Antimicrobial Masterbatch Solid State Polymerization
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Solution Overview
Problem
Existing processes for producing antimicrobial and antiviral polymeric masterbatch result in low yield of antimicrobial polymeric yarns or fibers due to hydrolysis, leading to instability and reduced intrinsic viscosity during extrusion and spinning.
Innovation Solution
Compounding antimicrobial particles with a base polymer, followed by solid state polymerization to increase the intrinsic viscosity and remove hydroxyl groups, which are then blended with a virgin polymer at a suitable ratio and extruded to produce antimicrobial masterbatch pellets with enhanced yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If antimicrobial particles are compounded with base polymer using conventional process, then antimicrobial properties are added to polymer, but hydrolysis occurs leading to low yarn yield and instability
Solution Approach 1:
The patent applies preliminary action by conducting solid state polymerization of the base polymer before compounding with antimicrobial particles. This pre-treatment increases the intrinsic viscosity and stabilizes the polymer, preventing hydrolysis during subsequent extrusion and spinning processes. The polymer is heated to 100-200°C under vacuum or inert atmosphere to achieve desired intrinsic viscosity (0.6-1.2 dL/g) before mixing with copper compounds, ensuring stable yarn production with yield greater than 80%.
2Reliability
If moisture is removed from masterbatch pellets by vacuum drying, then hydrolysis is prevented during storage, but processing time and energy consumption increase
Solution Approach 1:
The patent performs preliminary moisture removal during the solid state polymerization step before compounding, rather than requiring separate drying of masterbatch pellets. The base polymer is heated under vacuum or inert atmosphere to remove moisture and achieve desired intrinsic viscosity before mixing with antimicrobial particles. This integrated approach eliminates the need for extended vacuum drying of finished masterbatch pellets, reducing total processing time while ensuring polymer stability.
3Reliability
If intrinsic viscosity of base polymer is increased through solid state polymerization, then yarn yield and stability improve, but processing complexity and energy consumption increase
Solution Approach 1:
The patent merges the solid state polymerization step with the compounding process into a integrated two-stage procedure. Stage 1: Solid state polymerization of base polymer at 100-200°C under vacuum or inert atmosphere to increase intrinsic viscosity to 0.6-1.2 dL/g. Stage 2: Compounding with antimicrobial particles (40-80 wt% copper compounds) and extrusion. This combined approach achieves stable thread formation with yield greater than 80% while maintaining relatively simple processing equipment and procedures.
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 achieves a yarn yield of greater than 80% with stable thread formation and minimal degradation, significantly improving the production efficiency of antimicrobial polymeric fibers.
Implementation Method 1
solid state polymerization to increase the intrinsic viscosity and remove hydroxyl groups
Implementation Method 2
water insoluble copper compounds that release at least one of Cu+ ions and Cu++ ions upon contact with a fluid
Data Source
AI summary
A masterbatch may be blended with virgin polymer to add desired color or other properties to the virgin polymer prior to further processing. Methods and processes for producing an antimicrobial and/or antiviral polymeric masterbatch that may be used to add antimicrobial, antiviral and/or antifungal properties to a virgin polymer without significantly degrading the properties of the virgin polymer. The masterbatch may be extruded into pellets or formed into other particles for subsequent blending with the virgin polymer to add antimicrobial and antiviral properties to the polymeric materials. The method includes a heat treatment after compounding the base polymer with the antimicrobial, antiviral and/or antifungal are compounded together. The heat treatment comprises heating the masterbatch blend to a temperature between the glass transition temperature and the melting point of the base polymer.