Alkyl (Meth)acrylate-Polyester Binders via Suspension Polymerization
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Solution Overview
Problem
Existing methods for producing alkyl (meth)acrylate-polyester copolymers, such as those described in WO 2007/098819 A1, JP 11158204, and EP 0 462 785, are laborious, cost-intensive, and often include undesirable aromatic monomers like styrene, limiting their use in applications where odor nuisance or food contact is a concern, and they do not provide sufficient properties as compatibilizers and binders in printing inks.
Innovation Solution
A process involving suspension polymerization is used to produce alkyl (meth)acrylate-polyester copolymers by dispersing a first liquid phase containing alkyl (meth)acrylate monomer and polyester in a second liquid phase with a suspension aid, initiating polymerization without styrene, resulting in a solid polymer mixture suitable for use as a binder in printing inks, with improved adhesion to various plastics and reduced solvent dependency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solution polymerization is used to produce copolymer composition, then the composition has good properties as a binder for printing inks, but the production is laborious and cost-intensive, and the solvent choice is restricted
Solution Approach 1:
The patent changes the polymerization method from solution polymerization to suspension polymerization, altering the physical state parameters of the reaction system. This enables the production of solid polymer particles directly, eliminating the need for solvent removal and providing freedom in later solvent selection while maintaining binder performance
Solution Approach 2:
The invention utilizes phase transition by conducting polymerization in suspension form, where the polymer precipitates as solid particles during the reaction. This phase change from dissolved to suspended state simplifies the production process and eliminates solvent dependency, while the resulting particles can be redissolved in various solvents for ink formulation
2Productivity
If styrene is used in the monomer mixture for suspension polymerization, then the copolymer can be produced, but aromatic monomers give rise to odor nuisance and are undesirable in food contact applications
Solution Approach 1:
The patent extracts and removes styrene from the monomer mixture, replacing it with alternative vinyl monomers that do not produce odor nuisance. This substitution maintains the copolymerization process and productivity while eliminating the harmful aromatic component, making the product suitable for food contact and children's articles
Solution Approach 2:
The invention uses alternative monomers that are simpler and more benign than styrene, accepting that these may have slightly different properties but providing sufficient performance without the odor problem. This trade-off enables widespread application in consumer products where odor and safety are critical
3Productivity
If existing copolymer processes are used, then polymer production is achieved, but the copolymers do not have sufficiently good properties as compatibilizers and binders in printing inks
Solution Approach 1:
The patent creates a composite polymer system by copolymerizing polyester with vinyl monomers in suspension, producing particles with combined properties of both polymer types. This composite structure provides both the adhesion benefits of polyester and the compatibility of vinyl polymers, making the material effective as both compatibilizer and binder in printing ink applications
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 process allows for fast, solvent-free production of polymer mixtures with good adhesion properties, reducing transport and storage costs, and avoiding gelation, while maintaining performance comparable to prior art copolymers with less polyester, making them suitable for use in printing inks and other applications.
Implementation Method 1
polymerizing the at least one alkyl (meth)acrylate monomer present in the first liquid phase and the at least one polyester to obtain the polymer mixture comprising the alkyl (meth)acrylate-polyester copolymer wherein the polymerization in step d) is initiated by at least one initiator
Implementation Method 2
providing a second liquid phase comprising water and at least one suspension aid dispersed therein; dispersing the first liquid phase in the second liquid phase, wherein droplets of the first liquid phase form in the second liquid phase
Data Source
AI summary
A process produces alkyl (meth)acrylate-polyester copolymers by suspension polymerization. The process avoids styrene in production and allows for a fast, solvent-free production of polymer mixtures. The alkyl (meth)acrylate-polyester copolymers find application as binders in printing inks and have a very good adhesion to polyethylene terephthalate (PET), polyvinyl chloride (PVC), polypropylene (PP), polybutylene terephthalate (PBT), and polystyrene (PS).