Toner Production Circulation System for Uniform Particle Size
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Solution Overview
Problem
Existing methods for producing toner for developing electrostatic charge images often result in oversized toner particles due to high viscosity of the liquid dispersion, leading to poor mixing and particle overgrowth, which is not effectively addressed by reducing viscosity before heating.
Innovation Solution
A method involving the circulation of a liquid dispersion containing binder-resin particles between a stirring vessel and a disperser applying mechanical shear force, with the addition of a flocculant to reduce viscosity and promote aggregation, followed by heating to form toner particles, ensuring uniform size distribution and preventing oversized particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the liquid dispersion is heated to form aggregated particles without reducing viscosity, then aggregation occurs, but oversized toner particles are formed due to poor mixing and particle overgrowth
Solution Approach 1:
The liquid dispersion is circulated between a stirring vessel and disperser before heating to pre-mix the flocculant and binder-resin particles, ensuring uniform distribution and preventing localized overgrowth during subsequent heating and aggregation
Solution Approach 2:
The circulation system maintains continuous mixing and heat treatment during the aggregation process, preventing particle overgrowth by ensuring uniform temperature and concentration distribution throughout the liquid dispersion
2Quantity of substance
If the viscosity of the liquid dispersion is high during heating, then aggregated particles form, but mixing efficiency deteriorates leading to oversized toner
Solution Approach 1:
A circulation system acts as an intermediary mechanism, continuously moving the liquid dispersion between stirring and dispersing zones to maintain effective mixing even when viscosity increases during aggregation and heating processes
Solution Approach 2:
The system dynamically adjusts the circulation flow to match the changing viscosity conditions during heating, maintaining optimal mixing efficiency throughout the aggregation process by adapting flow rates and circulation patterns
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 oversized toner in the finished product by ensuring the liquid dispersion is not too viscous during heating, resulting in toner particles with a relatively narrow size distribution and improved mixing efficiency.
Implementation Method 1
a disperser that applies a mechanical shear force
Implementation Method 2
forming aggregated particles by heating the liquid dispersion with the flocculant therein
Implementation Method 3
forming toner particles by heating the liquid dispersion containing the aggregated particles and thereby making the aggregated particles fuse and coalesce
Data Source
AI summary
A method for producing a toner for developing an electrostatic charge image includes: mixing at least one flocculant into a liquid dispersion containing binder-resin particles by adding the flocculant into the liquid dispersion containing binder-resin particles while circulating the liquid dispersion containing binder-resin particles between a stirring vessel and a disperser that applies a mechanical shear force; forming aggregated particles by heating the liquid dispersion with the flocculant therein after reducing the viscosity of the liquid dispersion; and forming toner particles by heating the liquid dispersion containing the aggregated particles and thereby making the aggregated particles fuse and coalesce.