the dye's melting point but below the resin's decomposition temperature. This temperature parameter optimization enables the dye to melt and mix uniformly with the binder resin, resolving the contradiction between maintaining resin integrity and achieving uniform dye distribution.
2Manufacturing precision
If the mixing temperature is increased to melt the dye, then uniform mixing is achieved, but the resin may decompose if the temperature exceeds its thermal decomposition temperature
Solution Approach 1:
The patent resolves this contradiction by optimizing the temperature parameter within a specific range: T1 (dye melting point) ≤ T ≤ T2 (resin decomposition temperature). This controlled parameter change ensures the dye melts for uniform mixing while the resin remains intact, preventing decomposition.
Solution Approach 2:
The patent applies preliminary action by pre-drying the mixture to reduce moisture content before heating. This preliminary step prevents premature resin decomposition and allows controlled melting of the dye, ensuring uniform mixing without exceeding the resin's thermal stability limit.
3Ease of manufacture
If mixing is performed without pre-drying the mixture, then the process is simpler, but moisture causes resin decomposition and dye segregation during subsequent heating
Solution Approach 1:
The patent applies preliminary action by performing a pre-drying step before the main heating and mixing process. This preliminary removal of moisture prevents resin decomposition and dye segregation during subsequent heating, ensuring uniform mixing while maintaining process simplicity through a well-sequenced operation.
4Productivity
If the dye and binder resin are mixed without precise temperature control, then the manufacturing process is faster, but image unevenness occurs due to incomplete melting or segregation
Solution Approach 1:
The patent resolves this contradiction by optimizing the temperature parameter to a specific range that enables rapid melting of the dye while maintaining resin stability. This controlled parameter change allows fast mixing without sacrificing uniformity, as the dye melts quickly at the optimized temperature and distributes evenly throughout the binder resin.
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 method produces resin particles with improved uniformity of binder resin and dye mixing, leading to images with reduced image unevenness, especially under challenging environmental conditions.
Implementation Method 1
mixing a binder resin and a dye at temperature T that satisfies formula (1) below... the melting point T1 of the dye≤the temperature T≤the thermal decomposition temperature T2 of the binder resin
Implementation Method 2
the melting point T1 of the dye≤the temperature T≤the thermal decomposition temperature T2 of the binder resin
Implementation Method 3
emulsifying the mixture, a basic compound, a water-based solvent, and a surfactant to thereby obtain a resin base particle dispersion
Data Source
AI summary
A method for producing resin particles includes: mixing a binder resin and a dye at temperature T that satisfies formula (1) below to thereby obtain a mixture; and emulsifying the mixture, a basic compound, a water-based solvent, and a surfactant to thereby obtain a resin base particle dispersion:the melting point T1 of the dye≤the temperature T≤the thermal decomposition temperature T2 of the binder resin. Formula (1)