Resin Particle Dispersion Distillation Preventing Wall Adhesion
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Solution Overview
Problem
The existing methods for producing resin particle dispersion through reduced pressure distillation often result in a significant yield reduction due to resin adhesion to the inner wall surface of the distillation tank, particularly when an aqueous medium is not added during the process.
Innovation Solution
A method involving the preparation of a phase-inverted emulsion using an organic solvent and an aqueous medium, followed by reduced pressure distillation using a specific distillation device with a heating unit and agitating unit, where the aqueous medium is added during distillation to prevent excessive solid concentration and viscosity, thereby reducing resin adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reduced pressure distillation is performed without adding aqueous medium, then organic solvent removal efficiency is improved, but resin adhesion to distillation tank walls increases significantly
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the aqueous medium concentration during the distillation process. Initially, a small amount of aqueous medium is added to prevent resin adhesion, and then the concentration is gradually reduced as distillation progresses. This dynamic parameter adjustment allows maintaining high solvent removal efficiency while preventing resin adhesion to the distillation tank walls.
Solution Approach 2:
The patent implements periodic action through staged addition of aqueous medium during distillation. The aqueous medium is added in multiple stages: initially to prevent adhesion, then reduced gradually. This periodic adjustment of aqueous medium concentration allows the system to maintain optimal conditions at different stages of the distillation process, balancing solvent removal efficiency with resin adhesion prevention.
2Loss of substance
If aqueous medium is added during distillation, then resin adhesion is reduced, but distillation time and energy consumption increase
Solution Approach 1:
The patent uses parameter changes by dynamically adjusting the aqueous medium concentration during distillation. The concentration is initially high to prevent adhesion, then gradually reduced to maintain distillation efficiency. This dynamic adjustment optimizes the balance between preventing resin adhesion and maintaining acceptable distillation time.
Solution Approach 2:
The patent applies partial action by adding only the necessary amount of aqueous medium at each stage of distillation, rather than maintaining a constant high concentration throughout. This partial addition strategy prevents resin adhesion while minimizing the impact on distillation time and energy consumption.
3Loss of substance
If aqueous medium concentration is maintained high, then resin adhesion is minimized, but organic solvent removal efficiency decreases
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the aqueous medium concentration during the distillation process. The concentration is initially high to prevent resin adhesion, then gradually reduced as distillation progresses to maintain high solvent removal efficiency. This dynamic parameter adjustment resolves the contradiction between adhesion prevention and removal efficiency.
Solution Approach 2:
The patent implements periodic action through staged adjustment of aqueous medium concentration. The concentration is adjusted in multiple stages: initially high to prevent adhesion, then gradually reduced to maintain distillation efficiency. This periodic adjustment allows the system to optimize both adhesion prevention and solvent removal at different stages.
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 effectively minimizes resin adhesion to the distillation tank walls, maintaining a higher yield of resin particle dispersion by controlling the solid concentration and viscosity within the emulsion during distillation.
Implementation Method 1
a heating unit that heats a tank wall of the distillation tank by causing a heated fluid to flow inside the heating unit
Implementation Method 2
an agitating unit disposed inside the distillation tank, the agitating unit including an agitating shaft and one or a plurality of gutter-shaped agitation impellers that are attached to the agitating shaft, rotate to agitate the phase-inverted emulsion
Implementation Method 3
removing the organic solvent from the phase-inverted emulsion by reduced pressure distillation
Implementation Method 4
a reduced pressure distillation device including: a distillation tank that contains a phase-inverted emulsion
Data Source
AI summary
A method for producing a resin particle dispersion includes: preparing a phase-inverted emulsion by phase inversion emulsification of a resin using an organic solvent and an aqueous medium; and removing the organic solvent from the phase-inverted emulsion by reduced pressure distillation. The reduced pressure distillation is performed using a reduced pressure distillation device including: a distillation tank that contains the phase-inverted emulsion; a heating unit that heats a tank wall of the distillation tank by causing a heated fluid to flow inside the heating unit; and an agitating unit disposed inside the distillation tank, the agitating unit including an agitating shaft and one or plural gutter-shaped agitation impellers that are attached to the agitating shaft, rotate to agitate the phase-inverted emulsion, and draw up the phase-inverted emulsion to form a liquid film of the phase-inverted emulsion on a heat transfer surface of the distillation tank in a portion above a liquid level of the phase-inverted emulsion. The aqueous medium is added to the phase-inverted emulsion contained in the distillation tank during the reduced pressure distillation.