Toner Production via Vibration Ejection and Air Flow Transport
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Solution Overview
Problem
Conventional methods for producing electrophotographic toner result in broad particle size distribution and aggregation, leading to inefficient production and reduced image quality due to incomplete drying and aggregation of toner particles during the polymerization and spray dry processes.
Innovation Solution
A method and apparatus that utilize periodic ejection of a toner composition liquid through nozzles into a chamber, where droplets are solidified and transported by vertical downward or rotational air flows, preventing aggregation by ensuring droplets do not fall at free fall velocity before drying, using air flows with velocities greater than the droplets' terminal velocity to maintain uniform particle size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the polymerization method is used to produce toner, then a toner with small particle diameter and sharp particle size distribution can be obtained, but the production process becomes inefficient requiring long time, large amount of water and energy for washing and drying
Solution Approach 1:
The invention extracts and eliminates the inefficient washing and drying steps from the polymerization process by using a spray dry method that directly produces dry toner particles through rapid evaporation of the solvent during spraying, thereby maintaining sharp particle size distribution while dramatically improving production efficiency
Solution Approach 2:
The invention changes the physical state and processing parameters by transitioning from aqueous polymerization to organic solvent-based spray drying, where the solvent is rapidly evaporated during the spraying process itself, converting a multi-step wet process into a single-step dry process that maintains particle uniformity while boosting productivity
2Productivity
If conventional spray dry method with multiple nozzles is used, then production capacity is increased, but particle size distribution becomes broad due to droplet aggregation
Solution Approach 1:
The invention segments the spray process into individually controlled nozzle units, where each nozzle operates independently with optimized parameters to prevent droplet aggregation, allowing high production capacity through multiple nozzles while maintaining narrow particle size distribution
Solution Approach 2:
The invention introduces dynamic control of spray parameters including nozzle vibration at specific frequencies and adjustable spray patterns that prevent droplet coalescence during flight, enabling simultaneous achievement of high productivity through multiple nozzles and precise particle size control
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 and apparatus effectively prevent toner particle aggregation and achieve a uniform particle size distribution, enhancing production efficiency and image quality by ensuring complete drying and uniform particle formation.
Implementation Method 1
ejecting a toner composition liquid containing at least a resin and a colorant periodically from a plurality of nozzles into a chamber using a vibration unit, so as to form droplets in a gas phase
Implementation Method 2
the droplets are transported by transport air flow selected from at least one of vertical downward air flow and rotational air flow
Implementation Method 3
the vertical downward air flow has a flow velocity larger than the free fall velocity of the droplets
Implementation Method 4
solidifying the droplets, wherein the droplets are transported by transport air flow
Data Source
AI summary
A method for producing a toner, including ejecting a toner composition liquid containing at least a resin and a colorant periodically from a plurality of nozzles into a chamber using a vibration unit, so as to form droplets in a gas phase; and solidifying the droplets, wherein the droplets are transported by transport air flow selected from at least one of vertical downward air flow and rotational air flow, and the method can prevent toner particles from aggregation.