Micronized Polyetherimide Emulsion Drying Process
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Solution Overview
Problem
Existing methods for producing ultra-fine particles of high performance polymers, such as polyetherimide, result in yields less than 90%, which is not commercially viable.
Innovation Solution
A process involving dissolving the polymer in an organic solvent, emulsifying with water and a surfactant, and transferring the emulsion into surfactant-containing water to remove the solvent, with the surfactant ratio matching in both the emulsion and receiving water, to achieve a yield greater than 90% of particles less than 75 microns in diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If emulsion distillation process is used to make ultra-fine particles, then particles can be produced, but the yield of ultra-fine particles is less than 90%
Solution Approach 1:
The patent changes the fundamental parameter of solvent removal from distillation to water extraction. By transferring the emulsion into water, the organic solvent is extracted without thermal degradation, preserving polymer integrity and achieving over 90% yield of ultra-fine particles.
Solution Approach 2:
Water acts as an intermediary substance to remove the organic solvent from the emulsion. The water-soluble surfactant in the receiving water facilitates solvent extraction while maintaining particle stability, enabling high yield without direct thermal contact.
2Ease of manufacture
If conventional emulsion process is used, then polymer particles are formed, but commercial feasibility is compromised due to low yield
Solution Approach 1:
The patent modifies the process parameter from distillation-based solvent removal to water-based extraction. This fundamental change enables commercial feasibility by achieving over 90% yield while maintaining simplicity in the manufacturing process.
Solution Approach 2:
The receiving water containing surfactant automatically extracts the organic solvent from the emulsion through diffusion and solubility principles, eliminating the need for complex distillation equipment and operations.
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 process significantly increases the yield of ultra-fine particles to above 90%, improving the commercial feasibility of producing high performance polymer powders with enhanced properties.
Implementation Method 1
transferred into receiving water containing a surfactant to remove the organic solvent and form a slurry
Data Source
Figure 1
Figure 2~3
AI summary
A process for making ultra-fine particles of a high performance polymer in a yield greater than 90%, which includes dissolving the high performance polymer in an organic solvent capable of dissolving the polymer to form a solution; emulsifying the solution by combining the solution with water and a surfactant to form an emulsion; transferring the emulsion into a receiving water containing a surfactant to remove the organic solvent and form a slurry; and recovering particles of less than 75 microns in diameter in a yield greater than 90%.