Toner Heat Treatment With Humidity Control to Prevent Melt Adhesion
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Solution Overview
Problem
Existing toner manufacturing methods face challenges in achieving a predetermined degree of spheronization and particle size distribution while preventing toner melt-adhesion and uniting inside the apparatus, particularly due to imbalances in hot air supply and humidity control during heat treatment.
Innovation Solution
A method involving a heat-treating apparatus with controlled temperature and humidity conditions, using a cylindrical chamber with hot air between 100.0°C and 200.0°C and relative humidity between 3.0% and 80.0%, along with specific air flow and cooling mechanisms to suppress powder particle adhesion and melt-adhesion, ensuring uniform spheronization and improved productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If hot air is supplied to melt and spheronize the toner, then the degree of spheronization is improved, but the toner may melt-adhere inside the apparatus due to excessive melting
Solution Approach 1:
The patent applies parameter changes by precisely controlling the temperature of hot air within 100.0°C to 200.0°C range and maintaining relative humidity between 3.0% to 80.0%. This controlled parameter change allows the toner to be sufficiently melted for spheronization while preventing excessive melting that causes adhesion to apparatus walls.
Solution Approach 2:
The patent introduces humidity control as an intermediary mechanism. By controlling the relative humidity of hot air to be between 3.0% to 80.0%, the patent creates a controlled atmosphere that facilitates spheronization while preventing direct contact adhesion between molten toner and apparatus surfaces.
2Manufacturing precision
If the toner is not dispersed in the apparatus, then particle diameter control is improved, but united particles are generated reducing productivity
Solution Approach 1:
The patent employs pneumatic principles by using hot air flow to disperse and convey toner particles through the treatment chamber. The controlled hot air stream ensures particles remain dispersed during heating, preventing agglomeration while maintaining efficient throughput for high productivity.
3Stability of the object's composition
If superheated steam is used for heat treatment, then the cohesion degree of toner is reduced, but condensation occurs causing adhesion and melt-adhesion
Solution Approach 1:
The patent fundamentally changes the parameter from using superheated steam to using controlled hot air with specific humidity levels (3.0% to 80.0% relative humidity). This parameter change eliminates the condensation problem inherent in superheated steam while maintaining the beneficial effect of reduced toner cohesion for easier spheronization.
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 achieves toners with sharp particle size distribution and reduced maintenance downtime by minimizing adhesion and melt-adhesion within the apparatus, enhancing production efficiency and toner quality.
Implementation Method 1
heat treating the powder particles in the treating chamber by supplying hot air into the treating chamber
Implementation Method 2
the surface of the toner is melted and spheronized by heat treatment
Implementation Method 3
since the humidity of the superheated steam is high, condensation occurs immediately after contact with a low-temperature substance
Data Source
AI summary
A method for manufacturing a toner including supplying powder particles containing a binder resin via a plurality of powder-particle supplying units to a treating chamber, the treating chamber having a cylindrical inner peripheral surface, heat treating the powder particles in the treating chamber by supplying hot air into the treating chamber, wherein a temperature of the hot air supplied into the treating chamber is 100.0° C. or higher and 200.0° C. or lower, and adjusting a humidity of the hot air so that a relative humidity of the hot air supplied into the treating chamber is 3.0% or more and 80.0% or less.