Ultrasonic homogenizer for the industrial production of pigment and polymer dispersions

Ultrasonic homogenizer for the industrial production of pigment and polymer dispersions

What is the ultrasonic pigment?

Ultrasonic pigment dispersion refers to a process that uses ultrasonic waves to disperse pigments in a liquid medium. Pigments are finely ground particles that are insoluble in the liquid they are dispersed in, such as inks, paints, or coatings. The purpose of pigment dispersion is to evenly distribute the particles throughout the liquid to achieve a consistent color and appearance.

Ultrasonic dispersion involves the use of high-frequency sound waves, typically in the range of 20 to 100 kHz, generated by an ultrasonic device called a sonicator or ultrasonic homogenizer. The sonicator consists of a transducer that converts electrical energy into mechanical vibrations. When the transducer is immersed in the liquid containing the pigment particles, the vibrations create high-intensity pressure waves that induce cavitation.

Cavitation occurs when the pressure waves create alternating high and low-pressure zones in the liquid, causing the formation and implosion of tiny bubbles. The rapid implosion of these bubbles generates localized shock waves and intense shear forces, which help break down agglomerates or clusters of pigment particles. As a result, the pigment particles are dispersed and distributed more uniformly throughout the liquid.

Ultrasonic pigment dispersion offers several advantages over traditional dispersion methods, such as milling or stirring. It is a faster process that requires less energy and can achieve higher pigment loading levels. It also allows for better control of particle size distribution and reduces the risk of particle damage or contamination.

Overall, ultrasonic pigment dispersion is a widely used technique in industries where achieving uniform color and dispersion of pigments is crucial, such as in the manufacturing of paints, inks, coatings, and cosmetics.

Why is the ultrasonic important in the pigment processor?

Ultrasonic technology plays a crucial role in pigment processing for several reasons:

Efficient dispersion: Ultrasonic waves provide efficient dispersion of pigments by breaking down agglomerates or clusters of particles. The high-intensity pressure waves and cavitation generated by ultrasonic devices effectively disperse the pigment particles, resulting in a more uniform and consistent distribution throughout the liquid medium. 

Faster processing time: Ultrasonic pigment dispersion is generally a faster process compared to traditional methods such as milling or stirring. The intense shear forces and localized shock waves created by ultrasonic cavitation rapidly break down pigment agglomerates, reducing processing time and increasing productivity.

Higher pigment loading: Ultrasonic dispersion allows for higher pigment loading levels, which means a higher concentration of pigments can be incorporated into the liquid medium. This is particularly beneficial for industries that require intense and vibrant colors or high opacity, such as inks, paints, and coatings. 

Improved particle size control: Ultrasonic processing enables better control over particle size distribution. By adjusting the operating parameters of the ultrasonic device, such as intensity and duration, manufacturers can achieve the desired particle size range for their specific application. 

Reduced energy consumption: Ultrasonic pigment dispersion typically requires less energy compared to traditional dispersion methods. The efficient dispersion achieved through ultrasonic waves reduces the need for prolonged high-energy mechanical processes like milling. 

Preservation of pigment properties: Ultrasonic processing is a gentle method that minimizes the risk of pigment damage or degradation. The short processing time and absence of mechanical forces that can cause excessive heat or shear stress help preserve the integrity and functionality of the pigments. 

In summary, ultrasonic technology is important in the pigment processing industry due to its efficiency, speed, control over particle size, energy savings, and preservation of pigment properties. It enables manufacturers to achieve consistent and high-quality pigment dispersion, leading to improved product performance and cost-effectiveness.

Parameter:

Dispersion of Nanoparticles

Ultrasonic grinding and dispersing is often the only method to process nano-particles efficiently in order to obtain sinlge-dispersed primary particles. A small primary particle size results in a large surface area and correlates with the expression of unique particle characteristics and functionalities. At the same time, a smaller particle size is associated with a high surface energy for more severe aggregation and reactivity, so that the intense ultrasonic dispersing forces are required to disperse the nano particles homogeneously into the formulation. Furthermore, an ultrasonic surface treatment can modify the nano particles which leads to improved dispersibility, dispersion stability, hydrophobicity and other features. Researchers have recommended the ultrasonic dispersion method for nano particles as preferred solution, “because the material dispersed by the ultrasonic method is much purer than that produced by bead milling.”

how Ultrasonic can improve particle size?

Ultrasonic technology can improve particle size in pigment processing through the process of cavitation. Cavitation refers to the formation and implosion of tiny bubbles in a liquid medium caused by the high-intensity pressure waves generated by ultrasonic waves.

During ultrasonic processing, the cavitation bubbles collapse violently near the pigment particles. The collapse of these bubbles creates intense shear forces and localized shock waves. These forces act on the pigment agglomerates or clusters, causing them to break apart into smaller particles.

The combination of cavitation-induced shear forces and shock waves provides efficient and controlled particle size reduction. The high-intensity shear forces exerted during cavitation help to disintegrate larger agglomerates into smaller particles, resulting in a more uniform particle size distribution.

The particle size reduction achieved through ultrasonic dispersion offers several benefits. It improves the dispersibility and stability of the pigment in the liquid medium, leading to enhanced color development, improved opacity, and reduced settling. Additionally, a narrower particle size distribution can be achieved, which contributes to consistent product quality and performance.

It's important to note that the particle size reduction capabilities of ultrasonic technology are influenced by various factors, including the frequency and intensity of the ultrasonic waves, processing time, and the properties of the pigment and liquid medium. Optimizing these parameters allows manufacturers to control and customize the particle size distribution to meet specific requirements for their applications.

Overall, ultrasonic technology provides an effective means to improve particle size in pigment processing by breaking down larger agglomerates into smaller, more uniform particles. This contributes to improved dispersion, color quality, and overall performance of the final product.

Working video for reference: