Solvent-Free Phase Inversion for Toner Emulsions
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Solution Overview
Problem
Current methods for producing toners, such as solvent-based emulsion aggregation, are environmentally unfriendly, costly, and inefficient due to the use of organic solvents, which require lengthy evaporation processes and result in variable residual solvent amounts affecting the toner process and product.
Innovation Solution
A process involving melt mixing of resins without organic solvents, optionally adding surfactants and basic agents, followed by phase inversion to create a phase-inverted emulsion with toner-sized droplets, which are then solidified to form toner particles, reducing the number of stages and materials used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solvent-based phase inversion emulsification is used to produce resin emulsions, then the emulsion can be formed effectively, but large amounts of organic solvents must be evaporated which takes a long time and increases production cost
Solution Approach 1:
The invention extracts and eliminates the organic solvent component from the emulsification process. By using solvent-free phase inversion emulsification, the process removes the need for solvent addition and subsequent evaporation steps, directly addressing the time-consuming evaporation problem while maintaining effective emulsion formation
Solution Approach 2:
The invention changes the fundamental parameter of solvent content from 'solvent-containing' to 'solvent-free'. This parameter change transforms the process from requiring lengthy evaporation to direct emulsion formation, significantly reducing production time while maintaining emulsion quality
2Ease of manufacture
If solvent-based processes are used for resin emulsion production, then emulsification can be achieved, but waste treatment and solvent recovery add extra cost to the process
Solution Approach 1:
The invention extracts and removes the organic solvent from the process system entirely. By implementing solvent-free phase inversion emulsification, it eliminates the need for waste treatment and solvent recovery infrastructure, simplifying the manufacturing system while maintaining emulsification capability
Solution Approach 2:
The invention converts the harmful aspect of solvent use (environmental pollution and cost) into a benefit by completely eliminating solvent from the process. The phase inversion mechanism works effectively without solvent, turning a potentially harmful process into an environmentally friendly one
3Ease of manufacture
If solvent-containing processes are used for toner production, then resin dissolution and emulsification are facilitated, but residual solvent amounts vary affecting toner process and product quality
Solution Approach 1:
The invention extracts and eliminates organic solvent from the process, removing the source of residual solvent variability. By using solvent-free phase inversion emulsification, it ensures consistent toner production without the quality issues caused by variable residual solvent amounts
Solution Approach 2:
The invention changes the solvent content parameter from variable (in solvent-based processes) to zero (solvent-free). This parameter change eliminates residual solvent control issues entirely while maintaining effective resin dissolution and emulsification through the phase inversion mechanism
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 toner particles efficiently, reduces environmental impact, and minimizes production costs by eliminating the need for organic solvents and simplifying the process, while maintaining the molecular weight properties of the starting resin.
Implementation Method 1
adding to the resin a basic agent and water, performing a phase inversion to create a phase inversed emulsion including a disperse phase comprising toner-sized droplets
Implementation Method 2
solidifying the toner-sized droplets to result in toner particles
Data Source
AI summary
A process for making a resin emulsion suitable for use in forming toner particles includes melt mixing a resin possessing acid groups at a temperature higher than the glass transition temperature of the resin, optionally adding a surfactant before, prior to, during, or after melt mixing the resin, and adding a basic neutralization agent and water to the resin to form an emulsion. In embodiments, the resin emulsion thus produced may be utilized to form a toner.