Composite Membrane for Organic Zinc Catalyst Separation

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Solution Overview

Problem

Existing methods struggle to efficiently and economically separate organic zinc catalysts from polyalkylene carbonate resin solutions due to the catalyst's small particle size and soft shape, which limits their separation using conventional filters or centrifugation.

Innovation Solution

A method utilizing a composite filtering membrane composed of a hydroxyl group-containing material and polyolefin material, where the polyolefin material is coated with the hydroxyl group-containing material, to effectively separate the organic zinc catalyst from the polyalkylene carbonate resin solution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional filters or centrifugation are used to separate the organic zinc catalyst, then the separation process is simple, but the separation efficiency is poor due to the small particle size of the catalyst

Engineering Contradiction:

Improvesimplicity of separation processVSAvoidseparation efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

A composite filtering membrane is introduced as an intermediary between the catalyst particles and the filtration system. The membrane contains magnetic particles that act as mediators to capture the organic zinc catalyst particles through magnetic interaction, enabling efficient separation despite the catalyst's small size and soft shape

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The filtering membrane utilizes a porous structure with specific pore size distribution to allow the resin solution to pass through while retaining the catalyst particles. The porous material works in conjunction with magnetic particles to achieve both filtration and magnetic capture functions

Inventive Principle:

Principle #31Porous materials

2Productivity

If the pore size of the filter is reduced to capture small catalyst particles, then the separation efficiency improves, but the filtration resistance increases and the process becomes less economical

Engineering Contradiction:

Improveseparation efficiencyVSAvoidfiltration resistance

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Magnetic particles embedded in the filtering membrane serve as intermediaries that actively capture catalyst particles through magnetic interaction. This eliminates the need for extremely small pore sizes, as the magnetic capture mechanism works independently of pore size to retain the catalyst while maintaining low filtration resistance

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The filtering membrane is constructed as a composite material combining porous substrate, magnetic particles, and hydroxyl group-containing materials. This composite structure provides both the mechanical filtration capability and the magnetic capture function, achieving high separation efficiency without requiring excessively small pores that would increase resistance

Inventive Principle:

Principle #40Composite materials

3Productivity

If a filter with small pore size is used to separate the catalyst, then the catalyst separation efficiency improves, but the resin solution flow rate decreases

Engineering Contradiction:

Improvecatalyst separation efficiencyVSAvoidresin solution flow rate

Core Design Contradiction:

ProductivityVSSpeed

Solution Approach 1:

Magnetic particles act as intermediaries that capture catalyst particles through magnetic force rather than relying solely on physical pore blocking. This allows the use of larger pore sizes that maintain high flow rates while the magnetic capture mechanism ensures efficient catalyst retention

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the separation mechanism from purely physical filtration based on pore size to a combination of magnetic capture and filtration. This parameter change allows decoupling of the pore size from the separation efficiency, enabling optimization of both flow rate and separation efficiency independently

Inventive Principle:

Principle #35Parameter changes

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 method allows for the efficient removal of organic zinc catalyst particles from the polyalkylene carbonate resin solution, resulting in a transparent high-purity solution, while also being economically feasible and allowing for the reuse of the filtering membrane.

Implementation Method 1

filtering, through a composite filtering membrane, a polyalkylene carbonate resin solution containing a polyalkylene carbonate resin and an organic zinc catalyst

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Implementation Method 2

the composite filtering membrane is a composite material including a hydroxyl group-containing material and polyolefin material

Methodology Applied

Scientific EffectChemical adsorption: Adsorption

Data Source

PatentUS12312442B2Method for separating organic zinc catalyst using filtering membrane

Publication Date: 2025.05.27 LG CHEM LTD

AI summary

The present disclosure relates to a method for separating an organic zinc catalyst dispersed in a polyalkylene carbonate resin solution by filtering the polyalkylene carbonate resin solution using a composite filtering membrane, which is a composite material comprising a hydroxyl group-containing material and polyolefin material and has a form in which one or both surfaces of the polyolefin material is coated with the hydroxyl group-containing material.