TWI826942B - 色料分散體及其製造方法 - Google Patents
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Abstract
本發明公開一種色料分散體及其製造方法。色料分散體的製造方法包括下列步驟:混合一色粉、一分散劑及一可塑劑,以形成一分散液;均質分散液,以形成一色漿;添加一載體高分子粉體於色漿中,以形成一液態混合物;於80°C至100°C的溫度下,攪拌液態混合物,以獲得一色料分散體。可塑劑促進載體高分子粉體塑化,以使得在塑化過程中,載體高分子粉體吸附色漿並形成色料分散體。
Description
本發明涉及一種色料分散體及其製造方法,特別是涉及一種可側入料的色料分散體及其製造方法。
為了因應市場對產品的外觀需求,通常會於高分子原料中添加色粉或是色母粒,以製成各種顏色的高分子產品。
色粉的價格較為低廉,但粉狀的形式使得色粉容易受潮,而有不易儲存的問題。在加工的過程中,色粉無法自由流動,而容易負面影響色粉的分散性。當色粉的分散性不佳時,又會導致產品的著色效果不穩定,而負面影響產品的品質。另外,在添加色粉時,色粉容易於空氣中形成粉塵,而有操作安全的顧慮。
色母粒可克服色粉不易儲存以及加工不易的問題。然而,色母粒的製造成本與能耗較高,需使用特定的設備(例如:螺桿擠出),並經高溫熔融押出後才可製得。於目前市場中,為了降低色母粒的製造成本,製造商不斷提高色母粒中色料的濃度。因此,現有的色母粒也面臨了不易分散的挑戰,並可能連帶造成產品的色差值偏大以及產品表面有色點的問題。
故,如何通過成分結構的改良,提供一種新的色料,來克服上述的缺陷,已成為該項事業所欲解決的重要課題之一。
本發明所要解決的技術問題在於,針對現有技術的不足提供一種色料分散體及其製造方法。
為了解決上述的技術問題,本發明所採用的其中一技術方案是提供一種色料分散體的製造方法。色料分散體的製造方法包括下列步驟:混合一色粉、一分散劑及一可塑劑,以形成一分散液。均質分散液,以形成一色漿;添加一載體高分子粉體於色漿中,以形成一液態混合物。於80°C至100°C的溫度下,攪拌液態混合物,以獲得一色料分散體。可塑劑促進載體高分子粉體塑化,以使得在塑化過程中,載體高分子粉體吸附色漿並形成色料分散體。
於一些實施例中,在塑化過程中,所述載體高分子粉體吸收所述色漿中的液相成分,並吸附所述色漿中的固相成分。
於一些實施例中,色漿中色粉的平均粒徑為200奈米至2000奈米。
於一些實施例中,色漿的黏度為100 cps至750 cps。
於一些實施例中,色漿中包括20重量份至40重量份的色粉、0.5重量份至5重量份的分散劑以及50重量份至80重量份的可塑劑。
於一些實施例中,以色漿的總重為100重量份,載體高分子粉體的添加量為110重量份至150重量份。
於一些實施例中,色料分散體的平均粒徑為0.05毫米至5毫米。
於一些實施例中,載體高分子粉體是選自於由下列所構成的群組:聚氯乙烯、聚乙烯高分子蠟、乙烯-醋酸乙烯酯共聚物、聚甲基丙烯酸甲酯、氯乙烯-醋酸乙烯共聚物、醋酸乙烯-氯乙烯-順丁烯二酸共聚物、苯乙烯-丁二烯-丙烯腈共聚物及其組合物。
本發明所採用的另一技術方案是提供一種色料分散體,色料分散體是由前述製造方法所製成。
於一些實施例中,色料分散體的主結構是由載體高分子粉體形成的一塊狀多孔載體,色粉附著於塊狀多孔載體的全表面。
本發明的其中一有益效果在於,本發明所提供的色料分散體及其製造方法,其能通過“均質所述分散液,以形成一色漿”、“80°C至100°C的溫度下,攪拌所述液態混合物,以獲得一色料分散體”以及“在塑化過程中,載體高分子粉體吸附色漿並形成色料分散體”的技術方案,以較低的能耗製造粒徑尺寸小、色粉分散性良好且色粉濃度高的色料分散體。
為使能更進一步瞭解本發明的特徵及技術內容,請參閱以下有關本發明的詳細說明與圖式,然而所提供的圖式僅用於提供參考與說明,並非用來對本發明加以限制。
以下是通過特定的具體實施例來說明本發明所公開有關“色料分散體及其製造方法”的實施方式,本領域技術人員可由本說明書所公開的內容瞭解本發明的優點與效果。本發明可通過其他不同的具體實施例加以施行或應用,本說明書中的各項細節也可基於不同觀點與應用,在不背離本發明的構思下進行各種修改與變更。另外,本發明的附圖僅為簡單示意說明,並非依實際尺寸的描繪,事先聲明。以下的實施方式將進一步詳細說明本發明的相關技術內容,但所公開的內容並非用以限制本發明的保護範圍。另外,本文中所使用的術語“或”,應視實際情況可能包括相關聯的列出項目中的任一個或者多個的組合。
為了克服以往色母粒的製造成本較高以及色粉不易加工與儲存的問題,本發明提供一種色料分散體及其製造方法。有別於以往的色粉,本發明的色料分散體具有方便儲存、粒徑尺寸小、色粉分散性好以及色粉濃度高的優點。因此,在加工時,本發明的色料分散體可以側進料方式投入生產線。另外,相較於色母粒而言,本發明的色料分散體可在較低的溫度下製備,而具有生產成本較低的優勢。
請參閱圖1所示,本發明的色料分散體的製造方法包括以下步驟:混合一色粉、一分散劑及一可塑劑,以形成一分散液(步驟S1);於常溫下均質分散液,以形成一色漿(步驟S2);於色漿中添加一載體高分子粉體形成一液態混合物(步驟S3);於80°C至100°C的溫度下攪拌液態混合物,以獲得一色料分散體(步驟S4)。
本發明色料分散體的製造方法中,最高的操作溫度至多為100°C(步驟S4),相較於經高溫熔融押出後製得的色母粒,明顯具有較低的操作溫度,因此,本發明色料分散體的製造方法具有能耗較低的優勢。
本發明的色料分散體主要是由載體高分子粉體、色粉及可塑劑所構成,通過調整三者成分間的含量以及特性,可在較低的溫度(80°C至100°C)條件下,使三者成分相互作用,以形成具穩定結構的一固體混合物(色料分散體)。
在攪拌液態混合物的過程中,塑化劑會促使載體高分子粉體塑化,而載體高分子粉體在塑化的過程中會吸附色漿,進而達到承載色粉的效果。
具體來說,色漿中的液相成分(分散劑及可塑劑)會被載體高分子粉體吸收,又因為內聚力的作用,使得鄰近的載體高分子粉體逐漸團聚,形成不規則形狀的一塊狀多孔載體。當液相成分被吸收後,色漿中的固相成分(色粉)便會附著於載體高分子粉體的表面,由於塊狀多孔載體是由多個載體高分子粉體團聚形成,故塊狀多孔載體的外表面以及內部孔隙周圍的表面皆會吸附有色粉。
請參閱圖2所示,就微觀結構而言,色料分散體1的主結構是由載體高分子粉體10以不規則形狀團聚形成(塊狀多孔載體),且塊狀多孔載體的全表面(塊狀多孔載體的外表面以及內部孔隙周圍的表面)上附著有色粉20,或者。就巨觀結構而言,可視為色粉20被包覆於色料分散體1中或是吸附於色料分散體1上。
也就是說,本發明的色料分散體主要是由載體高分子粉體、色粉及可塑劑所構成,且形成色料分散體的過程中,成分並未重新塑形,僅是通過分子間的作用力形成固體混合物。
現有技術中的色母粒在製造過程中經熔融步驟,因此,高分子材料會因高溫熔融而重新塑形,進而形成緻密無孔隙的色母粒。具體來說,高分子材料在色母粒中扮演連續相,色粉則是以分散相的狀態存在色母粒中。簡言之,本發明的色料分散體的製法及結構,都與以往色母粒的製法及結構不同。
請參閱圖1所示,在步驟S1中,為了方便形成分散液,可先添加分散劑及可塑劑,再批次添加色粉,以避免形成大量的色粉團塊。
以分散液的總重為100重量百分比(wt%),色粉的含量為1 wt%至75 wt%,分散劑的含量為0.05 wt%至15 wt%,可塑劑的含量為25 wt%至99 wt%。於一示範實施例中,色粉的含量為20 wt%至50 wt%,分散劑的含量為1 wt%至10 wt%,可塑劑的含量為40 wt%至75 wt%。
需特別說明的是,色粉的含量會因不同的色粉種類而調整,例如:白色色粉的含量可以是45 wt%至55 wt%,紫色色粉的含量可以是15 wt%至20 wt%。具體來說,色粉的含量可以是25 wt%、30 wt%、35 wt%、40 wt%或45 wt%。可塑劑的含量可根據後續添加的載體高分子粉體的含量做調整,具體來說,可塑劑的含量可以是30 wt%、35 wt%、40 wt%、50 wt%、55 wt%、60 wt%、65 wt%或70 wt%。
本發明的色粉並不限於有機或無機的材料,舉例來說,色粉可以是二氧化鈦、氧化鋅、三氧化二銻、碳酸鈣、碳黑、石墨、氧化鐵、雙矽酸鋁鹽、硫酸銅、鐵藍、群青、酞菁、硫酸鈉、硫酸鋇、硫化鋅、高嶺土、立德粉、甲苯胺红、鎘紅、鉛鉻黃、鎘黃、鐵黃、聯苯胺黃、氧化鉻綠、鉻綠或偶氮顏料。
分散劑的添加可幫助均勻分散色粉,以利於進行後續的步驟S2至步驟S4。分散劑可以是聚醯胺、多元胺、鄰苯二甲酸酯、檸檬酸酯、乙醯檸檬酸酯、乙烯-醋酸乙烯共聚物蠟、石蠟、聚乙烯蠟、聚丙烯蠟、氧化聚乙烯蠟、醯胺蠟(例如:油酸醯胺或芥酸醯胺)、酯蠟(例如:單甘酯、季戊四醇酯或硬脂酸正丁酯)、硬脂酸、硬脂酸鹽、偏苯酸酯、白礦油或聚矽酮。然而,本發明並不限於此。
可塑劑的添加是為了在步驟S4中形成色料分散體,如此一來,本發明不需經過高溫熔融的程序,可在較低溫(80°C至100°C)的狀態製成色料分散體。可塑劑可以是對苯二甲酸二異辛酯(dioctyl terephthalate,DOTP)、鄰苯二甲酸二異壬酯(di-iso-nonyl phthalate,DINP)、鄰苯二甲酸二(2-丙基庚)酯(di(2-propylheptyl) phthalate,DPHP)、1, 2-環己烷二羧酸異壬酯(di-isononyl-cyclohexane-1, 2-dicarboxylate,DHIN)、鄰苯二甲酸二(2-乙基己基)酯(di(2-ethylhexyl)phthalate,DEHP)或環氧大豆油。較佳的,可塑劑是對苯二甲酸二異辛酯或1, 2-環己烷二羧酸異壬酯。然而,本發明並不限於此。
在步驟S2中,於常溫下,以300 rpm至30000 rpm的轉速均質分散液10秒至600秒,以使色粉均勻分散,並避免色粉產生團塊。
經均質後,色漿中色粉的粒徑為200奈米至2000奈米,較佳的,色漿中色粉的粒徑為330奈米至950奈米。當色粉的粒徑為上述特定範圍中時,有利於形成粒徑為0.1毫米至0.6毫米的色料分散體,並且,色料分散體可兼具高濃度色粉以及色粉均勻分散的效果。於其他實施例中,色漿中色粉的粒徑可以是300奈米、400奈米、500奈米、600奈米、700奈米、800奈米、900奈米、1000奈米、1100奈米、1200奈米、1300奈米、1400奈米、1500奈米、1600奈米、1700奈米、1800奈米或1900奈米。
經均質後,色漿的黏度小於或等於1000 cps,以利於進行後續的步驟S3。於其他實施例中,色漿的黏度可以是50 cps、100 cps、150 cps、200 cps、250 cps、300 cps、350 cps、400 cps、450 cps、500 cps、550 cps、600 cps、700 cps、800 cps或900 cps。
於本發明中,色漿中包含1重量份至75重量份的色粉、0.05重量份至15重量份的分散劑以及25重量份至99重量份的可塑劑。於一示範實施例中,色漿中包括20重量份至40重量份的色粉、0.5重量份至5重量份的分散劑以及50重量份至80重量份的可塑劑。於另一示範實施例中,色漿中包括10重量份至30重量份的色粉、0.5重量份至3重量份的分散劑以及50重量份至70重量份的可塑劑。於又另一示範實施例中,色漿中包括30重量份至50重量份的色粉、2重量份至5重量份的分散劑以及60重量份至80重量份的可塑劑。
在步驟S3中,載體高分子粉體是色料分散體的主要成分,載體高分子粉體形成的塊狀多孔載體是構成色料分散體的主要結構,並可用以吸附色粉。通過選用特定的載體高分子粉體,更可有利於製造色料分散體。舉例來說,載體高分子粉體是選自於由下列所構成的群組:聚氯乙烯、聚乙烯高分子蠟、乙烯-醋酸乙烯酯共聚物、聚甲基丙烯酸甲酯、氯乙烯-醋酸乙烯共聚物、醋酸乙烯-氯乙烯-順丁烯二酸共聚物、苯乙烯-丁二烯-丙烯腈共聚物及其組合物。然而,本發明並不限於此。
於一較佳實施例中,載體高分子粉體可在塑化過程中形成一多孔結構,或是以其他方式形成多孔結構。如此一來,載體高分子粉體形成的塊狀多孔載體可具有更佳的色粉吸附效果。於一示範實施例中,載體高分子粉體的材料是聚氯乙烯。
於一示範實施例中,載體高分子粉體的密度為0.8 g/cm
3至1.6 g/cm
3,載體高分子粉體的比表面積為10 m
2/g至70 m
2/g,載體高分子粉體的粉體尺寸為0.1毫米至1.0毫米。使用上述規格的載體高分子粉體,有利於形成粒徑尺寸小、色粉分散性良好且色粉濃度高的色料分散體。
於一些實施例中,步驟S3還可選擇性添加一功能助劑,例如:安定劑。安定劑的添加可增加色料分散體的耐熱性,如此一來,後續製造產品的步驟中,便無需再添加安定劑。舉例來說,安定劑可以是鈣鋅系類抗氧劑、鋇鋅系類抗氧劑、硫酯類抗氧劑、亞磷酸酯類抗氧劑或酚類抗氧劑。較几的,然而,本發明並不限於此。
以色漿的總重為100重量份,載體高分子粉體的添加量為110重量份至150重量份,安定劑的添加量為0.5重量份至5重量份。舉例來說,載體高分子粉體的添加量可以是120重量份、130重量份或140重量份,安定劑的添加量可以是1重量份、2重量份、3重量份或4重量份。
在步驟S4中,於80°C至100°C的溫度下,以100 rpm至2000 rpm的轉速攪拌液態混合物,經300秒至1200秒的攪拌後,原本的液態混合物逐漸轉變成固體狀的色料分散體。
在高速攪拌的過程中,除了前述載體高分子粉體吸收色漿中的液相成分並吸附固相成分的現象之外,在80°C至100°C的溫度下攪拌,還可促進載體高分子粉體在塑化過程吸附更多的色粉。也就是說,本發明的製造方法可提升色料分散體中所可包含的色粉的濃度,且仍可具有良好的分散性。
在攪拌的過程中,一部分的液相成分會蒸散。最後,可獲得本發明的色料分散體。於一示範實施例中,色料分散體的尺寸為0.05毫米至5毫米,較佳的,色料分散體的尺寸為0.1毫米至2毫米。更佳的,色料分散體的尺寸為0.2毫米至0.8毫米。舉例來說,色料分散體的尺寸可以是0.2毫米、0.3毫米、0.4毫米、0.5毫米、0.6毫米、0.7毫米、0.8毫米、0.9毫米、1毫米、2毫米、3毫米或4毫米。若色料分散體的尺寸過小,則於入料過程中容易產生粉塵,若色料分散體的尺寸過大,則不易控制色料分散體的添加量,且產品容易形成色點。
為了證實本發明的色料分散體的製造方法,可在較低的溫度條件,製備色粉分散均勻的色料分散體。本發明根據上述步驟S1至步驟S4,以不同的條件分別製得實施例1至6的色料分散體。實施例1至6中使用的成分種類及添加量列於表1中,若無特別註明,表1中的單位為重量份。實施例1至6中使用的色漿與色料分散體的特性也列於表1中。
[實施例1至6]
混合分散劑及可塑劑後,再逐量添加色粉,以形成分散液。以300 rpm至30000 rpm的轉速均質分散液10秒至600秒,以形成一色漿。補充說明的是,表1中使用的分散劑是經高分子量聚酯改性的聚醯胺分散劑以及經高分子量聚酯改性的多元胺分散劑。
色漿中包括20重量份至40重量份的色粉、0.5重量份至5重量份的分散劑以及50重量份至80重量份的可塑劑。經均質後色漿的黏度為100 cps至750 cps,且色漿中色粉的平均粒徑為200奈米至2000奈米。
接著,以色漿的總重為100重量份,於色漿中添加110重量份至150重量份的載體高分子粉體以及0.5重量份至5重量份的安定劑,以形成一液態混合物,並於80°C至100°C的溫度下,以100 rpm至2000 rpm的轉速攪拌液態混合物300秒至1200秒,最終可獲得一色料分散體,色料分散體的平均粒徑為0.05毫米至5毫米。
表1
(重量份) | 實施例 | ||||||
1 | 2 | 3 | 4 | 5 | 6 | ||
色粉 | 黑色色粉 | 30 | 30 | - | 30 | 30 | 30 |
藍色色粉 | - | - | 30 | - | - | - | |
分散劑 | 聚醯胺分散劑 | 2.4 | - | - | 2.4 | 2.4 | 2.4 |
多元胺分散劑 | - | 2.4 | 2.4 | - | - | - | |
可塑劑 | 對苯二甲酸二異辛酯 | 67.6 | 67.6 | 67.6 | - | 67.6 | 67.6 |
1, 2-環己烷二羧酸異壬酯 | - | - | - | 67.6 | - | - | |
色漿中色粉平均粒徑(奈米) | 472 | 891 | 356 | 527 | 472 | 472 | |
色漿黏度(cps) | 220 | 680 | 200 | 560 | 220 | 220 | |
安定劑 | 鈣鋅系氧化劑 | 1.8 | 1.8 | 1.8 | 1.8 | 1.8 | - |
鋇鋅系氧化劑 | - | - | - | - | - | 1.8 | |
載體高分子粉體 | 聚氯乙烯粉末 | 120 | 120 | 120 | 120 | - | 120 |
聚乙烯高分子蠟粉末 | - | - | - | - | 120 | - | |
色料分散體的平均粒徑(毫米) | 0.32 | 0.34 | 0.30 | 0.32 | 0.60 | 0.32 |
由表1的結果可得知,經均質後的色漿中色粉的粒徑可以是350奈米至550奈米,經均質後的色漿的黏度可以是180 cps至720 cps,顏色分散粒的平均粒徑為0.25毫米至0.65毫米。
當選用聚氯乙烯粉末作為載體高分子粉體時,顏色分散粒可具有較小的平均粒徑,顏色分散粒的平均粒徑為0.25毫米至0.45毫米,較佳的,顏色分散粒的平均粒徑為0.25毫米至0.35毫米。
相較於現有技術中的色母粒,本發明的色料分散體具有較小的尺寸,可適用於自動計量機器。因此,在添加色料分散體時,可選擇在押出機的設備端添加即可(側進料),也就是說,更換色粉顏色時,不需清洗整條生產線。
[實施例的有益效果]
本發明的其中一有益效果在於,本發明所提供的色料分散體及其製造方法,其能通過“均質分散液,以形成一色漿”、“80°C至100°C的溫度下,攪拌液態混合物,以獲得一色料分散體”以及“在塑化過程中,載體高分子粉體吸附色漿並形成色料分散體”的技術方案,以較低的能耗製造粒徑尺寸小、色粉分散性良好且色粉濃度高的色料分散體。
進一步而言,本發明通過均質的步驟均勻分散色粉,使得色漿中色粉的平均粒徑為200奈米至2000奈米,以便製得本發明粒徑較小的色料分散體。即便本發明的色料分散體具有較小的粒徑,通過添加可塑劑塑化載體高分子粉體,可提升色料分散體中色粉的濃度,並保持色粉均勻分散的優點。
進一步而言,通過調整色漿與載體高分子粉體的相對添加量或是色漿中色粉、分散劑及可塑劑的含量比,可達到本發明製備粒徑尺寸小、色粉分散性良好且色粉濃度高的色料分散體的效果。
進一步而言,本發明在80°C至100°C的溫度下攪拌液態混合物,可促進載體高分子粉體在塑化過程吸附更多的色粉,並可去除色漿中一部份的液相成分,以製成本發明的色料分散體。
以上所公開的內容僅為本發明的優選可行實施例,並非因此侷限本發明的申請專利範圍,所以凡是運用本發明說明書及圖式內容所做的等效技術變化,均包含於本發明的申請專利範圍內。
1:色料分散體
10:載體高分子粉體
20:色粉
圖1為本發明色料分散體的製造方法的步驟流程圖。
圖2為本發明色料分散體的剖面示意圖。
Claims (10)
- 一種色料分散體的製造方法,其包括:混合20重量份至40重量份的一色粉、0.5重量份至5重量份的一分散劑及50重量份至80重量份的一可塑劑,以形成一分散液;均質所述分散液,以形成一色漿,所述色漿中所述色粉的粒徑為200奈米至2000奈米;以所述色漿的總重為100重量份,添加110重量份至150重量份的一載體高分子粉體於所述色漿中,以形成一液態混合物;以及於80℃至100℃的溫度下,攪拌所述液態混合物,以獲得一色料分散體,所述色料分散體是一固體混合物;其中,所述可塑劑促進所述載體高分子粉體塑化,以使得在塑化過程中,所述載體高分子粉體吸收所述色漿中的液相成分,並吸附所述色漿中的固相成分,以形成所述色料分散體,所述色料分散體的平均粒徑為0.05毫米至5毫米。
- 如請求項1所述的製造方法,其中,所述可塑劑是對苯二甲酸二異辛酯、鄰苯二甲酸二異壬酯、鄰苯二甲酸二(2-丙基庚)酯、1,2-環己烷二羧酸異壬酯、鄰苯二甲酸二(2-乙基己基)酯或環氧大豆油。
- 如請求項1所述的製造方法,其中,所述分散劑是聚醯胺分散劑或多元胺分散劑。
- 如請求項1所述的製造方法,其中,所述色漿的黏度為100cps至750cps。
- 如請求項1所述的製造方法,其中,所述載體高分子粉體的密度為0.8g/cm3至1.6g/cm3。
- 如請求項1所述的製造方法,其中,所述載體高分子粉體的 比表面積為10m2/g至70m2/g。
- 如請求項1所述的製造方法,其中,所述載體高分子粉體的粉體尺寸為0.1毫米至1.0毫米。
- 如請求項1所述的製造方法,其中,所述載體高分子粉體是選自於由下列所構成的群組:聚氯乙烯、聚乙烯高分子蠟、乙烯-醋酸乙烯酯共聚物、聚甲基丙烯酸甲酯、氯乙烯-醋酸乙烯共聚物、醋酸乙烯-氯乙烯-順丁烯二酸共聚物、苯乙烯-丁二烯-丙烯腈共聚物及其組合物。
- 一種色料分散體,其是由如請求項1至8中任一項所述的製造方法所製成。
- 如請求項9所述的色料分散體,其中,所述色料分散體的主結構是由所述載體高分子粉體形成的一塊狀多孔載體,所述色粉附著於所述塊狀多孔載體的全表面。
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