Surface-Modified Inorganic Fillers for Reduced Binder Usage
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Solution Overview
Problem
Existing methods for preparing inorganic fillers and pigments in polymer dispersions are inefficient, leading to high binder usage and poor binding capabilities, especially in the paper and paint industries, where filler content and grain size significantly impact paper strength and porosity.
Innovation Solution
A process involving the milling of inorganic fillers or pigments with polymer dispersions under pressure and shear forces, using known milling aids and dispersing agents, to achieve a desired grain size and improved binding capabilities, while reducing binder usage and agglomeration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If inorganic fillers and pigments are bound with polymer dispersions using conventional mixing methods, then the preparation process is simple, but the binding capability is poor and binder usage is high
Solution Approach 1:
The patent replaces conventional mechanical mixing with a high-energy milling process that uses pressure and shear forces to achieve surface modification of inorganic fillers and pigments. This mechanical energy input during milling creates a much more effective contact between the polymer dispersion and filler surfaces, dramatically improving binding capability while reducing the amount of binder needed.
Solution Approach 2:
The patent changes the processing parameters by conducting the binding process under high pressure and shear forces during milling, rather than under gentle mixing conditions. This parameter change transforms the interaction between polymer dispersion and filler surfaces, enabling much stronger adhesion with reduced binder consumption.
2Stability of the object's composition
If filler content in paper composition is increased to improve formation and softness, then paper quality improves, but paper strength decreases
Solution Approach 1:
By using high-energy milling with pressure and shear forces to surface-modify fillers before papermaking, the patent enables much stronger binding between fillers and paper fibers. This allows high filler contents to be used while maintaining paper strength, because the improved binder-filler contact creates stronger composite material.
3Manufacturing precision
If inorganic fillers and pigments are milled to desired grain size without surface modification, then grain size control is achieved, but contact and binding with binders remains inefficient
Solution Approach 1:
The patent merges the grain size control function with the surface modification function into a single integrated milling process. By conducting both operations simultaneously under high pressure and shear forces, the filler particles achieve the desired grain size distribution while their surfaces are concurrently modified to dramatically improve binder contact and binding efficiency.
Solution Approach 2:
The patent uses high-energy mechanical milling with pressure and shear forces to simultaneously achieve grain size control and surface modification, replacing separate processing steps with a unified process that accomplishes both functions more effectively.
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 enhances the binding capacity of inorganic fillers and pigments, resulting in improved adhesion to substrates and reduced binder migration, leading to increased strength and resistance in paper and paint formulations.
Implementation Method 1
filler or pigment slurries of inorganic fillers or pigments are milled to the desired grain size with the action of pressure and shear forces
Implementation Method 2
inorganic pigments of a defined grain size whose surface is coated with binders during milling
Implementation Method 3
filler or pigment slurries of inorganic fillers or pigments are milled to the desired grain size with the action of pressure and shear forces using polymer dispersions, said fillers and/or pigments being further contacted with per se known milling aids and/or dispersing agents
Data Source
AI summary
The invention relates to a method for producing surface-modified inorganic fillers or pigments of a desired particle size. Said method is characterized in that filler or pigment slurries of inorganic fillers or pigments are milled to the desired particle size under the action of compressive and shear forces using polymer dispersions, whereby the fillers and/or pigments are additionally brought into contact with conventional milling auxiliary agents and/or dispersants (active agent) in a quantity of between 0.1 and 2.0 wt. %, in relation to the fillers or pigments. The invention also relates to the fillers and pigments that are obtained by said method and to their use for producing dispersion inks, adhesives, coatings or coating compounds for the paper industry, in particular coating compounds used in various industry segments, such as sheet fed offset printing, roll offset printing, gravure printing and for the production of cardboard and special papers.