Master Batch for Ultrafine Metal Particle Dispersion
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Solution Overview
Problem
Existing deodorants and adsorbents face issues such as saturation of adsorption sites, decreased adsorption performance due to resin coverage, and impaired moldability when ultrafine metal particles are used, as well as the need for continuous UV irradiation for photo-catalytic deodorants, and handling difficulties with ultrafine metal particle dispersion.
Innovation Solution
A master batch comprising a thermoplastic resin and metal organoates, specifically with Cu, Ag, Au, In, Pd, Pt, Fe, Ni, Co, Zn, Nb, Sn, or Rh, where the metal organoate is thermally decomposed to form ultrafine metal particles with a controlled average diameter of 1-100 nm, ensuring homogeneous dispersion and maintaining resin integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrafine metal particles are added to resin to improve adsorption performance, then adsorption effect is enhanced, but resin decomposition occurs and moldability is impaired
Solution Approach 1:
The patent introduces an organic acid component as an intermediary substance that forms a protective layer on the surface of ultrafine metal particles. This intermediary layer prevents direct contact between the metal particles and resin, thereby suppressing resin decomposition while maintaining the adsorption performance of the metal particles. The organic acid acts as a mediator that allows the metal particles to function without causing harmful effects to the resin.
2Stability of the object's composition
If inorganic filler is used to improve dispersion property, then dispersion is enhanced, but adsorption sites are covered and adsorption effect decreases
Solution Approach 1:
The patent changes the surface chemical parameters of the inorganic filler by coating it with organic acid. This parameter change modifies the surface properties of the filler to reduce its affinity for adsorption sites while maintaining its dispersion function. The organic acid coating alters the surface chemistry so that the filler disperses the metal particles effectively without covering the active adsorption sites.
3Reliability
If ultrafine metal particles are used to enhance adsorption, then adsorption capacity increases, but handling difficulty increases due to aggregation
Solution Approach 1:
The organic acid component serves as a dispersing intermediary between ultrafine metal particles, preventing their aggregation during handling and processing. The organic acid molecules adsorb onto the metal particle surfaces, creating steric or electrostatic repulsion that keeps particles separated and easily handleable while preserving their high adsorption capacity.
4Reliability
If photo-catalytic deodorant is used to achieve deodorizing effect, then deodorizing performance is improved, but continuous UV irradiation is required
Solution Approach 1:
The patent extracts the UV irradiation requirement from the photo-catalytic deodorizing system by using organic acid-coated metal particles that can function without continuous UV light. The organic acid coating enables the metal particles to provide deodorizing effects through alternative mechanisms that do not depend on photo-catalysis, thereby removing the need for continuous energy input in the form of UV irradiation.
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 master batch effectively expresses adsorption performance only in the molded article, maintaining stability and enhancing the dispersion and adsorption efficiency of ultrafine metal particles, while preventing resin decomposition and maintaining moldability.
Implementation Method 1
the metal organoate is thermally decomposed to form ultrafine metal particles
Implementation Method 2
capable of adsorbing offensively smelling components such as methyl mercaptans or volatile organic compounds
Data Source
AI summary
A master batch for use in forming ultrafine metal particles serving as an adsorptive material, a method of producing the same, and a method of molding an article containing ultrafine metal particles by using the master batch. The master batch comprises a thermoplastic resin and a metal organoate contained therein, the metal of the metal organoate being selected from the group consisting of Cu, Ag, Au, In, Pd, Pt, Fe, Ni, Co, Zn, Nb, Sn, Ru and Rh. Adsorption performance is not expressed by the master batch but is expressed by an article molded by blending the resin with the master batch.