Hollow Particle Shell Uniformity via HSP Distance Control
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Solution Overview
Problem
Conventional methods for producing hollow particles with a volume average particle diameter of 10 μm or more result in shell thickness non-uniformity and pressure resistance inconsistencies, leading to the production of porous particles or hollow particles with large shell thickness variations.
Innovation Solution
A method involving the control of the HSP distance between a crosslinkable monomer and a hydrophobic solvent within a specific range (5.80 to 6.50) during the suspension polymerization process to produce hollow particles with a volume average diameter of 10 μm or more, using a mixture containing a polymerizable monomer, hydrophobic solvent, polymerization initiator, and dispersion stabilizer, ensuring uniform shell thickness and suppressed non-uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional production methods are used for hollow particles with a volume average particle diameter of 10 μm or more, then the particle size is increased, but the shell thickness non-uniformity becomes large and pressure resistance becomes inconsistent
Solution Approach 1:
The patent applies parameter changes by controlling the HSP distance between the crosslinkable monomer and hydrophobic solvent within a specific range (5.80 to 6.50). This parameter control ensures uniform shell thickness and consistent pressure resistance when producing hollow particles with a volume average particle diameter of 10 μm or more, resolving the contradiction between particle size and manufacturing precision.
2Volume of moving object
If the particle diameter is increased to improve void ratio, then the pressure resistance increases, but the shell thickness non-uniformity becomes large
Solution Approach 1:
The patent controls the HSP distance parameter within the range of 5.80 to 6.50 to ensure that hollow particles with larger particle diameters maintain consistent pressure resistance. This parameter control prevents shell thickness non-uniformity that would otherwise occur with conventional methods, thereby improving reliability while maintaining the benefits of larger particle size.
3Ease of manufacture
If conventional methods are used to produce large diameter hollow particles, then production is simplified, but porous particles are produced or hollow particles with large shell thickness variations result
Solution Approach 1:
The patent maintains ease of manufacture by using a straightforward suspension polymerization process while improving manufacturing precision through parameter control. By controlling the HSP distance between crosslinkable monomer and hydrophobic solvent within the specific range of 5.80 to 6.50, the method produces hollow particles with uniform shell thickness without complicating the production process.
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 effectively produces hollow particles with a void ratio of 50% or more, achieving uniform shell thickness and improved pressure resistance by controlling the HSP distance between the crosslinkable monomer and hydrophobic solvent, resulting in high-quality hollow particles with consistent properties.
Implementation Method 1
obtaining resin particles containing a polymer of the crosslinkable monomer including the hydrophobic solvent, by polymerizing the crosslinkable monomer of the crosslinkable monomer droplets
Implementation Method 2
obtaining, by removing the hydrophobic solvent from the resin particles, hollow resin particles which are hollow inside and which contain the polymer of the crosslinkable monomer
Implementation Method 3
suspending the mixture liquid to prepare a suspension in which droplets of a monomer composition containing the polymerizable monomer, the hydrophobic solvent and the polymerization initiator are dispersed in the aqueous medium
Data Source
AI summary
A method for producing hollow particles which comprise a shell and a hollow portion surrounded by the shell and which have a void ratio of 50% or more, the method comprising: preparing a mixture liquid containing a polymerizable monomer, a hydrophobic solvent, a polymerization initiator, a dispersion stabilizer and an aqueous medium, suspending the mixture liquid to prepare a suspension in which droplets or a monomer composition containing the polymerizable monomer, the hydrophobic solvent and the polymerization initiator are dispersed in the aqueous medium, and subjecting the suspension to a polymerization reaction to prepare a precursor composition containing precursor particles which have a hollow portion surrounded by a shell containing a resin and which include the hydrophobic solvent in the hollow portion, wherein the polymerizable monomer contains a crosslinkable monomer, and wherein an HOP distance between the crosslinkable monomer and the hydrophobic solvent is 5.80 to 6.50.