High Solids Copolymerization with Metal Ion Catalysts
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Solution Overview
Problem
Existing processes for producing copolymers of aliphatic dicarboxylic acids with α,β-ethylenically unsaturated monomers fail to achieve high molecular weights while maintaining low residual content of unpolymerized dicarboxylic acid monomer, which is essential for applications like antiscalants and deflocculants in oil drilling operations.
Innovation Solution
A process involving single charge neutralization of the reaction mixture at the start of polymerization, running the reaction at high solids content, and using specific transition metal ions to produce high molecular weight copolymers with low residual content, achieving a weight average molecular weight of 70,000 to 180,000 daltons and residual content ranging from 0 to 4000 ppm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional copolymerization processes are used to reduce residual dicarboxylic acid content, then residual content is reduced to about 0.5 percent, but molecular weight remains low
Solution Approach 1:
The patent changes key process parameters including conducting polymerization at elevated temperatures (70-100°C), using high solids content (40-60% by weight), and implementing a single charge neutralization step with specific metal ions (Cu2+, Zn2+, Ni2+, Co2+, Mn2+) to achieve both low residual acid content and high molecular weight copolymers
Solution Approach 2:
The patent introduces metal ions (Cu2+, Zn2+, Ni2+, Co2+, Mn2+) as intermediaries that facilitate the polymerization reaction, enabling simultaneous achievement of low residual dicarboxylic acid content and high molecular weight by acting as catalysts or mediators in the copolymerization process
2Productivity
If high solids content is used in the reaction mixture, then productivity and binding properties are improved, but residual dicarboxylic acid content increases
Solution Approach 1:
The patent simultaneously optimizes multiple parameters: conducts polymerization at high solids content (40-60% by weight) combined with elevated temperatures (70-100°C) and uses specific metal ion catalysts, achieving both high productivity through high solids and low residual acid content through the synergistic effect of these parameter changes
3Strength
If single charge neutralization is employed at high solids, then high molecular weight and low residuals are achieved, but process complexity increases
Solution Approach 1:
The patent performs charge neutralization as a preliminary single step before polymerization begins, adding the required base and metal ions at the start of the process. This preliminary action eliminates the need for multiple subsequent neutralization steps, simplifying the overall process while achieving high molecular weight and low residual content
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 effectively produces high molecular weight copolymers with low residual content, enhancing their binding properties and reducing dusting in applications such as laundry granules, while maintaining high end-of-feed solids content.
Implementation Method 1
using specific transition metal ions to produce high molecular weight copolymers with low residual content
Implementation Method 2
copolymerization of monoethylenically unsaturated dicarboxylic acids with α,β-ethylenically unsaturated monomers
Data Source
AI summary
The present invention relates to the production of aqueous solutions or dispersions of high molecular weight, high solids copolymers of aliphatic dicarboxylic acids, especially maleic acid, with α,β-ethylenically unsaturated monomers having carboxyl or sulfonic acid groups, such as (meth)acrylic acid or 2-acrylamido-2-methyl propane sulfonic acid (AMPS), respectively, which solutions or dispersions have a very low residual content of unpolymerized dicarboxylic acid monomer.