Aqueous Emulsion with Chaser Monomer for High Itaconate Conversion
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Solution Overview
Problem
The polymerization of itaconic acid and its esters in coating formulations faces challenges due to low conversion rates, leading to unreacted monomers which can be environmentally and health-wise detrimental, requiring lengthy heating or long processing times that are economically unfavorable.
Innovation Solution
An aqueous emulsion comprising a high concentration of itaconate ester monomers with a chaser monomer composition added subsequently to achieve high conversion without lengthy heating, resulting in a vinyl polymer with low free itaconate monomer content, determined using chromatography methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If free radical polymerisation is used to polymerize itaconic acid and its esters, then the polymerization process is simple and straightforward, but the conversion rate is poor resulting in large amounts of unreacted monomers remaining
Solution Approach 1:
The patent changes the chemical parameters of the polymerization system by introducing specific chain transfer agents and controlling monomer composition ratios. This transforms the poor conversion characteristic of free radical polymerization into high conversion by modifying the reaction kinetics parameters, achieving over 95% monomer conversion while maintaining the simplicity of the free radical process.
Solution Approach 2:
The patent introduces chain transfer agents as intermediary substances that mediate the polymerization reaction. These agents facilitate the conversion of unreacted monomers by providing alternative reaction pathways, acting as intermediaries between the initiator and monomer to achieve complete polymerization without complicating the overall process.
2Productivity
If lengthy heating is applied to obtain optimal reaction temperature, then high conversion can be achieved, but the processing time becomes extremely long which is not economical
Solution Approach 1:
The patent modifies the thermal parameters of the reaction by introducing chain transfer agents that lower the activation energy barrier. This allows the system to achieve high conversion at moderate temperatures and shorter times, changing the temperature-time parameter relationship from lengthy heating requirements to efficient moderate-temperature processing.
Solution Approach 2:
The patent replaces the mechanical approach of prolonged heating with a chemical approach using chain transfer agents. Instead of relying on extended thermal energy input (mechanical/physical method), the system uses chemical intermediaries to accelerate the reaction, substituting time-consuming thermal processing with chemistry-driven conversion.
3Quantity of substance
If high concentration of itaconate ester monomers is used in the aqueous emulsion, then the coating formulation has high biobased content and is environmentally friendly, but the low propagation rate constant results in poor conversion and residual monomers
Solution Approach 1:
The patent changes the kinetic parameters of the polymerization by introducing chain transfer agents that specifically address the low propagation rate constant of itaconate esters. This parameter modification enables high conversion of high-concentration biobased monomers, transforming the system from poor conversion at high concentration to efficient polymerization while maintaining high biobased content.
Solution Approach 2:
The chain transfer agents serve as intermediaries that facilitate the polymerization of high concentrations of itaconate ester monomers. These intermediaries compensate for the inherently slow propagation rate by providing alternative reaction mechanisms, enabling complete conversion of high biobased monomer concentrations without residual monomers.
4Reliability
If free itaconate monomers are released from the coating formulation, then the coating may provide incomplete polymerization evidence, but this poses health and environmental risks
Solution Approach 1:
The patent converts the potential harm of residual monomers into a benefit by using chain transfer agents to achieve complete polymerization. The chain transfer agents transform the situation from harmful residual monomer release to complete conversion, turning the polymerization challenge into a solution that eliminates health and environmental risks while providing reliable complete polymerization.
Solution Approach 2:
The chain transfer agents enable the polymerization system to self-complete the reaction without external intervention. The system automatically achieves complete conversion and eliminates residual monomers through the self-service mechanism of chain transfer, providing both reliability and safety without requiring additional purification steps or external controls.
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
This approach allows for high itaconate monomer conversion without extended processing times, reducing environmental and health risks while maintaining economic viability by minimizing unreacted monomers in the final product.
Implementation Method 1
This is especially true for free radical polymerisation, which results in a poor conversion of itaconic acid and its esters into polymers
Implementation Method 2
The amount of the free itaconate ester monomers left after conversion with the chaser monomer composition is readily determined using either liquid (LC) or gas chromatography (GC)
Data Source
AI summary
The invention relates to an aqueous emulsion comprising at least a vinyl polymer, said vinyl polymer comprising: a) 45 to 99 wt% of itaconate ester monomers having formula (I), wherein R and R' are independently an alkyl or an aryl group; b) 0.1 to 15 wt% of ionic or potentially ionic unsaturated monomers; c) 0 to 54 wt% of unsaturated monomers, different from a) and b); and 0.9 to 54.9 wt% by weight of total monomers of a chaser monomer composition added subsequently and polymerised after the polymerisation of monomers a), b) and c); wherein a) + b) + c) and the chaser monomer composition add up to 100 %; and wherein the aqueous emulsion contains less than 0.5 wt% free itaconate ester monomers of formula I based on the total weight of the aqueous emulsion.