Catalyst Resin Beads with Intermediate Crosslinking

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Solution Overview

Problem

Existing strongly acidic cation exchange resins either lack catalytic effectiveness or physical toughness, necessitating a trade-off between these two properties when used as catalysts for alkyl ester production of (meth)acrylic acid.

Innovation Solution

A method involving a reaction mixture of monovinyl aromatic monomer, multivinyl aromatic monomer, and porogen, followed by aqueous suspension polymerization and sulfonation, to produce resin beads with a high BET surface area and volume capacity, balancing catalytic effectiveness and physical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If gel resins are used with low crosslinking level, then catalytic effectiveness is improved, but physical toughness deteriorates

Engineering Contradiction:
Improvecatalytic effectivenessVSAvoidphysical toughness
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The patent changes the crosslinking level parameter to an intermediate range (5-15%) rather than using traditional low crosslinking for gel resins or high crosslinking for macroporous resins. This parameter optimization resolves the contradiction by achieving both adequate catalytic effectiveness and improved physical toughness, as demonstrated by the resin's ability to maintain structural integrity while providing sufficient active sites for catalysis.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite resin structure combining characteristics of both gel and macroporous resins. The resin incorporates a controlled crosslinking density that produces an intermediate pore structure, effectively combining the high catalytic activity of gel resins with the physical robustness of macroporous resins, thereby resolving the trade-off between these two properties.

Inventive Principle:
Principle #40Composite materials

2Strength

If macroporous resins are used with high crosslinking level, then physical toughness is improved, but catalytic effectiveness deteriorates

Engineering Contradiction:
Improvephysical toughnessVSAvoidcatalytic effectiveness
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The patent optimizes the crosslinking level parameter to an intermediate range (5-15%), avoiding the excessively high crosslinking of traditional macroporous resins. This parameter adjustment maintains sufficient physical toughness while preventing over-crosslinking from blocking pores and reducing catalytic effectiveness, thus resolving the contradiction.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent creates local variations in crosslinking density within the resin structure, providing regions of higher crosslinking for physical strength and regions of lower crosslinking for catalytic activity. This local quality differentiation allows the resin to simultaneously exhibit both physical toughness and catalytic effectiveness.

Inventive Principle:
Principle #3Local quality

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 resulting resin beads exhibit enhanced catalytic performance and physical toughness, effectively addressing the limitations of previous resin types by maintaining high catalytic effectiveness while improving physical strength.

Implementation Method 1

Some useful catalysts are strongly acidic cation exchange resins (SAC resins). Historically, typical gel resins were made without the use of porogen and are made with relatively low level of crosslinking; while they tended to be effective when used as catalysts

Methodology Applied
Scientific EffectCatalysis: Catalysis

Implementation Method 2

A first aspect of the present invention is a method of making a plurality of resin beads comprising (a) providing a reaction mixture comprising monovinyl aromatic monomer, multivinyl aromatic monomer, and porogen... (c) sulfonating said resin beads

Methodology Applied
Scientific EffectSulfonation: Chemical Bonding

Implementation Method 3

A first aspect of the present invention is a method of making a plurality of resin beads comprising (a) providing a reaction mixture comprising monovinyl aromatic monomer, multivinyl aromatic monomer, and porogen... (b) performing aqueous suspension polymerization on said reaction mixture to form resin beads

Methodology Applied
Scientific EffectPolymerization: Chemical Bonding

Data Source

PatentUS9809692B2Catalyst resin
Publication Date: 2017.11.07 DDP SPECIALTY ELECTRONICS MATERIALS US 8 LLC
  • US9809692B2 patent drawing
  • US9809692B2 patent drawing
  • US9809692B2 patent drawing

AI summary

Provided is a plurality of resin beads, wherein the resin beads comprise polymerized units of monovinyl aromatic monomer and polymerized units of multivinyl aromatic monomer, and wherein the resin beads have BET surface area of 15 to 38 m2/g and volume capacity of 0.7 or higher. Also provided is a method of making a product of the chemical reaction of one or more reactants, where the method comprises reacting the reactants with each other in the presence of such resin beads.