Resin Particle Dispersion via Phase-Inversion Power Control
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Solution Overview
Problem
Existing methods for producing resin particle dispersions result in the formation of coarse and fine particles due to inadequate agitation power during phase inversion emulsification, leading to issues with toner quality and image unevenness.
Innovation Solution
A method involving phase-inverted emulsion production with controlled agitation power between 0.4 W to 20 W per unit mass of resin, using a neutralizer to neutralize a resin solution in an organic solvent and adding an aqueous medium, followed by solvent removal, to minimize coarse and fine particle formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If maximum agitation power per unit mass of resin is less than 0.4 W or more than 20 W during phase inversion emulsification, then phase inversion emulsification can be performed, but coarse particles and fine particles occur leading to poor toner quality
Solution Approach 1:
The patent applies parameter changes by precisely controlling the maximum agitation power per unit mass of resin within the range of 0.4 to 20 W during phase inversion emulsification. This specific parameter range resolves the contradiction by preventing both coarse and fine particle formation while maintaining uniform particle size distribution, thereby improving manufacturing precision without making the process difficult to control.
2Use of energy by moving object
If inadequate agitation power is used during phase inversion emulsification, then energy consumption is reduced, but coarse and fine particles form leading to image unevenness
Solution Approach 1:
The patent optimizes the agitation power parameter to a specific range (0.4 to 20 W per unit mass of resin) that balances energy consumption with particle size control. This parameter optimization ensures adequate particle formation control without excessive energy consumption, resolving the contradiction between energy efficiency and manufacturing precision.
3Stability of the object's composition
If high agitation power is used during phase inversion emulsification, then particle dispersion is improved, but fine particles occur and toner quality deteriorates
Solution Approach 1:
The patent applies parameter changes by setting the maximum agitation power per unit mass of resin within the optimal range of 0.4 to 20 W. This controlled parameter range achieves sufficient resin particle dispersion while preventing the formation of fine particles, thereby maintaining both composition stability and manufacturing precision simultaneously.
4Device complexity
If phase inversion emulsification is performed without controlled agitation power, then the process is simpler, but coarse and fine particles form reducing image stability
Solution Approach 1:
The patent resolves the contradiction by establishing a specific parameter range for agitation power (0.4 to 20 W per unit mass of resin) that can be implemented with relatively simple equipment while ensuring reliable particle formation. This parameter control improves image stability without requiring complex agitation control systems.
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
Reduces the occurrence of coarse and fine particles, enhancing toner quality and preventing exposure of low-melting components, thereby improving image stability and reducing image unevenness.
Implementation Method 1
adding a neutralizer to a resin solution prepared by dissolving a resin having an acid value in an organic solvent to thereby neutralize the resin
Implementation Method 2
adding an aqueous medium to subject the resin to phase inversion emulsification
Implementation Method 3
removing the organic solvent from the phase-inverted emulsion
Data Source
AI summary
A method for producing a resin particle dispersion includes: obtaining a phase-inverted emulsion by adding a neutralizer to a resin solution prepared by dissolving a resin having an acid value in an organic solvent to thereby neutralize the resin and then adding an aqueous medium to the resulting resin solution to subject the resin to phase inversion emulsification; and removing the organic solvent from the phase-inverted emulsion. In the course of obtaining the phase-inverted emulsion, a maximum agitation power per unit mass (kg) of the resin when the resin solution containing the aqueous medium added thereto is agitated to perform the phase inversion emulsification is from 0.4 W to 20 W inclusive.