Phase Inversion Emulsification Latex Particle Size Control
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Solution Overview
Problem
Current latex production methods face challenges in reliably controlling latex particle size during solvent removal, leading to variability and the risk of producing particles outside specifications, as existing methods for predicting particle shrinkage are inconsistent and unreliable.
Innovation Solution
A phase inversion emulsification process that controls the distillate temperature by adjusting the jacket temperature and vacuum level in the reactor, allowing for precise control of latex particle size distribution during solvent removal by manipulating the distillate temperature within a range of 30 to 80°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional solvent removal methods are used during latex production, then solvent removal is achieved, but latex particle size distribution becomes variable and unreliable
Solution Approach 1:
The patent applies parameter changes by controlling the distillate temperature within a specific range (30-80°C) during solvent removal. This temperature parameter control prevents excessive particle shrinkage and maintains reliable particle size distribution, resolving the contradiction between solvent removal effectiveness and particle size precision.
Solution Approach 2:
The patent applies preliminary anti-action by taking measures before solvent removal to prevent particle size variability. By establishing the distillate temperature control system beforehand and setting the appropriate temperature range, the process preemptively counteracts the harmful effect of particle shrinkage that would otherwise occur during solvent removal.
2Ease of manufacture
If distillate temperature is not controlled during solvent removal, then solvent removal process is simple, but particle size distribution shifts and variability increases
Solution Approach 1:
The patent introduces distillate temperature as a controlled parameter during solvent removal, maintaining it within 30-80°C. This parameter change transforms the simple but imprecise solvent removal process into a controlled process that achieves both ease of manufacture and manufacturing precision by preventing particle size distribution shifts.
3Measurement precision
If existing prediction methods for particle shrinkage are used, then particle size prediction is attempted, but results are inconsistent and unreliable
Solution Approach 1:
The patent applies feedback by monitoring and controlling the distillate temperature during solvent removal. This real-time feedback mechanism ensures that the temperature remains within the optimal range, providing consistent and reliable particle size prediction and control, thereby resolving the inconsistency of existing prediction methods.
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 approach ensures a consistent and reliable control of latex particle size distribution, reducing variability and ensuring that the final particle size meets specifications, thereby improving the quality of latex for toner applications.
Implementation Method 1
Phase inversion emulsification (PIE) processes are known... adding a second portion of water to the reactor to convert the water-in-oil dispersion mixture into an oil-in-water dispersion comprising a latex emulsion
Implementation Method 2
forming a distillate and controlling the distillate temperature... volatile organic compounds are pulled out of the liquid phase in the reactor to a vapor phase and transferred to the condenser
Implementation Method 3
cooling distillate vapor in the condenser to a liquid phase... collecting the liquid condensate in the receiver
Data Source
AI summary
A phase inversion emulsification process for controlling latex particle size including a) combining a resin, an organic solvent, an optional neutralizing agent, and a first portion of water in a reactor; wherein said reactor is equipped with a jacket, a vacuum, a condenser connected to the reactor by a distillate conduit, and a receiver connected to the condenser by a condensate conduit, to form a water-in-oil dispersion mixture; b) adding a second portion of water to the reactor to convert the water-in-oil dispersion mixture into an oil-in-water dispersion comprising a latex emulsion of latex particles; c) forming a distillate and controlling the distillate temperature by at least one of: adjusting the jacket temperature, adjusting the vacuum level, or a combination thereof; wherein controlling the distillate temperature controls a particle size distribution change of the latex particles during solvent removal; wherein the distillate temperature is from about 30 to about 80° C.; d) performing solvent removal wherein volatile organic compounds are pulled out of the liquid phase in the reactor to a vapor phase and transferred to the condenser via the distillate conduit; e) cooling distillate vapor in the condenser to a liquid phase; and f) collecting the liquid condensate in the receiver.