ABS Resin Emulsifier for High-Temperature Thermomolding
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Solution Overview
Problem
Existing ABS-based resin compositions face limitations in surface gloss and sharpness due to gas generation during high-temperature thermomolding processes, such as extrusion or injection-molding, caused by conventional emulsifiers vaporizing and leaving residues like unreacted monomers and oligomers.
Innovation Solution
Incorporating a multimeric acid of unsaturated fatty acid or its metal salt as an emulsifier in the diene-based rubber latex polymerization and ABS graft polymerization steps, which stabilizes the polymerization process and reduces gas generation, thereby enhancing the surface characteristics of ABS-based injection-molded articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional emulsifiers are used in diene-based rubber latex polymerization and ABS graft polymerization, then the polymerization process can be carried out, but gas generation occurs during high-temperature thermomolding due to vaporization of the emulsifier, resulting in poor surface gloss and sharpness
Solution Approach 1:
The patent changes the chemical parameters of the emulsifier by using multimeric acid of unsaturated fatty acid (containing carboxyl groups) instead of conventional emulsifiers. This parameter change results in an emulsifier with higher thermal stability that does not vaporize during high-temperature thermomolding, thereby eliminating gas generation and improving surface gloss and sharpness while maintaining polymerization processability
Solution Approach 2:
The patent creates a composite emulsifier system by combining multimeric acid of unsaturated fatty acid with specific secondary emulsifiers (alkyl aryl sulfonate, alkali metal alkyl sulfate, sulfonated alkyl ester, or metal salts of unsaturated fatty acid) in controlled ratios. This composite approach leverages the thermal stability of the multimeric acid while incorporating the surfactant properties of secondary emulsifiers, achieving both processability and surface quality
2Productivity
If conventional emulsifiers are used, then the polymerization can proceed, but the emulsifier vaporizes during high-temperature thermomolding causing gas generation and fogging on the resin surface
Solution Approach 1:
The patent converts the potential harm of emulsifier vaporization into a benefit by selecting multimeric acid of unsaturated fatty acid, which has high molecular weight and thermal stability. This substance does not vaporize during thermomolding, thus converting from a potential source of gas generation into a stable component that maintains polymerization efficiency while preventing fogging and gas generation on the resin surface
3Ease of manufacture
If traditional surfactants are used as emulsifiers, then the polymerization process is effective, but the surfactants are easily vaporized during high-temperature processing leading to poor surface characteristics
Solution Approach 1:
The patent fundamentally changes the temperature resistance parameter of the emulsifier by using multimeric acid of unsaturated fatty acid with high molecular weight and strong intermolecular forces (carboxyl groups). This parameter change enables the emulsifier to maintain stability at high thermomolding temperatures, preventing vaporization while preserving emulsion polymerization effectiveness
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
The use of multimeric acid or its metal salt as an emulsifier results in improved surface gloss and sharpness of ABS-based injection-molded articles, with reduced gas generation and increased productivity, as evidenced by higher gloss values and lower reflection haze.
Implementation Method 1
a step of polymerizing 100 parts by weight of a conjugated diene based monomer, 0.5 to 5 parts by weight of an emulsifier, and 0.01 to 6 parts by weight of a water-soluble polymerization initiator
Implementation Method 2
a step of graft-polymerizing 100 parts by weight of a monomer mixture including 40 to 70 % by weight (based on solid) of the large-diameter diene-based rubber latex, 15 to 35 % by weight of an aromatic vinyl monomer, and 5 to 25 % by weight of a vinyl cyan monomer
Data Source
AI summary
The present invention relates to a method of preparing an ABS-based resin composition and a method of manufacturing an ABS-based injection-molded article including the same. More particularly, the present invention provides a method of preparing an ABS-based resin composition using a multimeric acid of unsaturated fatty acid or a metal salt thereof, as an emulsifier, in a diene-based rubber latex polymerization step and an ABS-based graft polymerization step. In accordance with the present invention, when an ABS-based resin composition is prepared using a multimeric acid of unsaturated fatty acid or a metal salt thereof as an emulsifier, stability of polymerization is secured and surface characteristics, such as surface gloss or sharpness, of an ABS-based injection-molded article are improved.