Crosslinking Primer Mixture for Homogeneous Polymer Impregnation
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Solution Overview
Problem
The existing processes for impregnating polymer granules with free-radical initiators face challenges such as premature crosslinking, desorption of initiators, and high volatile organic compound (VOC) generation, leading to inefficiencies and homogeneity issues in polymer production.
Innovation Solution
Predissolving the free-radical initiator in a crosslinking promoter to create a primer mixture that is liquid at room temperature, allowing for reduced impregnation time, improved retention, and lower initiator amounts, while maintaining crosslinking density and reducing VOC release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the free-radical initiator is impregnated into polymer granules by heating above its melting point, then homogeneous impregnation is achieved, but the impregnation time and energy consumption increase significantly
Solution Approach 1:
The patent changes the physical state parameter of the initiator from solid to liquid by dissolving it in a crosslinking promoter, enabling impregnation at lower temperatures without compromising homogeneous distribution throughout the polymer granules
Solution Approach 2:
The crosslinking promoter acts as an intermediary solvent that facilitates the dissolution and subsequent impregnation of the initiator into the polymer matrix, eliminating the need for high-temperature melting and reducing both time and energy requirements
2Duration of action of stationary object
If the free-radical initiator is stored in polymer granules for several months, then sufficient storage stability is achieved, but desorption occurs leading to lack of composition homogeneity
Solution Approach 1:
The patent creates a composite system where the initiator is dissolved in a crosslinking promoter within the polymer matrix, forming a stable integrated structure that prevents desorption and maintains composition homogeneity throughout the storage period
Solution Approach 2:
By changing the physical state of the initiator from solid particles that can desorb to a dissolved state in the promoter, the system achieves long-term storage stability while maintaining uniform composition distribution
3Manufacturing precision
If a sufficient amount of free-radical initiator is used for crosslinking, then desired crosslinking density is achieved, but substantial generation of VOCs occurs
Solution Approach 1:
The patent employs a composite initiator-promoter system where the initiator is dissolved in the crosslinking promoter, enabling efficient crosslinking reactions that achieve desired density while minimizing VOC generation through optimized chemical pathways
Solution Approach 2:
By dissolving the initiator in the promoter, the patent optimizes the chemical reaction parameters to achieve effective crosslinking at lower initiator concentrations, thereby reducing VOC emissions while maintaining the required crosslinking density
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 significantly reduces impregnation time, minimizes desorption, and decreases VOC emissions by up to 40%, while maintaining equivalent crosslinking density, allowing for more stable and homogeneous polymer production.
Implementation Method 1
Free-radical initiators decompose thermally, producing free radicals
Implementation Method 2
Predissolving the free-radical initiator in a crosslinking promoter to create a primer mixture that is liquid at room temperature
Implementation Method 3
They make it possible to give to many polymers, and more particularly to rubbers and polyolefins, excellent mechanical, thermal and chemical properties, by means of the formation of covalent bonds between the polymer chains
Data Source
AI summary
A primer mixture intended for crosslinking polyethylene, including at least an initiator of free radicals chosen from organic peroxides, azo compounds or mixtures thereof, wherein the mixture has said free-radical initiator and at least one crosslinking promoter chosen from the cycloalkanes having 5 to 7 carbon atoms, substituted by 1 to 3 vinyl, allyl or isopropenyl groups, the aromatic compounds substituted by 1 to 3 vinyl, allyl or isopropenyl groups, the methacrylate, acrylate and maleimide monomers being multi-substituted, and in that the weight ratio of free-radical initiator to the crosslinking promoter is greater than or equal to 1, and preferably between 1.5 and 4. Also, a method and to a use related to this primer mixture.