Toner Manufacturing Agitation Speed Control
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Solution Overview
Problem
In the manufacturing of electrostatic charge image developing toners, the existing methods face challenges in reducing the generation of coarse particles due to particle agitation, which affects the quality and consistency of the toner particles.
Innovation Solution
A manufacturing method that involves aggregating binder resin particles in a dispersion to form aggregated particles, followed by heating them while gradually decreasing the agitation speed after reaching the glass transition temperature of the binder resin, to fuse the particles and minimize coarse particle formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the agitation speed is maintained at a constant high level during heating to ensure thorough mixing of particles, then mixing efficiency is improved, but coarse particles are generated due to excessive mechanical stress
Solution Approach 1:
The agitation speed is dynamically adjusted during the heating process. Initially, agitation is performed at a first speed to mix particles thoroughly, then the speed is reduced to a second speed (lower than the first) when the binder resin reaches its glass transition temperature to prevent coarse particle formation while maintaining sufficient mixing.
Solution Approach 2:
The agitation process is divided into distinct phases with different speeds. The first agitation phase occurs at higher speed before heating, and the second agitation phase occurs at lower speed during heating after the glass transition temperature is reached, creating a periodic variation in agitation intensity that optimizes both mixing and particle integrity.
2Object-generated harmful factors
If the agitation speed is decreased to reduce coarse particle formation, then particle quality is improved, but mixing efficiency deteriorates
Solution Approach 1:
Thorough mixing is performed at higher agitation speed before the heating process begins, ensuring that particles are well-distributed. This preliminary mixing action prevents the need for high-speed agitation during heating, allowing the system to switch to lower speed without compromising overall mixing quality.
Solution Approach 2:
The agitation speed parameter is changed based on the thermal state of the binder resin. When the temperature reaches the glass transition temperature, the agitation speed is reduced from the first speed to the second speed, optimizing the balance between mixing efficiency and coarse particle prevention at different stages of the process.
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 effectively reduces the generation of coarse particles by controlling the agitation speed post-heating, resulting in improved toner particle quality and consistency.
Implementation Method 1
heating the aggregated particles to raise a temperature of the aggregated particles and fuse the aggregated particles
Implementation Method 2
fuse the aggregated particles
Implementation Method 3
after raising the temperature to equal to or higher than a glass transition temperature of a binder resin in the binder resin particles
Data Source
AI summary
A manufacturing method of an electrostatic charge image developing toner includes aggregating particles including binder resin particles in a dispersion to form aggregated particles and heating the aggregated particles to raise a temperature of the aggregated particles and fuse the aggregated particles, in which, in the fusing, after raising the temperature to equal to or higher than a glass transition temperature of a binder resin in the binder resin particles, while agitating a dispersion containing the aggregated particles, an agitating rotation speed in the agitation of the dispersion is decreased in a stepwise manner or in a continuous manner.