Toner Production Pipe Heating for Scale Prevention
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Solution Overview
Problem
Existing toner production methods for electrophotography face challenges with scale formation and pipe clogging due to vapor condensation, leading to decreased yield and image quality during continuous production.
Innovation Solution
A toner production method that involves heating the pipes through which powdery raw materials are added to the liquid raw materials, ensuring the heating temperature is above the condensation temperature of the vapor to prevent condensation and subsequent scale formation, thereby preventing pipe clogging and ensuring stable, efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the polymerization container temperature is high to prevent polymer deposit formation, then scale attachment is prevented, but the polymerizable monomer is vaporized to produce large amounts of vapor that wet the powdery raw materials and cause pipe clogging
Solution Approach 1:
The patent divides the pipe into multiple heating zones with different temperature control. The first heating section (near the polymerization container) is maintained at a higher temperature to prevent monomer vaporization, while the second heating section (near the powder injection point) is maintained at a lower temperature to prevent vapor condensation. This segmented temperature control resolves the contradiction by addressing different locations with different temperature requirements.
Solution Approach 2:
Different sections of the pipe are assigned different thermal properties through localized heating sections. The first heating section has higher temperature characteristics to prevent vaporization at the source, while the second heating section has lower temperature characteristics to prevent condensation before powder contact. This local quality differentiation allows simultaneous prevention of both scale attachment and pipe clogging.
2Productivity
If continuous production is maintained for high productivity, then efficient toner production is achieved, but scale accumulates on pipe inner walls causing clogging and requiring pipe detachment for cleaning
Solution Approach 1:
The patent applies preliminary heating to the pipe sections before powder injection begins. The first heating section is pre-heated to prevent monomer vaporization, and the second heating section is pre-heated to the appropriate temperature to prevent vapor condensation. This preliminary action ensures that the pipe is ready for continuous operation without clogging, maintaining both productivity and reliability.
Solution Approach 2:
The heating sections are designed to maintain continuous operation throughout the toner production process. The first heating section continuously prevents vaporization, and the second heating section continuously prevents condensation, allowing uninterrupted powder injection and continuous production without pipe detachment for cleaning, thus maintaining both high productivity and production stability.
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
This method effectively prevents scale formation and pipe clogging, allowing for stable and efficient long-term continuous production of toner with improved image quality by suppressing vapor condensation in the pipes.
Implementation Method 1
a toner production method comprising: a dispersing step for obtaining a colorant dispersion by, in a stirring tank, (a) dispersing or dissolving a colorant and a charge control agent in a polymerizable monomer, or (b) dispersing or dissolving a binder resin, a colorant and a charge control agent in an organic solvent, and a droplets forming step by suspending the colorant dispersion in an aqueous dispersion medium, wherein, in the dispersing step, the binder resin, colorant or charge control agent is added to the polymerizable monomer or organic solvent in the stirring tank, from a hopper disposed in an upper part of the stirring tank, through a pipe heated by a heating device
Data Source
AI summary
The present invention is to provide a toner production method configured to prevent scale formation, be resistant to pipe clogging, and realize stable and efficient toner production, even in the case of long-term continuous production. Disclosed is a toner production method comprising: a dispersing step for obtaining a colorant dispersion by, in a stirring tank, (a) dispersing or dissolving a colorant and a charge control agent in a polymerizable monomer, or (b) dispersing or dissolving a binder resin, a colorant and a charge control agent in an organic solvent, and a droplets forming step by suspending the colorant dispersion in an aqueous dispersion medium, wherein, in the dispersing step, the binder resin, colorant or charge control agent is added to the polymerizable monomer or organic solvent in the stirring tank, from a hopper, through a pipe heated by a heating device.