Crosslinker Compound Synthesis for High-Yield Superabsorbent Polymers
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Solution Overview
Problem
Conventional methods for producing crosslinker compounds for super absorbent polymers face low yields and process difficulties, particularly due to the need for inert atmospheres in ring-opening reactions, leading to issues with adhesiveness and gel strength.
Innovation Solution
A method involving the hydrogenation of compounds with a triple bond using a Pd/C catalyst, followed by an esterification reaction, to produce a crosslinker compound with improved yield and structural diversity, allowing for higher productivity and easier processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a ring-opening reaction using a Grignard reagent is used to produce crosslinker compounds, then the crosslinker compound can be produced, but the yield is low and the process is complex due to requiring inert atmosphere
Solution Approach 1:
The patent changes the reaction parameters by replacing the Grignard reagent with an organolithium reagent (n-butyllithium). This substitution fundamentally alters the reaction conditions, eliminating the need for inert atmosphere and significantly improving the yield from the conventional low yield to 90% or higher. The parameter change in reagent type directly resolves both the productivity and complexity issues.
2Quantity of substance
If the overall crosslink density of the super absorbent polymer is controlled to be low, then the absorbing amount increases, but the adhesiveness increases and gel strength decreases
Solution Approach 1:
The patent applies local quality by using a crosslinker compound with asymmetric structure where one end contains a thermally decomposable group and the other end contains a crosslinking reactive group. This allows different regions of the polymer to have different crosslinking densities: the interior maintains low crosslink density for high absorbing amount, while the surface can achieve high crosslink density through thermal decomposition for high gel strength. The asymmetric crosslinker structure enables spatial differentiation of crosslinking properties.
3Strength
If a thermally decomposable crosslinker compound is used to improve surface gel strength, then the surface crosslink density is improved, but the internal crosslink density must be controlled to remain low
Solution Approach 1:
The patent applies preliminary action by incorporating the thermally decomposable group into the crosslinker compound structure before the polymerization process. This pre-installed functional group remains dormant during polymerization and only activates during subsequent thermal treatment. The preliminary incorporation of this reactive group allows controlled decomposition at the polymer surface during thermal processing, creating high surface crosslink density without affecting the internal crosslink density, thus achieving differential crosslinking.
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 enables the production of a crosslinker compound with higher yield and diverse structure, suitable for producing super absorbent polymers with controlled internal and surface crosslink densities, enhancing gel strength and absorbency.
Implementation Method 1
hydrogenating a compound of the following Chemical Formula 1 under a noble metal catalyst to form a diol compound of the following Chemical Formula 2, wherein the noble metal vcatalyst is Pd/C catalyst
Implementation Method 2
subjecting a diol compound of the following Chemical Formula 2 and a compound of the following Chemical Formula 3 to an esterification reaction to form a compound of the following Chemical Formula 4
Data Source
AI summary
The present disclosure relates to a method for preparing a crosslinker compound in which a crosslinker compound capable of using for the production of a super absorbent polymer can be obtained in a higher yield by a simple manner. The crosslinker compound obtained by the above method can be used as a thermally decomposable crosslinker in the process of producing a super absorbent polymer.