Composite Resin Particles via Stepwise Polymerization
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Solution Overview
Problem
Existing methods for producing liquid dispersions of composite resin particles often result in high residual monomer content, which can lead to environmental concerns and reduced adhesive properties when applied and dried.
Innovation Solution
A method involving the polymerization of styrene and extra vinyl monomers to form a styrene resin, followed by the polymerization of (meth)acrylate compounds in the presence of the styrene resin to create intermediate resin particles. Subsequently, styrene and extra vinyl monomers are polymerized again in the presence of these intermediate resin particles to produce a liquid dispersion containing composite resin particles, with the addition of a polymerization initiator to promote complete polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polymerization is performed without adding a polymerization initiator in the final step, then the production process is simpler and faster, but the residual monomer content increases and adhesive properties decrease
Solution Approach 1:
The patent applies preliminary action by pre-installing polymerization initiators during the first two polymerization stages. These initiators remain in the system and automatically activate in the third stage without requiring additional initiator addition, thus simplifying the process while ensuring complete polymerization and low residual monomer content.
2Device complexity
If polymerization is performed without adding a polymerization initiator in the final step, then the production process is simpler, but the adhesive strength when pressure-bonded decreases
Solution Approach 1:
The patent uses preliminary action by incorporating polymerization initiators during earlier stages that remain dormant or inactive until the final stage conditions are met. This ensures complete polymerization occurs automatically, producing resin particles with proper adhesive strength without requiring complex additional操作步骤.
3Manufacturing precision
If higher polymerization completeness is achieved by adding a polymerization initiator, then residual monomer content decreases, but the production process becomes more complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-installing polymerization initiators during the first two polymerization stages. These initiators remain in the system and automatically activate in the third stage without requiring additional initiator addition, thus simplifying the process while ensuring complete polymerization and low residual monomer content.
Solution Approach 2:
The system uses self-service by designing the polymerization process so that initiators added in earlier stages automatically perform the function of completing polymerization in the final stage. The process serves itself by utilizing previously added components rather than requiring external intervention or additional materials.
4Manufacturing precision
If higher polymerization completeness is achieved by adding a polymerization initiator, then residual monomer content decreases, but production time increases
Solution Approach 1:
The patent applies preliminary action by pre-installing polymerization initiators during the first two polymerization stages. These initiators remain in the system and automatically activate in the third stage without requiring additional initiator addition, thus simplifying the process while ensuring complete polymerization and low residual monomer content.
Solution Approach 2:
The system uses self-service by designing the polymerization process so that initiators added in earlier stages automatically perform the function of completing polymerization in the final stage. The process serves itself by utilizing previously added components rather than requiring external intervention or additional materials.
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 method achieves a lower residual monomer content, resulting in a liquid dispersion that is more adhesive when pressure-bonded and more stable when stored, while also reducing environmental burdens.
Implementation Method 1
polymerizing a styrene compound and an extra vinyl monomer to give a styrene resin; polymerizing a (meth)acrylate compound in the presence of the styrene resin to give intermediate resin particles A
Data Source
AI summary
A method for producing a liquid dispersion of composite resin particles includes polymerizing a styrene compound and an extra vinyl monomer together to give a styrene resin; polymerizing a (meth)acrylate compound in the presence of the styrene resin to give intermediate resin particles A, which are resin particles containing the styrene resin and a (meth)acrylate resin; polymerizing a styrene compound and an extra vinyl monomer in the presence of intermediate resin particles A to give liquid dispersion B, which is a liquid dispersion containing intermediate resin particles B; and adding a polymerization initiator to liquid dispersion B to give a liquid dispersion containing composite resin particles. In the composite resin particles as a whole, the ratio by mass between the styrene and (meth)acrylate resins is between 80:20 and 20:80. There is a difference of 30° C. or more between the lowest and highest glass transition temperatures of the composite resin particles.