Bio-based Thermally Expandable Microspheres for Sustainable Foaming
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Solution Overview
Problem
There is a need for alternative thermoplastic expandable microspheres with polymer shells derived from sustainable sources that maintain acceptable expansion performance, as conventional petrochemical-based microspheres are not easily replaceable with bio-based alternatives due to requirements for specific surface energy, gas barrier properties, and viscoelastic properties above the glass transition temperature.
Innovation Solution
The development of thermoplastic polymeric microspheres with a polymer shell comprising a homopolymer or copolymer of specific bio-based monomers, such as those described in Formula 1, which are produced through a process involving dispersion of an organic phase with monomers and blowing agents in a continuous aqueous phase, initiated by a polymerization initiator, allowing for the creation of expandable microspheres with a hollow core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional petrochemical-based monomers are used to produce thermoplastic expandable microspheres, then acceptable expansion performance and functional characteristics are achieved, but sustainability is compromised
Solution Approach 1:
The patent changes the chemical composition parameters of the polymer shell by using bio-based monomers (such as hydroxyalkyl (meth)acrylates with specific hydroxyl group configurations) instead of conventional petrochemical monomers. This parameter change maintains the necessary surface energy, gas barrier properties, and viscoelastic characteristics while improving sustainability. The specific structural parameters of the bio-based monomers are optimized to ensure acceptable expansion performance.
2Object-generated harmful factors
If bio-based monomers are used to replace petrochemical monomers, then sustainability is improved, but expansion performance and functional characteristics deteriorate
Solution Approach 1:
The patent applies local quality by specifically designing the polymer shell with bio-based monomers that have particular local structural characteristics (such as hydroxyl group positions and alkyl chain configurations). These localized structural features are optimized to provide the necessary surface energy for core-shell particle formation, adequate gas barrier properties, and appropriate viscoelastic behavior above glass transition temperature, thereby maintaining expansion performance while using sustainable materials.
3Object-generated harmful factors
If the polymer shell is made from bio-based monomers, then the environmental sustainability is improved, but the gas barrier properties and viscoelastic properties above glass transition temperature may worsen
Solution Approach 1:
The patent employs composite material strategies by combining bio-based monomers (such as hydroxyalkyl (meth)acrylates) with specific structural characteristics. The polymer shell is designed as a composite system where the bio-based monomer structure provides both sustainability and the necessary functional properties. The specific molecular architecture of the bio-based monomers creates a composite-like structure within the polymer chain that maintains gas barrier properties while improving sustainability.
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
These bio-based microspheres achieve the necessary expansion properties, increasing the sustainability of thermally expandable microspheres while maintaining their functional characteristics, such as low density and suitable expansion ratios, and can be used as low-density fillers or foaming agents.
Implementation Method 1
polymerisation is initiated by a polymerisation initiator to form an aqueous dispersion of thermoplastic polymeric microspheres
Implementation Method 2
the blowing agent vaporises and expands, thus expanding the microsphere
Implementation Method 3
the microsphere diameter can increase between about 1.5 and about 8 times during expansion
Implementation Method 4
the thermoplastic polymeric shell softens, and the blowing agent vaporises and expands
Data Source
AI summary
The present disclosure relates to thermoplastic polymeric microspheres comprising a thermoplastic polymer shell surrounding a hollow core, in which the thermoplastic polymer shell comprises a homopolymer or copolymer of a monomer of Formula 1wherein:each of A1 to A11 are independently selected from H and C1 to C4 alkyl, in which each C1-4 alkyl group can optionally be substituted with one or more substituents selected from halogen, hydroxy and C1-4 alkoxy;X is a linking group selected from —O—, —NR″—, —S—, —OC(O)—, —NR″C(O)—, —SC(O)—, —C(O)O—, —C(O)NR″—, and —C(O)S—; andR″ is H or C1-2 alkyl optionally substituted with one or more substituents selected from halogen and hydroxy.