Toner Particle Production via Pressure Plasticization
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Solution Overview
Problem
Conventional methods for plasticizing thermoplastic resins to produce toners require high temperatures, leading to increased costs, degradation of resin properties, and environmental concerns due to waste generation and solvent use.
Innovation Solution
A method involving the use of a compressive fluid, such as carbon dioxide, to plasticize pressure plastic materials at lower temperatures without heating, using a surfactant to granulate the material and produce toners with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic resins are heated at high temperatures for plasticization, then the resin can be processed and emulsified, but the resin degrades, molecular weight decreases, and production cost increases
Solution Approach 1:
The invention changes the physical state parameters of the resin by applying high pressure (100-1000 MPa) instead of high temperature to achieve plasticization. This pressure-induced plasticization allows the resin to be processed without thermal degradation, maintaining molecular weight and resin durability while enabling emulsification and particle formation.
Solution Approach 2:
The invention replaces the thermal field (heating system) with a mechanical field (pressure application system). By using a pressure application device to apply compressive pressure to the resin, the process substitutes thermal energy with mechanical energy, achieving plasticization without the harmful effects of high temperature heating.
2Ease of manufacture
If conventional heat treatment is used for toner production, then the thermoplastic resin can be processed, but waste liquid is generated and environmental load increases
Solution Approach 1:
The invention changes the processing parameters from temperature-based to pressure-based, using high pressure plasticization instead of thermal processing. This parameter change eliminates the need for subsequent drying steps and prevents waste liquid generation, making the toner production process environmentally friendly while maintaining manufacturing capability.
3Ease of manufacture
If high temperature heating is applied to plasticize resin, then the resin viscosity decreases and processability improves, but production cost increases due to heat treatment requirements
Solution Approach 1:
The invention substitutes the thermal processing system with a high-pressure mechanical processing system. By applying pressure (100-1000 MPa) to plasticize the resin, the process eliminates the need for energy-intensive heat treatment while achieving the same viscosity reduction and processability improvement, thereby reducing production costs.
4Ease of manufacture
If thermoplastic resin is heated above glass transition temperature, then the resin can be emulsified in fluidized state, but molecular chain cutting occurs and durability decreases
Solution Approach 1:
The invention changes the state transition method from thermal (temperature-based) to mechanical (pressure-based). By applying high pressure to induce plasticization and enable emulsification, the process avoids heating above the glass transition temperature, thereby preventing molecular chain cutting and maintaining molecular weight stability and resin durability.
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 approach reduces environmental impact, eliminates waste liquids, and lowers production costs by maintaining resin durability and stability while avoiding heat-induced degradation.
Implementation Method 1
bringing a compressive fluid into contact with a pressure plastic material, so as to plasticize the pressure plastic material
Implementation Method 2
applying a shear force to the compressive fluid and the plasticized pressure plastic material, between which an interface exists, in the presence of a surfactant to granulate the pressure plastic material
Data Source
AI summary
A method for producing particles, including: bringing a compressive fluid into contact with a pressure plastic material, so as to plasticize the pressure plastic material; applying a shear force to the compressive fluid and the plasticized pressure plastic material, between which an interface exists, in the presence of a surfactant to granulate the pressure plastic material in the compressive fluid, so as to produce particles.