Toner Classification Rotor Segmented Vanes Pressure Loss
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Solution Overview
Problem
Current toner classification methods face challenges in achieving high yields of small diameter toner particles due to erroneous suctioning of larger particles and increased pressure loss, particularly when using centrifugal wind force classifiers, which affects the quality and productivity of electrophotographic processes.
Innovation Solution
A toner classification apparatus with a classification rotor design featuring a combination of first and second vane groups, where the second vanes have a shorter length than the first vanes, and specific gap relationships between them, optimizing the balance between centrifugal force and air flow to improve particle separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a centrifugal wind force classifier is used to remove small diameter particles, then classification capability is improved, but particles with too small diameter are erroneously suctioned and removed, reducing yield
Solution Approach 1:
The classification rotor is segmented into two distinct vane groups: first vanes extending from the center to the outer circumference, and second vanes extending from the center to a position before the outer circumference. This segmentation allows different vane regions to perform different classification functions, preventing erroneous removal of suitable particles while maintaining classification capability.
Solution Approach 2:
Different regions of the classification rotor are given different local qualities through the two vane groups. The first vanes create a classification flow field for removing small diameter particles, while the second vanes modify the flow field in their region to prevent erroneous suctioning of larger particles, optimizing local classification performance.
2Manufacturing precision
If classification is performed to remove small particles, then particle size control is improved, but pressure loss increases
Solution Approach 1:
The rotor is divided into two vane groups with different configurations. The first vanes handle the primary classification function while the second vanes are positioned to reduce flow resistance and pressure loss in their region, achieving a balance between particle size control and energy efficiency.
3Device complexity
If the classification rotor uses uniform vanes, then structural simplicity is maintained, but classification efficiency decreases due to vortex generation
Solution Approach 1:
Rather than using uniform vanes, the rotor is segmented into two vane groups with different lengths and positions. This segmentation reduces vortex generation between vanes by creating more uniform flow distribution, thereby improving classification efficiency without excessive structural complexity.
Solution Approach 2:
The two vane groups are asymmetric in their extension lengths from the center. The first vanes extend to the outer circumference while the second vanes extend only to a position before the outer circumference. This asymmetric design optimizes flow patterns and reduces vortex formation, improving classification efficiency.
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
The apparatus effectively removes particles with too small a diameter while maintaining high yields and reducing pressure loss, even at smaller toner particle sizes, enhancing the quality and productivity of the electrophotographic process.
Implementation Method 1
Due to the rotation of the classification rotor, a centrifugal force is applied at the outer circumference of the classification rotor. The centrifugal force acting on the particles to be classified is a force directed to the outside of the classification rotor and is proportional to the particle mass
Implementation Method 2
the pulverized material—which comprises the particles to be classified and derives from the toner starting material kneadate—is transported from the inlet port to the vicinity of the outer circumference of a classification rotor by an air flow that is directed from the outer circumference side to the inside of the classification rotor
Data Source
AI summary
A toner classification apparatus comprising a classification rotor, wherein the classification rotor comprises a first vane group containing first vanes and a second vane group containing second vanes, the second vanes have a length shorter than the first vane group; the number of second vanes, which are disposed between two adjacent first vanes, is 1 to 2, independently; each of the first vanes draws first trajectory and each of the second vanes draws second trajectory when the classification rotor rotates, a distance from the center of rotation to an outer circumference side end of the first and second trajectory are defined as L1 and L3, respectively, and a distance from the center of rotation to the center side end of the first and second trajectory are defined as L2 and L4, respectively, L1 to L4 satisfy prescribed relationships, and a toner production method using the toner classification apparatus.