Toner Production Nozzle Array with Local Quality Design
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Solution Overview
Problem
Current toner production methods face challenges in discharging uniform liquid droplets from multiple nozzles simultaneously without aggregation, leading to low productivity and inefficient energy use due to uneven discharge speeds and particle size distribution.
Innovation Solution
A toner production apparatus with a liquid droplet-forming unit that discharges a toner composition liquid at a uniform speed from nozzles of varying shapes, using a vibration generator to create a standing wave for uniform droplet formation and a conveyance gas flow to prevent aggregation, resulting in monodispersed particles with improved productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple nozzles discharge liquid droplets simultaneously, then productivity increases, but droplet aggregation occurs due to uneven discharge speeds
Solution Approach 1:
The patent applies local quality by making each nozzle have a different discharge hole shape (circular, slit-shaped, or a combination) according to its position in the array. This local differentiation compensates for position-dependent variations in discharge speed, ensuring that all nozzles discharge droplets at substantially the same speed despite being in different locations, thereby preventing droplet aggregation while maintaining high productivity
Solution Approach 2:
The patent changes the geometric parameters of the discharge holes (shape, size, orientation) to optimize discharge characteristics for each nozzle position. By adjusting these parameters locally, the system achieves uniform droplet discharge speeds across all nozzles, resolving the contradiction between high-speed simultaneous discharge and uniform particle size
2Device complexity
If conventional spray granulation is used, then equipment complexity is reduced, but particle size distribution becomes broad and productivity decreases
Solution Approach 1:
The patent introduces mechanical vibration to the discharge structure, causing the liquid droplets to be discharged with vibrational energy. This vibration helps to break up liquid bridges between adjacent droplets, preventing aggregation and enabling the production of fine monodispersed particles. The vibration mechanism adds controlled complexity that dramatically improves productivity and particle quality
Solution Approach 2:
The patent replaces conventional mechanical spray granulation systems with a vibration-based droplet formation system. Instead of relying on high-pressure mechanical spraying that produces coarse particles, the system uses controlled vibration to generate fine droplets, achieving both simplicity in operation and superiority in particle quality and productivity
3Productivity
If nozzles are arranged in a large array, then productivity increases, but discharge uniformity decreases due to varying distances from vibration source
Solution Approach 1:
The patent applies local quality by differentiating the discharge hole characteristics of nozzles based on their positions in the array. Nozzles at different locations (different distances from the vibration source) have differently shaped discharge holes that compensate for their position-specific vibration characteristics, ensuring uniform discharge speeds across the entire large array while maintaining high total productivity
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 efficiently produces toner particles with a narrow particle size distribution and high monodispersibility, increasing productivity and energy efficiency by allowing simultaneous discharge from multiple nozzles without droplet aggregation.
Implementation Method 1
a liquid droplet-forming unit configured to discharge a toner composition liquid at a uniform discharge speed from a plurality of discharge holes some of which have different shapes from each other to thereby form liquid droplets
Implementation Method 2
a conveyance gas flow to prevent aggregation
Data Source
Figure 1
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AI summary
An apparatus for producing a toner, including a liquid droplet-forming unit configured to discharge a toner composition liquid containing at least a resin and a colorant at a uniform discharge speed from a plurality of discharge holes some of which have different shapes from each other to thereby form liquid droplets, and a particle-forming unit configured to solidify the liquid droplets of the toner composition liquid to thereby form particles.