Bio-based Polyester Resin One-Pot Synthesis
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Solution Overview
Problem
Current processes for producing bio-based resins for toners are complex, time-consuming, and costly, and they struggle to achieve a high bio-based content, which is essential for sustainability and compliance with regulations such as the USDA's requirement of at least 20% bio-content in toners and inks.
Innovation Solution
A one-pot process is developed to produce a bio-based polyester resin by reacting a rosin derivative with dimethyl terephthalate, terephthalic acid, succinic acid, and 1,2-propanediol in a single reactor, eliminating the need for multiple reactors and excess reactants, while maintaining thermal properties similar to traditional four-reactor processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-reactor process is used to produce bio-based polyester resin, then the resin can be produced with controlled thermal properties, but the process complexity, time, and cost increase significantly
Solution Approach 1:
The patent combines multiple reaction steps that were previously performed in separate reactors into a single reactor system. The multi-component condensation reaction integrates the formation of polyester chains with the incorporation of bio-based monomers (terephthalic acid, succinic acid, 1,2-propanediol, and rosin derivative) in one continuous process, eliminating the need for sequential reactor operations while maintaining product quality
Solution Approach 2:
The single reactor system performs multiple functions simultaneously: it conducts the condensation polymerization reaction, incorporates bio-based monomers, controls molecular weight distribution, and achieves the desired thermal properties all in one operation. This multi-functional approach replaces the specialized sequential operations of multiple reactors
2Reliability
If traditional multi-step processes are used for resin production, then reaction control is maintained, but the overall process time increases
Solution Approach 1:
The patent implements a continuous one-pot reaction process where all condensation polymerization steps occur simultaneously without interruption. The reaction mixture is heated and stirred continuously, allowing all monomers to react and polymerize in a single continuous operation rather than through discrete batch steps with transfer times between reactors
Solution Approach 2:
All reactants including the rosin derivative, terephthalic acid, succinic acid, and 1,2-propanediol are prepared and combined in the reactor before the reaction begins. This preliminary mixing and preparation of all components in one vessel eliminates the need for sequential addition and multiple reaction cycles, reducing overall process time
3Reliability
If multiple reactors and excess reactants are used, then complete reaction is achieved, but material costs and waste increase
Solution Approach 1:
The patent modifies the reaction parameters by using a catalytic amount of tin(II) 2-ethylhexanoate instead of excess reactants. The catalyst enables the condensation reaction to proceed to completion with stoichiometric amounts of monomers, eliminating the need for excess reactants that would otherwise be required to drive the equilibrium reaction to completion in traditional processes
Solution Approach 2:
The process eliminates the need to discard excess reactants by using precise stoichiometric ratios enabled by catalysis. The water byproduct of condensation is removed continuously through distillation, driving the reaction to completion without requiring excess monomers, thereby reducing material waste and cost
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 simplifies the production process, reduces costs, and achieves a bio-based content of at least 45% by weight, meeting sustainability standards and ensuring the resin's thermal properties are comparable to those produced by more complex methods.
Implementation Method 1
reacting said rosin derivative with dimethyl terephthalate or terephthalic acid, succinic acid and 1,2-propanediol in said reactor to form said polyester polymer
Data Source
AI summary
The disclosure describes a one reaction process for making a bio-based polyester resin. The resultant polyester resin retains thermal properties as compared to a similar resin but made using previous multi-step processes conducted in separate vessels.