Toner Manufacturing via Controlled Emulsification Temperature
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing manufacturing methods of electrostatic charge image developing toners often result in image density unevenness and inadequate heat storage properties.
Innovation Solution
A manufacturing method involving the aggregation and coalescence of material particles containing colorant-containing polyester resin particles, where the production step includes mixing a basic colorant with a polyester resin, applying heat, and emulsifying the mixture, with a time-weighted average temperature and time relationship of 200 ≤ (T × ln R) ≤ 550.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for electrostatic charge image developing toners, then the production process is simple, but image density unevenness occurs and heat storage properties are inadequate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the temperature-time relationship during emulsification, specifically maintaining the polyester resin temperature in the range of 35°C to 100°C with a time-weighted average satisfying 200 ≤ (T × ln R) ≤ 550. This controlled parameter change ensures uniform colorant distribution and proper particle formation, resolving the image density unevenness problem while managing process complexity through defined temperature boundaries
Solution Approach 2:
The patent implements preliminary action by pre-controlling the temperature conditions during the emulsification step before aggregation and coalescence. By establishing the appropriate temperature-time profile in advance during colorant mixing and emulsification, the foundation for uniform image density and good heat storage properties is created before subsequent processing steps
2Reliability
If the temperature-time relationship during emulsification is not controlled, then the manufacturing process is fast and simple, but heat storage properties are inadequate
Solution Approach 1:
The patent optimizes the temperature-time parameter relationship by defining the specific range 35°C to 100°C and the criterion 200 ≤ (T × ln R) ≤ 550. This parameter control ensures that sufficient thermal energy is provided for complete emulsification and uniform colorant distribution, achieving reliable heat storage properties without requiring excessive processing time
Solution Approach 2:
The patent applies partial action by maintaining the temperature within the optimal range rather than using excessive high temperature throughout. The time-weighted average approach allows the process to spend appropriate time at each temperature level, achieving complete emulsification without unnecessary thermal exposure, thus balancing reliability with time efficiency
3Productivity
If high temperature is applied during emulsification, then the emulsification speed is fast, but image density unevenness occurs
Solution Approach 1:
The patent changes the temperature parameter from uncontrolled high temperature to a controlled range of 35°C to 100°C, with the time-weighted average satisfying 200 ≤ (T × ln R) ≤ 550. This parameter optimization maintains adequate emulsification speed while preventing the image density unevenness that occurs with excessive temperature, achieving a balanced processing condition
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 suppresses image density unevenness and enhances heat storage properties of the toner, compared to methods where the (T × ln R) value is outside the specified range.
Implementation Method 1
emulsifying the mixture
Implementation Method 2
applying heat to obtain a mixture
Implementation Method 3
aggregating and coalescing material particles
Implementation Method 4
aggregating and coalescing material particles
Data Source
AI summary
A manufacturing method of an electrostatic charge image developing toner includes aggregating and coalescing material particles containing colorant-containing polyester resin particles in a dispersion medium to obtain toner particles, the manufacturing method including a production step of the colorant-containing polyester resin particles, in which the production step of the colorant-containing polyester resin particles includes mixing a basic colorant and a polyester resin while applying heat to obtain a mixture, and emulsifying the mixture, and in the production step of the colorant-containing polyester resin particles, a time-weighted average T°C of a temperature of the polyester resin and a time R seconds during which the temperature of the polyester resin is in a range of 35°C or higher and 100°C or lower satisfy a relationship of200 ≤ (T × ln R) ≤ 550.