Emulsifier-Free Fluorinated Polymer Production in Aqueous Dispersion
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Solution Overview
Problem
Existing methods for producing fluorinated polymers in an aqueous medium result in the emulsifier remaining in large amounts, necessitating its removal, which is environmentally impactful.
Innovation Solution
A method involving polymerizing a fluorinated monomer in an aqueous dispersion containing a first fluorinated polymer with specific unit proportions and particle sizes, using an aqueous medium with controlled sulfate ion concentrations, to produce a second fluorinated polymer without requiring an emulsifier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an emulsifier is used in aqueous medium for polymerization, then the polymerization process can proceed, but the emulsifier remains in large amounts in the aqueous dispersion requiring removal
Solution Approach 1:
The invention extracts and eliminates the emulsifier component from the polymerization system by using fluorinated polymer particles as alternative dispersants, thereby removing the source of harmful residues while maintaining the polymerization process
Solution Approach 2:
The invention introduces fluorinated polymer particles as an intermediary substance that performs the dispersant function previously provided by emulsifiers, enabling the polymerization to proceed without harmful emulsifier residues
2Object-affected harmful factors
If emulsifier removal is performed to reduce environmental impact, then environmental friendliness improves, but additional processing steps and costs are required
Solution Approach 1:
The invention converts the potentially harmful emulsifier residue issue into a benefit by using fluorinated polymer particles that naturally provide dispersion functionality without requiring removal, thus eliminating environmental impact concerns while simplifying the process
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
Efficient production of fluorinated polymers is achieved with minimal environmental impact by utilizing the first fluorinated polymer as a polymerization site, reducing the need for emulsifiers and minimizing residual compounds in the aqueous dispersion.
Implementation Method 1
polymerizing a monomer comprising a fluorinated monomer in an aqueous dispersion containing a first fluorinated polymer... to produce a second fluorinated polymer
Data Source
AI summary
To provide a method for producing a fluorinated polymer, by which a fluorinated polymer can be efficiently produced without requiring an emulsifier, while an aqueous medium with a small environmental impact is used. The method for producing a fluorinated polymer of the present invention is a method for producing a fluorinated polymer, which comprises polymerizing a monomer comprising a fluorinated monomer in an aqueous dispersion containing a first fluorinated polymer having TFE units and PAVE units, and an aqueous medium, to produce a second fluorinated polymer, wherein in the first fluorinated polymer, the units based on a perfluoro(alkyl vinyl ether) is 20 to 60 mol% to the total amount of the units based on tetrafluoroethylene and the units based on a perfluoro(alkyl vinyl ether), the average particle size of the first fluorinated polymer is 1 to 150 nm, and the content of the first fluorinated polymer before start of the polymerization of the monomer is 0.01 to 4.0 mass% to the total mass of the aqueous dispersion.