Resin Particle Aggregate for Light Diffusion and Matting
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Solution Overview
Problem
Existing resin particle aggregates face issues with poor dispersibility into primary particles, fusion during processing, and reduced optical transparency due to the use of cross-linked polymer particles and inorganic powders, leading to inefficient production and suboptimal performance in light diffusion and matting applications.
Innovation Solution
A resin particle aggregate is formed by aggregating vinyl monomer polymer particles with a surfactant and cross-linkable monomer, using a seed polymerization method and spray drying process with controlled temperature and solid concentration, minimizing the use of inorganic components to enhance dispersibility and optical transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If resin particles with small particle diameter are used to achieve excellent light diffusion properties, then light diffusion function is improved, but handling difficulty increases due to poor flowability and dust generation
Solution Approach 1:
Multiple resin particles are aggregated into a single handleable unit with controlled particle diameter of 10 μm to 1 mm, combining the optical properties of fine particles with the handling properties of larger particles
Solution Approach 2:
A binder resin is used as an intermediary material to bind multiple fine resin particles together, creating an aggregate that maintains the optical properties of the fine particles while providing adequate handling characteristics
2Strength
If cross-linked polymer particles are used to achieve high strength, then particle strength is improved, but dispersibility into primary particles deteriorates
Solution Approach 1:
The aggregate is designed as a segmented structure where multiple primary particles are bound together, allowing the aggregate to disperse into individual primary particles when subjected to external forces during processing
Solution Approach 2:
The cross-linking degree is controlled within a specific range (cross-linkable monomer content of 5-50 mass%) to achieve optimal balance between particle strength and dispersibility, avoiding excessive cross-linking that would prevent dispersion
3Ease of operation
If inorganic powders are added to resin particle aggregates to improve handling properties, then flowability is improved, but optical transparency deteriorates
Solution Approach 1:
The inorganic powder component is removed from the aggregate structure, replacing it with organic binder resin to maintain handling properties while preserving optical transparency
Solution Approach 2:
An organic composite material system is used consisting of resin particles and binder resin, eliminating inorganic components that compromise optical properties while maintaining the composite structure needed for handling
4Ease of operation
If resin particles are aggregated by spray drying to improve handling properties, then ease of handling is improved, but production efficiency deteriorates due to long drying time
Solution Approach 1:
The slurry solid concentration is optimized to 20-40 mass% to achieve adequate particle aggregation during spray drying while minimizing drying time, balancing handling properties with production efficiency
Solution Approach 2:
The spray drying process is designed to achieve partial aggregation rather than complete drying, creating handlesable aggregates without requiring excessive drying time that would reduce production efficiency
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 resulting resin particle aggregate exhibits improved dispersibility, optical transparency, and handling properties, enabling efficient production of light diffusible compositions and coatings with enhanced light diffusion and matting effects.
Implementation Method 1
a plurality of resin particles are aggregated by, for example, spray drying to yield a resin particle aggregate, which is easily handled
Implementation Method 2
the resin particles are cross-linked by a cross-linkable monomer
Implementation Method 3
a polymer of a vinyl monomer
Data Source
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Figure 2
AI summary
A resin particle aggregate is the resin particle aggregate formed by aggregating a plurality of resin particles including a polymer of a vinyl monomer, includes 100 parts by mass of the resin particles and 1 to 5 parts by mass of a surfactant. The resin particles are cross-linked by a cross-linkable monomer in an amount of 10 to 50% by mass relative to the total mass of the resin particles, the resin particle aggregate contains an inorganic component in an amount of 0.5% by mass or less, the resin particles have a volume average particle diameter D1, particles contained in a dispersion liquid of the resin particle aggregate in water have a volume average particle diameter D2, and the ratio of D2/D1 is 15 or less.