Amorphous Resin Esterification Solvent Reduction
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Solution Overview
Problem
Current processes for preparing amorphous resins for robust solid ink applications are inefficient, requiring large amounts of solvent, long reaction times, and significant solvent use for isolation and purification, which are not cost-effective or environmentally friendly.
Innovation Solution
A method involving the reaction of organic acids with alcohols in the presence of a small amount of solvent (0.5 to 1.5 grams per gram of product) to form esters of tartaric or citric acid, reducing reaction time and overall solvent use, with optional heating and catalysts to enhance the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional solvent-based processes are used to prepare amorphous resins, then the reaction can proceed, but large amounts of solvent are required and reaction times are excessively long (exceeding 45 hours)
Solution Approach 1:
The patent changes the fundamental parameter of solvent usage from traditional large amounts to a minimal amount (0.5 to 1.5 grams per gram of product). This dramatic parameter change enables the reaction to proceed efficiently with drastically reduced solvent requirements while maintaining acceptable reaction times of less than 10 hours.
Solution Approach 2:
The patent introduces a specific intermediary substance (boric acid or boron trifluoride etherate) as a catalyst to mediate the esterification reaction. This intermediary enables the reaction to proceed efficiently under minimal solvent conditions, resolving the contradiction between reduced solvent usage and maintained reaction efficiency.
2Quantity of substance
If solvent-less reaction processes are used, then solvent usage during reaction is reduced, but significant amounts of solvent are still required for isolation and purification, and reaction times exceed 20 hours
Solution Approach 1:
The patent optimizes the solvent parameter to a minimal non-zero amount (0.5 to 1.5 grams per gram of product), which is sufficient to enable efficient reaction progression without requiring the extensive solvent amounts needed for isolation and purification in solvent-less processes. This parameter optimization reduces both reaction time and total solvent consumption.
Solution Approach 2:
The use of boric acid or boron trifluoride etherate as a catalyst intermediary enables the reaction to proceed rapidly under minimal solvent conditions, eliminating the need for long reaction times associated with solvent-less processes while avoiding the need for large solvent amounts for isolation and purification.
3Ease of manufacture
If conventional esterification processes are used, then the reaction can proceed, but they require large amounts of solvent and extended reaction times, making them costly and environmentally unfriendly
Solution Approach 1:
The patent fundamentally changes the solvent quantity parameter from conventional large amounts to a minimal amount (0.5 to 1.5 grams per gram of product). This parameter change dramatically improves process efficiency and reduces environmental impact while maintaining manufacturing feasibility through the use of a catalyst.
Solution Approach 2:
The introduction of boric acid or boron trifluoride etherate as a catalyst intermediary enables the esterification reaction to proceed efficiently under minimal solvent conditions, resolving the contradiction between ease of manufacture and reduced overall solvent requirement.
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 significantly reduces reaction time and solvent use, achieving yields of 65% to 80% in less than 10 hours, improving the efficiency and reducing the overall solvent requirement by orders of magnitude compared to traditional solvent-based and solvent-less methods.
Implementation Method 1
reacting at least one organic acid of the formula R'COOH with at least one alcohol of the formula R—OH, in the presence of a solvent in an amount of from about 0.5 to about 1.5 grams of solvent per gram of product to form a reaction product selected from: (a) an ester of tartaric acid
Implementation Method 2
The reaction may be carried out with or without the use of a solvent and, optionally, with or without heating and/or use of a catalyst.
Data Source
AI summary
Methods for making amorphous resins for use in robust solid ink applications are disclosed in which an organic acid is reacted with an alcohol in the presence of a solvent in the amount of from about 0.5 to about 1.5 grams of solvent per gram of reaction product. The reaction product is an ester of tartaric acid or an ester of citric acid.