Hollow Resin Particle Drying for Low Residual Solvent
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for producing hollow resin particles fail to effectively remove a large amount of hydrocarbon solvent from the particles, especially when the shell is strengthened with a high ratio of crosslinkable monomer, leading to potential particle breakage and residual solvent issues.
Innovation Solution
A method involving suspension polymerization followed by heat-drying at specific temperature and pressure conditions, with crosslinkable monomer ratios and using fine particles to coat the precursor particles, effectively removes hydrocarbon solvent while minimizing particle breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the ratio of crosslinkable monomer is increased to strengthen the shell, then the shell strength is improved, but a large amount of organic solvent remains inside the hollow resin particles
Solution Approach 1:
The invention changes the drying temperature parameter from conventional temperatures (around or below the boiling point of the organic solvent) to a higher temperature range (5°C to 20°C below the decomposition temperature of the hollow resin particles). This parameter change enables effective removal of residual organic solvent while maintaining the strengthened shell structure formed by high crosslinkable monomer content (40-100% by mass).
Solution Approach 2:
The invention introduces a dynamic drying process where the temperature is controlled to be within a specific range relative to the decomposition temperature (5°C to 20°C below), allowing the system to adaptively remove solvent at optimal rates without causing shell degradation. This dynamic temperature control resolves the contradiction between maintaining strong shells and removing residual solvent.
2Productivity
If the hollow resin particles are dried at high temperature to remove organic solvent, then the solvent removal efficiency is improved, but particle breakage occurs
Solution Approach 1:
The invention optimizes the drying temperature parameter to a specific range (5°C to 20°C below decomposition temperature) rather than using excessively high temperatures. This parameter optimization achieves effective solvent removal while preventing particle breakage, resolving the contradiction between productivity and reliability.
Solution Approach 2:
The drying temperature is determined based on feedback from the decomposition temperature of the hollow resin particles. By setting the drying temperature at a controlled distance (5°C to 20°C below decomposition temperature), the process automatically adapts to the specific material properties, ensuring efficient solvent removal without particle damage.
3Ease of manufacture
If conventional drying methods are used, then the process is simple and low-cost, but a large amount of organic solvent remains inside the particles
Solution Approach 1:
The invention modifies only the temperature parameter of the conventional drying process, setting it to 5°C to 20°C below the decomposition temperature. This simple parameter change maintains ease of manufacture while dramatically improving solvent removal efficiency, avoiding the need for complex equipment or multi-step processes.
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 produces hollow resin particles with reduced residual solvent and suppressed breakage, ensuring strong shells and controlled void ratios, suitable for applications requiring low solvent content and stability.
Implementation Method 1
subjecting the suspension to a polymerization reaction to prepare a precursor composition containing precursor particles having a hollow portion and including the hydrocarbon solvent in the hollow portion
Implementation Method 2
heat-drying the precursor particles separated from the aqueous medium to remove the hydrocarbon solvent from the precursor particles
Implementation Method 3
with respect to a boiling point T1 (° C.) of the hydrocarbon solvent and a thermal decomposition initiation temperature T2 (° C.) of the precursor particles, a temperature T0 (° C.) of the heat-drying for the removal of the hydrocarbon solvent satisfies (T1+70)≤T0≤(T2−5)
Data Source
AI summary
Provided is a method for producing hollow resin particles in which a residual amount of a hydrocarbon solvent once held inside particles in a production process is reduced and particle breakage is suppressed. The method for producing hollow resin particles, which include preparing a mixture liquid containing a polymerizable monomer, a hydrocarbon solvent, a polymerization initiator and an aqueous medium, suspending the mixture liquid to prepare a suspension, subjecting the suspension to a polymerization reaction to prepare a precursor composition containing precursor particles having a hollow portion and including the hydrocarbon solvent in the hollow portion, and removing the hydrocarbon solvent from the precursor particles, wherein the polymerizable monomer contains a crosslinkable monomer in an amount of from 40% by mass to 100% by mass, and wherein the removal of the hydrocarbon solvent is performed by a specific method.