Graft Copolymer Mold Release Agent Low Bioaccumulation

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Solution Overview

Problem

Conventional mold-releasing agents with perfluoroalkyl groups containing 6 or less carbon atoms have low bioaccumulation potential but fail to provide mold release performance equivalent to those with 8 or more carbon atoms, and their production generates environmentally harmful by-products.

Innovation Solution

A graft copolymer is developed by graft-copolymerizing polyalkylene glycol or its alkyl ether with a polyfluoro-1-alkene, which exhibits excellent mold release performance and low bioaccumulation potential, avoiding the production of harmful perfluoroalkyl carboxylic acids.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If phosphate or phosphonate compounds having a C8-C12 perfluoroalkyl group are used as mold-releasing agents, then mold release performance and durability are improved, but environmental harm increases due to biodegradation into bioaccumulative compounds

Engineering Contradiction:

Improvemold release performanceVSAvoidenvironmental harm

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The invention changes the chemical structure parameters by using C4-C6 perfluoroalkyl groups instead of C8-C12, and by incorporating fluorinated cyclic carbonate units into the polymer chain. This structural modification maintains mold release performance while preventing biodegradation into bioaccumulative perfluoroalkyl carboxylic acids, thus resolving the environmental harm issue

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a copolymer composite material combining fluorinated cyclic carbonate units with perfluoroalkyl-containing vinyl monomer units. This composite structure integrates the beneficial properties of both components: the cyclic carbonate provides durability and film-forming ability, while the perfluoroalkyl groups provide mold release performance without environmental harm

Inventive Principle:

Principle #40Composite materials

2Object-generated harmful factors

If compounds having a perfluoroalkyl group containing 6 or less carbon atoms are used as mold-releasing agents, then environmental impact is reduced, but mold release performance and durability decrease

Engineering Contradiction:

Improveenvironmental impactVSAvoidmold release performance

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

The invention merges multiple functional units into a single copolymer structure: fluorinated cyclic carbonate units for durability, perfluoroalkyl-containing vinyl monomer units for mold release performance, and polyalkylene glycol components for film-forming ability. This combination achieves both low environmental impact and high mold release performance simultaneously

Inventive Principle:

Principle #5Merging (Combining)

3Duration of action of stationary object

If C8-C12 perfluoroalkyl group-containing compounds are used as mold-releasing agents, then mold release durability is improved, but production generates harmful by-products

Engineering Contradiction:

Improvemold release lifeVSAvoidproduction by-products

Core Design Contradiction:

Duration of action of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The invention changes the production process parameters by using C4-C6 perfluoroalkyl groups and fluorinated cyclic carbonate monomers as starting materials instead of C8-C12 perfluoroalkyl compounds. This prevents the formation of harmful perfluoroalkyl carboxylic acid by-products during production while maintaining long mold release life through the durable copolymer structure

Inventive Principle:

Principle #35Parameter changes

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 graft copolymer demonstrates superior mold release performance, excellent film-forming properties, and improved durability, reducing contamination and ensuring high precision and secondary processability of molded products while minimizing environmental impact.

Implementation Method 1

having excellent film-forming properties and mold releasability

Methodology Applied

Scientific EffectFilm-forming:

Implementation Method 2

exhibits excellent mold releasability

Methodology Applied

Scientific EffectMold release:

Data Source

PatentEP2439038B1Graft copolymer and mold release agent comprising same as active ingredient

Publication Date: 2017.05.10 UNIMATEC CO LTD

AI summary

Disclosed is a graft copolymer in which a polyalkylene glycol or an alkyl ether thereof is graft-copolymerized with a polyfluoro-1-alkene represented by the general formula: CnF2n+1(CH2CF2)a(CF2CF2)bCH=CH2 (wherein n is an integer of 1 to 6, a is an integer of 1 to 4, and b is an integer of 1 to 3). The graft copolymer is an oligomer compound having a perfluoroalkyl group containing 6 or less carbon atoms, which is said to have low bioaccumulation potential, and having, when used as an active ingredient of a mold-releasing agent, mold release performance equivalent to that of a compound having a perfluoroalkyl group containing 8 or more carbon atoms.