Aqueous Composite Particle Dispersion Stabilization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing stable aqueous composite particle dispersions using silane monomers are limited in achieving high stability and uniform particle distribution, with existing processes often resulting in incomplete dispersion and larger particle sizes.
Innovation Solution
A process involving radical aqueous emulsion polymerization using a combination of silane monomers and finely divided inorganic solids, where the inorganic solids are stabilized in an aqueous medium with a high initial concentration and dispersed to maintain over 90% of the solids in a dispersed form with particle diameters ≤100 nm, and the monomers are metered under controlled conditions to ensure uniform polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional emulsion polymerization methods are used with silane monomers, then polymerization can proceed, but the inorganic solids do not disperse uniformly and particle sizes become large
Solution Approach 1:
The inorganic solids are pre-dispersed in water to form a stable aqueous dispersion before polymerization begins. This preliminary dispersion ensures uniform distribution of inorganic particles throughout the reaction medium, preventing aggregation during subsequent polymerization steps and achieving consistent particle sizes in the final composite particles.
Solution Approach 2:
Aqueous dispersion serves as an intermediary medium between the inorganic solids and the polymerization system. By using pre-formed aqueous dispersions of inorganic solids as intermediaries, the patent enables uniform distribution and stable incorporation of inorganic particles into the polymer matrix during emulsion polymerization, resolving the contradiction between dispersion stability and particle size uniformity.
2Quantity of substance
If high concentrations of inorganic solids are used, then composite particle performance improves, but dispersion stability decreases and particles aggregate
Solution Approach 1:
Aqueous dispersions of inorganic solids with high initial concentrations are prepared and stabilized before use in polymerization. This preliminary stabilization at high concentrations prevents aggregation during storage and handling, allowing the system to maintain both high inorganic content and dispersion stability throughout the polymerization process.
3Productivity
If silane monomers are added all at once, then polymerization is fast, but incomplete dispersion occurs and particle distribution is non-uniform
Solution Approach 1:
The addition of silane monomers is segmented into multiple stages rather than added all at once. This segmented addition approach allows progressive incorporation of silane monomers into the polymerizing system, ensuring complete dispersion and uniform particle distribution while maintaining efficient polymerization rates through controlled monomer availability.
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 stable aqueous composite particle dispersions with uniform particle sizes and high stability, allowing for the production of composite particle powders suitable for various applications, including improved mechanical strength and adhesion in films.
Implementation Method 1
polymerized using the free-radical aqueous emulsion polymerization method
Data Source
AI summary
The invention relates to a method for producing aqueous composite particle dispersions using silane-group containing monomers.