Monomer Emulsion Dispersion With Phase Inversion Stability
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Solution Overview
Problem
Existing methods for producing colored resin fine particles with water resistance and scratch resistance require high-viscosity mixers and result in insufficient dispersion stability of polymerizable unsaturated monomers, leading to rapid separation and colorant precipitation in the aqueous medium.
Innovation Solution
A monomer emulsion particles-containing aqueous dispersion is formulated with specific components (alkyl (meth)acrylates, styrene monomers, nonionic emulsifiers, aliphatic organic acid esters, and lipophilic active ingredients) and processed through a controlled phase inversion method to achieve stable particle sizes and improved dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phase inversion emulsification is used to produce colored resin fine particles, then water resistance and weather resistance are improved, but dispersion stability of monomer in aqueous medium deteriorates
Solution Approach 1:
The patent changes the physical parameters of the system by controlling temperature during phase inversion emulsification. By heating to a specific temperature range (above the cloud point of the emulsifier) and then cooling, the patent achieves stable emulsion formation while maintaining monomer dispersion stability, resolving the contradiction between water resistance and dispersion stability.
Solution Approach 2:
The patent utilizes phase transition of the emulsifier during the process. The emulsifier transitions from a soluble state at low temperature to an insoluble state at elevated temperature (cloud point), and back to soluble state upon cooling. This phase transition mechanism enables controlled emulsion formation that maintains both water resistance and dispersion stability.
2Reliability
If phase inversion emulsification is used to produce colored resin fine particles, then weather resistance and scratch resistance are improved, but monomer separation occurs in short period
Solution Approach 1:
The patent performs preliminary emulsification of the monomer in the aqueous medium before the main phase inversion emulsification step. This preliminary action creates a stable initial dispersion that prevents rapid monomer separation, extending the stability period while maintaining the desired weather and scratch resistance properties.
Solution Approach 2:
The patent uses a nonionic emulsifier as an intermediary substance that mediates between the hydrophobic monomer and the hydrophilic aqueous medium. The emulsifier forms stable micellar structures that keep the monomer dispersed in the aqueous phase for extended periods, preventing premature separation while allowing the final emulsion to achieve water and weather resistance.
3Reliability
If phase inversion emulsification is used to produce colored resin fine particles, then colorant water resistance is improved, but colorant precipitation occurs in short period
Solution Approach 1:
The patent merges the colorant with the monomer phase before emulsification, creating a combined organic phase that is then emulsified together. This merging ensures that the colorant is uniformly distributed within the emulsion particles from the beginning, achieving both water resistance and extended stability without precipitation.
Solution Approach 2:
The nonionic emulsifier acts as an intermediary that stabilizes the colorant within the emulsion structure. The emulsifier's hydrophobic portion interacts with the colorant and monomer, while the hydrophilic portion interacts with the aqueous medium, preventing colorant precipitation and maintaining stability over extended periods.
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 enhances the dispersion stability of monomer components, maintaining the integrity of active ingredients like colorants, and allows for efficient polymerization into polymer emulsion particles with improved properties.
Implementation Method 1
heating the resulting mixture to a temperature equal to or higher than a phase inversion-initiating temperature of the mixture
Data Source
AI summary
This aqueous dispersion contains monomer emulsion particles comprising a monomer component, wherein the monomer component contains (A) at least one monomer X selected from the group consisting of styrene-based monomers and alkyl (meth)acrylates including an alkyl group having 4 to 12 carbon atoms, (B) a nonionic emulsifier, (C) an aliphatic organic acid (alkyl ester) having 15 or more carbon atoms, and (D) a lipophilic active component, and the mean particle size of the monomer emulsion particles is 10 to 200 nm.