Continuous Reactor Modification Polymerization Initiator Preparation

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Solution Overview

Problem

Conventional methods for preparing modification polymerization initiators face issues such as low solubility, reactivity, and storage stability, leading to side reactions and reduced yield, particularly in batch-type processes, which affect the physical properties of the final polymerized rubber materials for tires.

Innovation Solution

A method involving the reaction of specific compounds in a continuous reactor with separate channels to minimize side reactions and enhance solubility and reactivity, using a continuous reactor to control the injection rates and molar ratios of reactants, thereby increasing the conversion ratio and purity of the polymerization initiator.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If batch type process is used to prepare modification polymerization initiator, then process simplicity is maintained, but side reactions increase and conversion ratio decreases

Engineering Contradiction:
Improveprocess simplicityVSAvoidconversion ratio
Core Design Contradiction:
Ease of manufactureVSProductivity

Solution Approach 1:

The patent applies continuous flow reaction instead of batch processing, where reactants continuously flow through the reaction system maintaining steady-state conditions. This continuous action prevents side reactions by avoiding concentration fluctuations and temperature spikes that occur during batch loading and unloading, thereby achieving high conversion ratio while maintaining process simplicity through automated continuous operation.

Inventive Principle:
Principle #20Continuity of useful action

2Reliability

If hexamethylene lithium initiator is used, then polymerization initiation is achieved, but solubility is low and precipitation occurs over time

Engineering Contradiction:
Improvepolymerization initiation capabilityVSAvoidsolubility stability
Core Design Contradiction:
ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent uses a composite initiator system combining hexamethylene lithium with specific additives or modifiers that enhance solubility while maintaining polymerization initiation capability. The composite structure allows the initiator to remain dissolved in the reaction medium over time, preventing precipitation while retaining its function to initiate polymerization effectively.

Inventive Principle:
Principle #40Composite materials

3Reliability

If modification polymerization initiator is prepared by further reacting conjugated diene compound with hexamethylene lithium, then solubility and reactivity are improved, but precipitation still occurs over time

Engineering Contradiction:
ImprovereactivityVSAvoidstorage stability
Core Design Contradiction:
ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent modifies the chemical structure parameters of the modification polymerization initiator by selecting specific conjugated diene compounds with appropriate molecular weights and functional groups. This parameter optimization achieves a balance where the initiator maintains high reactivity for polymerization initiation while simultaneously improving long-term storage stability to prevent precipitation during storage.

Inventive Principle:
Principle #35Parameter changes

4Temperature

If vinyl content in SSBR is increased to control glass transition temperature, then rolling resistance and braking force are controlled, but wet skid resistance decreases

Engineering Contradiction:
Improveglass transition temperatureVSAvoidwet skid resistance
Core Design Contradiction:
TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent applies local quality modification by introducing specific functional groups at chain terminals through the modification polymerization initiator, while maintaining the bulk vinyl content for glass transition temperature control. This localized functionalization at terminal positions enhances wet skid resistance without altering the overall vinyl content and glass transition temperature of the SSBR, thereby resolving the contradiction between rolling resistance control and wet skid resistance.

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

This approach allows for the efficient preparation of a modification polymerization initiator with improved solubility and reactivity, reducing unreacted materials and by-products, resulting in a polymer with enhanced affinity to fillers and improved physical properties, such as reduced rolling resistance and increased wet skid resistance.

Implementation Method 1

reacting a compound represented by Formula 1 and a compound represented by Formula 2

Methodology Applied
Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

the compound represented by Formula 1 is injected into the continuous reactor via the first continuous channel and the compound represented by Formula 2 is injected into the continuous reactor via the second continuous channel

Methodology Applied
Scientific EffectMixing: Diffusion

Data Source

PatentUS11472818B2Method for preparing modification polymerization initiator using continuous type reactor
Publication Date: 2022.10.18 LG CHEM LTD
  • US11472818B2 patent drawing
  • US11472818B2 patent drawing
  • US11472818B2 patent drawing

AI summary

The present invention relates to a method for preparing a modification polymerization initiator with a high conversion ratio by minimizing side reactions. According to the method for preparing a modification polymerization initiator, a modification polymerization initiator which may easily initiate polymerization and provide a polymer with a functional group having affinity with a filler, may be prepared. Particularly, by performing the method using a continuous reactor, the production of by-products may be decreased, and as a result, the conversion ratio may be increased and a modification polymerization initiator with high purity may be prepared in a high yield.