Nanoscale AZO Pigment Production in Microreactors
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Solution Overview
Problem
Conventional pigment particles for inkjet inks are large and have wide size distributions, leading to issues with reliable jetting and image quality due to blockage of ink nozzles and poor lightfastness, while microreactors face challenges in producing solid materials without clogging and have limited productivity.
Innovation Solution
A method for producing nanoscale organic azo pigment particles using a microreactor or micromixer, where a sterically bulky stabilizer compound non-covalently associates with the pigment precursor to limit particle growth and aggregation, allowing for continuous production under laminar or turbulent flow conditions, enhancing coloristic properties and preventing clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pigment particles are used for inkjet inks, then production is simpler, but jetting reliability and image quality deteriorate due to nozzle blockage and poor lightfastness
Solution Approach 1:
The patent applies parameter changes by controlling particle size to be below 150 nm through specific reaction conditions in microreactors, including temperature, pressure, and residence time parameters. This size control resolves the contradiction by enabling reliable jetting while maintaining a manageable production process through continuous flow chemistry.
Solution Approach 2:
The patent uses microreactors as intermediary devices that facilitate controlled particle formation. These microreactors act as mediators between the chemical reaction process and the final pigment product, enabling precise size control that improves jetting reliability without requiring complex post-processing equipment.
2Manufacturing precision
If pigment particle size is reduced to nanoscale, then jetting reliability and color properties improve, but particle aggregation and clogging risks increase
Solution Approach 1:
The patent employs parameter changes by adjusting reaction temperature, pressure, and residence time in the microreactor to control particle growth. By maintaining specific parameter ranges, the process achieves nanoscale particle size control while preventing aggregation that would lead to clogging.
Solution Approach 2:
The patent implements continuous flow synthesis in microreactors, ensuring continuous production of nanoscale particles with consistent size distribution. This continuous action prevents aggregation by maintaining steady-state conditions and immediate stabilization of formed particles.
3Productivity
If microreactors are used for pigment production, then productivity and color properties improve, but clogging of microreactor channels occurs
Solution Approach 1:
The patent optimizes operational parameters including flow rate, temperature, and pressure to maintain high productivity while preventing clogging. By carefully controlling these parameters, the microreactor operates continuously at high efficiency without channel blockage.
Solution Approach 2:
The patent replaces mechanical particle handling with in-situ particle formation in the microreactor. Instead of mechanically processing larger particles that could clog channels, the system synthesizes nanoscale particles directly within the flow, eliminating clogging risks while maintaining high productivity.
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 higher production rates and controlled assembly of nanoscale pigment particles, preventing clogging in microreactors, and providing enhanced color properties and reliability in inkjet printing by maintaining particle size below 150 nm, thus ensuring efficient inkjet printing and improved image quality.
Implementation Method 1
a sterically bulky stabilizer compound non-covalently associates with the pigment precursor to limit particle growth and aggregation
Implementation Method 2
A method for producing nanoscale organic azo pigment particles using a microreactor or micromixer
Implementation Method 3
allowing for continuous production under laminar or turbulent flow conditions
Implementation Method 4
allowing for continuous production under laminar or turbulent flow conditions
Data Source
AI summary
A process for preparing nanoscale azo pigment particles includes providing an organic pigment precursor that contains at least one functional moiety, providing a sterically bulky stabilizer compound that contains at least one functional group, and carrying out a chemical reaction to form a pigment composition in a microreactor or micromixer, whereby the functional moiety found on the pigment precursor is incorporated within the pigment and non-covalently associated with the functional group of the stabilizer, so as to allow the formation of nanoscale-sized pigment particles and the production of such in a microreactor under laminar or turbulent flow conditions without clogging.