Inorganic Particle Surface Coating via Aerosol Sintering
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Solution Overview
Problem
Current methods for producing durable inorganic particles, such as titanium dioxide pigments, require wet treatment processes that are costly, hazardous, and involve volatile silicon halides, which are difficult to handle and result in additional processing steps and debris.
Innovation Solution
A process involving the contact of inorganic particles with a sinterable material and a liquid medium at elevated temperatures to evaporate the medium and form aerosol particles that sinter onto the particles, creating a durable surface coating without the need for wet treatments or volatile silicon halides, typically using silicon dioxide for titanium dioxide particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wet treatment methods are used to deposit surface treatments on inorganic particles, then durable pigment can be produced, but additional processing steps, cost, and hazardous volatile silicon halides are required
Solution Approach 1:
The patent combines the surface treatment deposition step with the existing oxidation process by introducing silicon-containing compounds into the oxidation reactor. This merging eliminates separate wet treatment steps and integrates the coating function into the primary production process, reducing overall process complexity while maintaining durability.
Solution Approach 2:
The patent changes the physical state and delivery method of silicon compounds from liquid/volatile phases (wet treatment) to solid particulate form introduced during oxidation. This parameter change allows the coating material to be deposited simultaneously with pigment formation, eliminating hazardous volatile halides and additional processing steps.
2Reliability
If wet treatment methods are used to deposit surface treatments on inorganic particles, then durable pigment can be produced, but hazardous volatile silicon halides and debris are generated
Solution Approach 1:
The patent converts the harmful volatile silicon halides into beneficial solid silicon-containing compounds that are introduced during oxidation. The same silicon source that would normally create hazardous fumes is instead utilized as a safe solid material that forms the desired protective coating, eliminating the harmful byproducts while maintaining the coating function.
Solution Approach 2:
The patent extracts and removes the hazardous volatile silicon halide component from the process by using alternative solid silicon-containing compounds. This extraction eliminates the harmful emissions associated with wet treatment methods while preserving the essential coating deposition function needed for durability.
3Manufacturing precision
If separate wet treatment step is added after oxidation, then surface treatment can be applied, but processing time and cost increase
Solution Approach 1:
The patent merges the surface treatment deposition with the oxidation process by introducing silicon-containing compounds into the oxidation reactor. This combination allows coating formation to occur simultaneously with pigment production, eliminating the need for separate wet treatment steps and reducing total processing time while maintaining surface treatment quality.
Solution Approach 2:
The patent performs the surface treatment deposition during the oxidation process rather than after completion. By introducing silicon compounds in advance during oxidation, the coating forms as part of the primary production sequence, eliminating subsequent processing steps and reducing overall manufacturing time.
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 process produces durable inorganic particles with complete and uniform surface coverage, reducing processing steps and debris, and achieving high durability and improved dispersion characteristics, meeting industry standards for acid solubility and outdoor exposure requirements.
Implementation Method 1
contacting inorganic particles with a composition comprising a sinterable material and a liquid medium, at a temperature sufficient to (1) evaporate the liquid medium and release the sinterable material as aerosol particles
Implementation Method 2
cause the aerosol particles to sinter to form a coating on the inorganic particles
Data Source
AI summary
The present disclosure relates to a process for making treated inorganic particles by vapor phase deposition of surface treatments on the particle surface by reacting inorganic particles, typically titanium dioxide particles, with a composition comprising a sinterable material and a liquid medium at a temperature sufficient to evaporate the medium and release the sinterable material as aerosol particles. The aerosol particles sinter and form a treatment on the surfaces of the inorganic particles.