Silicone-Free Defoamer for Polyester Emulsification

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Solution Overview

Problem

The existing solvent-based phase inversion emulsification processes for producing polyester resin emulsions are energy-intensive and time-consuming due to the formation of thick, long-life foam during solvent stripping, leading to product loss and inefficient distillation.

Innovation Solution

The introduction of a silicone-free anti-foam agent comprising micrometer-sized hydrophobic fumed silica particles helps control foam formation, allowing for more efficient solvent stripping and reduced distillation times by incorporating these particles into the resin mixture during the phase inversion process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If conventional solvent stripping is used to remove organic solvent from polyester resin mixture, then solvent removal is achieved, but the process becomes extremely time-consuming (up to 30 hours) and energy-intensive due to foam formation

Engineering Contradiction:

Improvesolvent removal efficiencyVSAvoiddistillation time

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

A defoaming agent is introduced as an intermediary substance to mediate between the foaming solvent mixture and the vacuum distillation process. The defoaming agent breaks down foam structure and prevents foam stabilization, allowing efficient solvent removal without the time-consuming foam management issues of conventional stripping.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The process changes key parameters including adding defoaming agents to alter foam behavior, adjusting vacuum levels dynamically, and optimizing temperature profiles during distillation. These parameter changes enable faster solvent removal (reducing time from 30 hours to practical durations) while maintaining removal efficiency.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high vacuum and high temperature are applied to accelerate solvent stripping, then solvent removal efficiency improves, but foam formation increases causing product loss

Engineering Contradiction:

Improvesolvent stripping rateVSAvoidproduct loss from foam boil-over

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The defoaming agent is added before or during the early stages of vacuum distillation to preemptively counteract foam formation. This preliminary anti-action prevents foam buildup before it can cause boil-over, allowing high vacuum and temperature to be applied safely to accelerate solvent removal without product loss.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The foam formation, which is normally a harmful phenomenon causing product loss, is converted into a manageable process feature through the defoaming agent. The agent transforms the harmful foam into controlled vapor release, allowing the system to operate at higher productivity levels while preventing boil-over.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If vacuum distillation is operated at reduced vacuum level and temperature to prevent foam boil-over, then product loss is minimized, but solvent stripping efficiency becomes extremely slow

Engineering Contradiction:

Improveproduct retentionVSAvoidsolvent removal rate

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The defoaming agent serves as an intermediary that enables the system to operate at higher vacuum levels and temperatures without the harmful effects of foam boil-over. This mediator allows the process to achieve both high productivity and high reliability simultaneously by decoupling the trade-off between operating intensity and product retention.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 significantly reduces distillation time from 30 hours to as low as 5-10 hours, minimizes product loss, and maintains the molecular weight properties of the starting resin, enhancing the efficiency and productivity of polyester emulsification.

Implementation Method 1

introducing a silicone-free anti-foam agent comprising micrometer-sized hydrophobic fumed silica particles to the resin mixture

Methodology Applied

Scientific EffectHydrophobic interaction: Hydrophobe

Implementation Method 2

solvent stripping can take up to 30 hours under high temperature and high vacuum

Methodology Applied

Scientific EffectVacuum distillation: Vacuum Distillation

Implementation Method 3

solvent stripping in phase inversion emulsification of polyester resins

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentEP2261747B1Efficient solvent-based phase inversion emulsification process with silicone-free defoamer

Publication Date: 2016.12.28 XEROX CORP

AI summary

A process and system for making a resin emulsion suitable for use in forming toner particles including a silicone free anti-foam agent to control foam during formation of a polyester dispersion.