Microreactor Synthesis of Dispersible Pigment Red 112
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Solution Overview
Problem
C.I. Pigment Red 112 requires high dispersion effort for finely divided incorporation into binder systems, leading to increased energy consumption and potential unwanted alterations in performance properties when using dispersing assistants.
Innovation Solution
A process using microreaction technology to precipitate and couple the coupling component in an upstream microreactor, eliminating the need for additives or surface modifications, resulting in uncoated, readily dispersible C.I. Pigment Red 112 with low dispersion harshness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If C.I. Pigment Red 112 is incorporated into binder systems without surface modification, then the pigment maintains its original performance properties, but high dispersion effort and energy consumption are required
Solution Approach 1:
The coupling component is precipitated in an upstream microreactor before the main azo coupling reaction, creating a pre-prepared reactive intermediate that couples more efficiently with the diazo component. This preliminary precipitation step generates pigment particles with inherent dispersibility characteristics without requiring subsequent surface modification or dispersing assistants.
2Use of energy by moving object
If dispersing assistants are used to reduce dispersion effort, then energy consumption is reduced, but unwanted alterations in performance properties occur
Solution Approach 1:
The pigment particles are designed to be self-dispersible through the specific microreactor synthesis process and precipitation methodology. The pigment serves its own dispersion function without requiring external dispersing assistants, thereby maintaining original performance properties while reducing dispersion effort.
3Ease of operation
If surface coating with polymer layers is applied to enhance dispersibility, then dispersion harshness is reduced, but additional costs and process complexity increase
Solution Approach 1:
The invention extracts and eliminates the need for surface coating processes and polymer layer applications. By using the microreactor precipitation method, dispersibility is achieved directly during pigment synthesis, removing the separate surface modification step entirely from the process flow.
4Device complexity
If conventional azo coupling is used without upstream precipitation, then the process is simpler, but dispersion harshness increases
Solution Approach 1:
The upstream microreactor precipitation of the coupling component serves as a preliminary action that creates optimally prepared reactive particles for the subsequent azo coupling. This pre-precipitation step, while adding a reactor unit, creates pigment with superior dispersibility that simplifies downstream processing and eliminates the need for dispersing assistants.
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 process achieves a dispersion harshness of less than 45 in alkyd resin varnish, reducing energy input and maintaining performance properties without the use of auxiliaries, while minimizing residual coupler and PCB content.
Implementation Method 1
precipitating the coupling component in an upstream microreactor
Implementation Method 2
precipitated in an upstream microreactor and coupling the precipitated coupling component in finely divided form
Implementation Method 3
azo coupling in a microreactor, which comprises precipitating the coupling component in an upstream microreactor and coupling the precipitated coupling component in finely divided form to the diazo component
Data Source
AI summary
The invention provides a process for preparing uncoated, readily dispersible C.I. Pigment Red 112 by azo coupling in a microreactor, which comprises precipitating the coupling component in an upstream microreactor and coupling the precipitated coupling component in finely divided form to the diazo component in a microreactor.The C.I. Pigment Red 112 of the invention features low dispersion harshness in alkyd resin varnish, and a PCB content of below 25 ppm.