Toner Particle Production via Droplet Solidification
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Solution Overview
Problem
Existing toner production methods struggle to produce particles with a sharp particle diameter distribution efficiently and cost-effectively, often resulting in the formation of aggregated particles and residual solvents.
Innovation Solution
A particulate material production method involving the ejection of a particulate material composition liquid, which includes a resin dissolved or dispersed in an organic solvent, forming droplets in a gas phase and solidifying them using a poor solvent to prevent aggregation and efficiently remove residual solvents, utilizing a liquid column resonance type droplet ejecting device to achieve uniform particle size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If polymerization methods are used to produce toner particles, then relatively small particles with narrow diameter distribution and spherical shape can be obtained, but all particles are produced simultaneously making it difficult to achieve a sharper particle diameter distribution
Solution Approach 1:
The invention segments the particle production process by ejecting droplets sequentially through a nozzle and controlling their solidification at different positions in the drying chamber. This allows particles to be formed individually rather than all at once, enabling sharper particle diameter distribution while maintaining production efficiency.
Solution Approach 2:
The invention performs preliminary action by ejecting droplets with controlled size and composition before they reach the drying chamber. The droplets are prepared in advance with specific resin concentration and solvent content, allowing precise control over final particle size and properties when they solidify.
2Reliability
If conventional drying methods are used to remove solvent from droplets, then particles can be formed, but aggregated particles and residual solvents remain problematic
Solution Approach 1:
The invention introduces a poor solvent as an intermediary substance in the drying chamber. This poor solvent mediates the solidification process by causing the organic solvent in the droplets to precipitate out, forming particles that are then washed with the poor solvent to remove residual organic solvent and prevent aggregation.
Solution Approach 2:
The invention converts the harmful effect of residual organic solvent into a benefit by using it as a driving force for particle formation. The organic solvent's tendency to evaporate or be removed is harnessed to drive the solidification process, while the poor solvent simultaneously prevents aggregation and removes residuals.
3Manufacturing precision
If liquid ejection methods are used to form droplets, then particles with controlled size can be produced, but aggregated particles form during drying
Solution Approach 1:
The poor solvent acts as a mediator that prevents droplet aggregation during the drying process. By introducing this intermediary substance, the system maintains particle separation while completing solvent removal, thus preserving the controlled particle size distribution achieved during droplet ejection.
Solution Approach 2:
The invention changes the chemical environment parameters in the drying chamber by introducing a poor solvent. This parameter change affects the solubility and interaction between droplets, preventing aggregation while allowing controlled solidification and particle formation with precise size distribution.
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 method effectively produces toner particles with a sharp particle diameter distribution, minimizing aggregation and residual solvent content, thereby enhancing image quality and reducing production costs.
Implementation Method 1
ejecting a particulate material composition liquid... from at least one nozzle to form droplets
Implementation Method 2
The solidifying process includes contacting the droplets with a poor solvent for the particulate material composition
Implementation Method 3
utilizing a liquid column resonance type droplet ejecting device to achieve uniform particle size
Data Source
AI summary
A particulate material production method is provided. The particulate material production method includes ejecting a particulate material composition liquid, which includes an organic solvent and a particulate material composition including at least a resin and dissolved or dispersed in the organic solvent, from at least one nozzle to form droplets of the particulate material composition liquid in a gas phase; and solidifying the droplets of the particulate material composition liquid to prepare particles of the particulate material composition. The droplet solidifying step includes contacting the droplets with a poor solvent for the particulate material composition.