Polyester Resin Particle Size Control via Glycol Ether Solvation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing fine polyester-based resin particles are inefficient, costly, and result in particles with reduced meltability and strength due to high crystallization, while also generating byproducts and requiring complex treatment processes.
Innovation Solution
Polyester-based resin particles with specific endothermic peak ratios and volume average diameters are produced by contacting a polyester-based raw material resin with a glycol ether-based solvent, followed by grinding, to achieve fine particle size without significantly altering the crystallization degree, using a method that includes a temperature above the crystallization temperature and 3-methoxy-3-methyl-1-butanol as the solvent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If heating to melting point and cooling for solid phase/liquid phase separation is used, then fine polyester-based resin particles can be obtained, but producing cost increases and production efficiency decreases due to high temperature requirement and solvent extraction
Solution Approach 1:
The invention changes the temperature parameter from high temperature (melting point 200°C or higher) to moderate temperature (crystallization temperature or higher, typically 80-150°C), and changes the phase separation mechanism from solid phase/liquid phase separation to liquid phase separation, thereby reducing energy consumption and improving production efficiency while still achieving fine particle sizes
Solution Approach 2:
The invention uses glycol ether-based solvent as an intermediary substance that enables liquid phase separation at lower temperatures. The solvent mediates the phase separation process by forming a complex with the polyester-based resin, allowing fine particle formation without requiring high temperature heating and subsequent solvent extraction
2Manufacturing precision
If heating to melting point and cooling for solid phase/liquid phase separation is used, then fine polyester-based resin particles can be obtained, but troublesome treatment of extracting intermediate solvent is necessary
Solution Approach 1:
The glycol ether-based solvent acts as a temporary intermediary that facilitates particle formation but is easily removed. The solvent forms a complex with the resin during processing, enabling controlled phase separation, and can be subsequently removed by simple drying without complex extraction equipment
Solution Approach 2:
The invention replaces the complex mechanical solvent extraction system with a simple thermal drying process. Instead of using elaborate extraction equipment to remove the intermediate solvent, the process relies on evaporating the solvent through heating and drying, significantly simplifying the overall process complexity
3Manufacturing precision
If partial depolymerization with glycol is used to form porous pellets, then fine particles can be obtained, but byproducts remain and utility is limited
Solution Approach 1:
The invention changes the chemical parameter by using glycol ether-based solvent instead of glycol for depolymerization. This parameter change prevents the formation of byproducts such as terephthalic acid ester while still achieving the desired porous structure and fine particle size through liquid phase separation
Solution Approach 2:
The invention converts the potential harm of using depolymerization agents into a benefit by selecting glycol ether-based solvent that enables phase separation without generating harmful byproducts. The solvent facilitates the desired particle formation while its easy removability and lack of harmful decomposition products turn the depolymerization process into a beneficial step
4Ease of manufacture
If heat treatment to increase crystallization degree to 55% or more is used, then ambient temperature grinding becomes easy, but fine grinding below 50 μm cannot be performed and particle strength decreases
Solution Approach 1:
The invention changes the crystallization degree parameter from 55% or more to a moderate range (20-50%), and changes the grinding temperature condition from ambient temperature to elevated temperature (crystallization temperature or higher). This parameter combination maintains particle strength while enabling fine grinding below 50 μm through reduced resin strength at processing temperature
5Ease of manufacture
If heat treatment to increase crystallization degree to 55% or more is used, then ambient temperature grinding becomes easy, but meltability of particles at the time of baking is reduced
Solution Approach 1:
The invention changes the crystallization degree parameter from 55% or more to a moderate range (20-50%), which preserves the meltability of particles during baking while still enabling easy grinding. The lower crystallization degree maintains the resin's melting properties needed for coating applications
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 method allows for the production of fine polyester-based resin particles with maintained crystallization degree, improved grindability, and enhanced mechanical strength, reducing production costs and byproduct generation, while enabling their use in coatings and cosmetics.
Implementation Method 1
contacting a polyester-based raw material resin with a glycol ether-based solvent, followed by grinding
Implementation Method 2
grinding a mixture after the contact, wherein the contact is performed under a temperature of the crystallization temperature of the polyester-based raw material resin or higher
Data Source
AI summary
Polyester-based resin particles including a polyester-based resin as a base resin, in which the base resin exhibits a plurality of endothermic peaks corresponding to crystal melting temperatures by DSC measurement, at least one of the endothermic peaks exists in each region of a low temperature side region and a high temperature side region, a maximum endothermic peak of the low temperature side region and a maximum endothermic peak of the high temperature side region exhibit a crystal melting heat amount ratio (low temperature side crystal melting heat amount/high temperature side crystal melting heat amount) in a range of 0.1 to 1.5, and the polyester-based resin particles have a volume average particle diameter of 1 to 50 μm.