Biosolvent Latex Emulsion via Hydrolysis
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Solution Overview
Problem
Current resin emulsion production methods rely on hazardous organic solvents, which are costly to remove and dispose of, and lack environmental sustainability.
Innovation Solution
A process using 100% biodegradable and biobased lactate esters as biosolvents to dissolve resins, which hydrolyze in water, forming latex emulsions without the need for energy-intensive solvent removal, and allowing for the regeneration of the biosolvent for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If organic solvents (MEK, IPA) are used to dissolve resin and produce latex emulsion, then resin dissolution and emulsion formation are achieved, but environmental hazard increases and cost increases due to solvent removal and disposal requirements
Solution Approach 1:
The patent changes the chemical composition parameter of the solvent from hazardous organic solvents (MEK, IPA) to bio-based lactate esters. This parameter change maintains the solvent's ability to dissolve resin and form emulsions while eliminating environmental hazards and disposal costs associated with organic solvent removal
Solution Approach 2:
The patent employs lactate esters that are biodegradable and can be disposed of or degraded naturally, eliminating the need for expensive solvent removal and disposal processes. The lactate ester serves its purpose during the emulsion formation and then can be broken down environmentally, avoiding long-term environmental contamination issues
2Ease of manufacture
If organic solvents are used in PIE process, then resin emulsion can be produced, but energy consumption increases due to energy-intensive solvent removal processes
Solution Approach 1:
The lactate ester solvent is designed to be biodegradable and environmentally benign, eliminating the need for energy-intensive distillation or evaporation processes required to remove organic solvents. The solvent can be degraded naturally through hydrolysis, significantly reducing energy consumption while maintaining effective resin dissolution and emulsion formation
Solution Approach 2:
The patent converts the potential harm of using any solvent into a benefit by selecting lactate esters that can be easily degraded. The solvent fulfills its function of dissolving resin and forming emulsion, then can be broken down into benign products, eliminating the need for energy-intensive removal processes while maintaining manufacturing effectiveness
3Ease of manufacture
If conventional PIE process is used, then resin emulsion is produced, but production cost increases due to solvent disposal requirements
Solution Approach 1:
The patent replaces expensive organic solvents that require costly removal and disposal with lactate esters that are biodegradable and environmentally benign. The lactate ester can be degraded naturally through hydrolysis, eliminating disposal costs while maintaining the effectiveness of resin dissolution and emulsion formation processes
Solution Approach 2:
The patent enables the lactate ester solvent to be discarded or degraded naturally after use, rather than requiring recovery and disposal processes. The solvent serves its purpose during emulsion formation and then can be broken down environmentally, eliminating the need for costly solvent recovery and disposal operations
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 simplifies the production process, reduces costs, and results in environmentally friendly latex emulsions suitable for toner production, with stable resin particles and minimal residual biosolvent levels.
Implementation Method 1
combining the homogenous mixture with water to hydrolyze the lactate ester and to form a latex emulsion
Data Source
AI summary
A process for making a latex emulsion, where the process involves dissolving resin in a biosolvent that hydrolyzes on exposure to water.