Solvent-Free Bio-Based Polyester Resin Emulsion via Melt Extrusion
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Solution Overview
Problem
Conventional processes for producing bio-based polyester resin emulsions for toners are time and energy-consuming, require large amounts of organic solvents, and are not environmentally friendly, limiting their scalability and application.
Innovation Solution
A solvent-free extrusion process is developed to produce bio-based polyester resin emulsions by blending the resin with a surfactant and neutralizing agent, followed by melt-mixing and emulsification with de-ionized water in an extruder, creating an oil-in-water latex without the use of organic solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based batch processes are used to produce polyester resin emulsions, then the resin can be dissolved and emulsified, but large amounts of organic solvents are required and subsequent energy-intensive distillation is needed to form latexes
Solution Approach 1:
The invention extracts and eliminates the organic solvent step from the conventional emulsification process. By using a solvent-free melt emulsification approach, the process directly emulsifies the polyester resin without requiring dissolution in organic solvents followed by energy-intensive distillation, thereby removing the harmful solvent removal step while maintaining emulsification capability
Solution Approach 2:
The invention changes the physical state parameters of the emulsification process by operating in the melt state rather than solution state. The polyester resin is emulsified directly from its melt form at elevated temperatures, changing the process from a solution-based approach to a melt-based approach, which eliminates the need for solvent addition and subsequent removal
2Ease of manufacture
If solvent flash emulsification and/or solvent-based phase inversion emulsification are used, then resin emulsion can be formed, but large amounts of organic solvents such as ethyl acetate, ketones or alcohols are used which are not environmentally friendly
Solution Approach 1:
The invention extracts and removes the organic solvent component entirely from the emulsification process. By implementing a solvent-free melt emulsification method, the process achieves resin emulsion formation without introducing harmful organic solvents like ethyl acetate, ketones, or alcohols, thereby eliminating the environmental harm associated with solvent use and disposal
Solution Approach 2:
The invention converts the potential harm of requiring high temperatures for melt processing into a benefit by utilizing the melt state directly for emulsification. The elevated temperatures needed to melt the polyester resin are not viewed as a drawback requiring solvent mediation, but rather as an enabling condition for direct, environmentally friendly emulsion formation
3Ease of manufacture
If conventional batch processes are used for resin emulsion preparation, then emulsion can be produced, but the process is time-consuming and not scalable
Solution Approach 1:
The invention inverts the conventional batch processing approach by implementing a continuous extrusion-based melt emulsification process. Instead of adding solvents and processing in batches, the system continuously feeds polyester resin through an extruder where it is melted and emulsified in a continuous stream, fundamentally reversing the processing sequence from batch solution-based to continuous melt-based operation
Solution Approach 2:
The invention establishes continuous operation by using an extruder to continuously feed, melt, and emulsify the polyester resin without interruption. This continuous melt emulsification process eliminates the start-stop nature of batch processing, maintaining continuous useful action throughout the emulsion production, thereby improving productivity and enabling easy scalability
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 efficiently produces bio-based resin emulsions with controlled particle size and solids content, enabling the production of toners and other materials in an environmentally friendly and scalable manner, free from solvent residues.
Implementation Method 1
melt-mixing the pre-blend mixture
Implementation Method 2
melt-mixing the pre-blend mixture
Implementation Method 3
contacting the melt-mixed mixture with de-ionized water to form an oil in water emulsion
Data Source
AI summary
A process comprising:contacting at least one bio-based amorphous polyester resin with an optional plasticizer to form a pre-blend mixture;neutralizing the pre-blend mixture with a neutralizing agent;contacting the pre-blend mixture with a surfactant;melt-mixing the pre-blend mixture;contacting the melt-mixed mixture with de-ionized water to form an oil in water emulsion possessing a latex; andrecovering the latex.