Flow-Type Polymerization System with Static Mixer
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Solution Overview
Problem
The existing methods for living anionic polymerization, particularly in batch and flow-type systems, face limitations in achieving high molecular weight polymers with monodisperse molecular weight distribution and high monomer conversion rates, due to issues like side reactions, viscosity increases, and inefficient mixing.
Innovation Solution
Incorporating a static mixer into the flow-type reaction system during the polymerization process, where anionic polymerizable monomers and initiators are introduced through separate flow paths, allowing them to join and flow downstream while a polymerization terminator is introduced to terminate the reaction, optimizing flow rates, path diameters, and temperatures to enhance mixing and molecular weight control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If living anionic polymerization is performed by batch method at extremely low temperature to remove heat and inhibit side reactions, then side reactions are suppressed, but cryogenic cooling facilities are required and the method is not suited for mass production
Solution Approach 1:
The patent replaces the batch mechanical stirring system with a flow-type continuous reaction system. The mechanical stirring that causes uneven localization is substituted by continuous flow dynamics, where monomer and initiator are continuously fed through flow paths, eliminating the need for mechanical stirrers while achieving uniform mixing through flow characteristics.
Solution Approach 2:
The patent changes the temperature parameter from extremely low temperatures (≤-78°C) required in batch methods to a higher temperature range (-20°C to 40°C) in the flow-type system. This parameter change is enabled by the continuous flow configuration that allows efficient heat management without cryogenic cooling, thus simplifying the device while maintaining polymerization control.
2Ease of operation
If living anionic polymerization is performed by batch method with mechanical stirring, then mixing is provided, but monomer and initiator are unevenly localized and dispersity and monomer conversion rate cannot be improved
Solution Approach 1:
The patent replaces mechanical stirring with a flow-type continuous mixing system. The mixing function is achieved through the continuous flow of monomer and initiator solutions through contact zones, where diffusion and flow dynamics ensure uniform localization without mechanical agitation, thereby improving both mixing quality and manufacturing precision.
3Productivity
If flow-type reaction device is used to continuously obtain polymer by living anionic polymerization, then mass production is enabled, but monomer conversion rate is low and manufacturing efficiency is unsatisfactory
Solution Approach 1:
The patent optimizes the flow rates of monomer and initiator solutions, the residence time in the reaction zone, and the temperature parameters to achieve high monomer conversion rates. By carefully controlling these parameters in the continuous flow system, the patent achieves both high productivity and high conversion efficiency, converting approximately 90% or more of the monomer.
4Weight of moving object
If polymerization reaction is performed to obtain high molecular weight polymer, then molecular weight is increased, but viscosity increases and mixing becomes restricted
Solution Approach 1:
The patent replaces mechanical stirring with continuous flow dynamics that are not hindered by increasing viscosity. The flow-type system maintains effective mixing even at high polymer concentrations and high molecular weights by relying on flow-driven mixing mechanisms rather than mechanical agitation, which would fail under high viscosity conditions.
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 enables the production of polymers with high molecular weight and highly monodisperse molecular weight distribution at excellent monomer conversion rates, overcoming previous limitations in industrial scalability and efficiency.
Implementation Method 1
the liquids having joined together are flowing to downstream in a reaction flow path
Implementation Method 2
subjecting the anionic polymerizable monomer to anionic polymerization while the liquids having joined together are flowing to downstream in a reaction flow path
Data Source
AI summary
The present invention provides a method for manufacturing a polymer by a flow-type reaction. The method includes introducing a liquid A of an anionic polymerizable monomer, a liquid B of an anionic polymerization initiator, and a polymerization terminator into different flow paths, allowing the liquids to flow in the flow paths, allowing the liquid A and the liquid B to join together, subjecting the monomer to anionic polymerization while the liquids having joined together are flowing to downstream in a reaction flow path, and allowing a solution, which is obtained by the polymerization reaction and flows in the reaction flow path, and the polymerization terminator to join together so as to terminate the polymerization reaction and to obtain a polymer having a number-average molecular weight of 5,000 to 200,000. A static mixer is disposed in the reaction flow path, and a polymer having a number-average molecular weight equal to or greater than 2,000 is introduced into an inlet port of the mixer. The present invention also provides a flow-type reaction system suitable for performing the manufacturing method.