Deformed Shaped Resin Particles via Seed Polymerization
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Solution Overview
Problem
Existing methods for producing resin particles are limited in controlling the shape of the particles, which restricts their application in various additives such as coating agents, paper, and cosmetics, as they primarily produce flat shapes rather than deformed shapes.
Innovation Solution
A method involving seed polymerization where seed particles derived from (meth)acrylic esters with specific alkyl groups absorb a polymerizable vinyl type monomer containing crosslinkable monomers and (meth)acrylic esters with alkylene oxide groups, allowing for the formation of deformed shapes like horseshoe, mushroom, and semi-spherical shapes by adjusting the composition and polymerization conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If seed polymerization method is used with conventional seed particles, then resin particles with high sphericity can be formed, but it is difficult to control the shape to be deformed
Solution Approach 1:
The invention changes the parameters of the seed particles by specifying they must be derived from (meth)acrylic esters with specific alkyl groups (3-5 carbon atoms) and have specific weight average molecular weights (150,000-1,000,000). These parameter changes enable the seed particles to produce deformed shaped resin particles while maintaining manufacturing precision through controlled polymerization
Solution Approach 2:
The invention uses composite monomer systems containing crosslinkable monomers (5-50 wt%) and (meth)acrylic esters with alkylene oxide groups (1-40 wt%). This composite approach allows the formation of deformed shapes by combining the effects of crosslinking and specific monomer interactions during polymerization
2Shape
If conventional seed polymerization is used, then production process is simple, but the shapes obtained are merely flat and cannot be arbitrarily controlled
Solution Approach 1:
By changing the chemical composition parameters of the monomer system (adding crosslinkable monomers and (meth)acrylic esters with alkylene oxide groups) and seed particle parameters (specific alkyl groups and molecular weight range), the invention enables arbitrary shape control without significantly complicating the overall polymerization process
Solution Approach 2:
The invention performs preliminary preparation of specific seed particles with defined characteristics (alkyl group type, molecular weight range) before the main polymerization process. This preliminary action ensures that the subsequent polymerization naturally produces deformed shapes without requiring complex in-process control
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 method enables the efficient production of deformed shaped particles with controlled shapes, expanding their application in coating agents, paper, light diffusion films, and cosmetics by enhancing their performance and functionality.
Implementation Method 1
absorbing a polymerizable vinyl type monomer contained in an aqueous emulsion in a seed particles
Implementation Method 2
polymerizing an absorbed polymerizable vinyl type monomer
Data Source
Figure 1(a)~1(d)
Figure 2
Figure 3~4
AI summary
A method for producing a deformed shaped particles comprising step of: absorbing a polymerizable vinyl type monomer contained in an aqueous emulsion in a seed particles and polymerizing an absorbed polymerizable vinyl type monomer, wherein the seed particles are a resin particles which are derived from a (meth)acrylic ester having an ester part containing at least an alkyl group with a number of carbon atoms of 3 or more and less than 6, and which have a weight average molecular weight of 150000 to 1000000 (measured by GPC: gel permeation chromatography) and the polymerizable vinyl type monomer contains 5 to 50 wt. % of a crosslinkable monomer to the entire amount of the polymerizable vinyl type monomer.