Granular Polymer Blend Production via pH-Controlled Mixing

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Solution Overview

Problem

Existing methods fail to produce a granular blend of polymers with compositional homogeneity, high bulk density, and low water content, which are desirable for applications like detergents, where large quantities of water are undesirable.

Innovation Solution

A method involving combining a first polymer with 22-80 wt% monoethylenically unsaturated C3-C6 carboxylic acid monomers and 20-78 wt% C1-C12 alkyl (meth)acrylate monomers, with a weight-average molecular weight of 20,000 to 100,000, and a second polymer with 50-100 wt% monoethylenically unsaturated C3-C6 carboxylic acid monomers and a weight-average molecular weight of 1,000 to 45,000, at specific pH levels to form a homogeneous granular blend.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If granulated polymers are produced from blends of two or more polymers, then favorable properties of constituent polymers can be exploited, but existing methods fail to produce granular blends with compositional homogeneity and high bulk density

Engineering Contradiction:
Improvecompositional homogeneityVSAvoidmanufacturing process capability
Core Design Contradiction:
Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by controlling the pH levels of the polymer solutions during blending. Specifically, the first polymer is combined with the second polymer at controlled pH values (pH 3-4 for the first polymer, pH 2-4 for the second polymer), which enables proper intermolecular bonding and forms homogeneous granular blends with high bulk density that are difficult to achieve through conventional mixing methods

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent creates composite granular materials by blending multiple polymer types (first polymer with 22-80 wt% carboxylic acid monomers and 20-78 wt% alkyl (meth)acrylate monomers, and second polymer with 50-100 wt% carboxylic acid monomers) in specific ratios and under controlled pH conditions, resulting in granular blends that exhibit properties superior to individual components

Inventive Principle:
Principle #40Composite materials

2Quantity of substance

If granulated polymers are produced from blends of two or more polymers, then favorable properties of constituent polymers can be exploited, but existing methods fail to produce granular blends with high bulk density and low water content

Engineering Contradiction:
Improvebulk densityVSAvoidwater content
Core Design Contradiction:
Quantity of substanceVSLoss of substance

Solution Approach 1:

The patent utilizes pH control as a critical parameter to achieve high bulk density and low water content. By adjusting the pH of the polymer solutions before and during blending, the method promotes efficient packing of polymer chains and reduces water retention, resulting in granules with high bulk density and low water content that are superior to conventional granulated polymers

Inventive Principle:
Principle #35Parameter changes

3Stability of the object's composition

If granulated polymers are produced from blends of two or more polymers, then favorable properties of constituent polymers can be exploited, but existing methods fail to produce single granules with compositional homogeneity

Engineering Contradiction:
Improvecompositional homogeneityVSAvoidgranule formation quality
Core Design Contradiction:
Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent employs controlled pH conditions (pH 3-4 for the first polymer, pH 2-4 for the second polymer) during the blending process to ensure uniform distribution of polymer chains throughout the granule. This pH control mechanism prevents phase separation and ensures compositional homogeneity at the granule level, achieving manufacturing precision that conventional methods cannot attain

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 method produces a granular polymer blend with improved compositional homogeneity, high bulk density, and low water content, suitable for use in detergents as an effective dispersant and spotting reduction agent.

Implementation Method 1

combining at least one first polymer at a pH from 3 to 4 with at least one second polymer at a pH from 2 to 4 to form the blend

Methodology Applied
Scientific EffectElectrostatic interaction: Electrostatics

Implementation Method 2

combining at least one first polymer at a pH from 3 to 4 with at least one second polymer at a pH from 2 to 4 to form the blend

Methodology Applied
Scientific EffectHydrogen bonding:

Data Source

PatentEP3548545B1Method for producing a granular polymer blend
Publication Date: 2020.12.23 ROHM & HAAS CO

AI summary

A method for producing a blend of at least one first polymer and at least one second polymer. The first polymer comprises: (a) polymerized units of 22 to 80 wt % of one or more monoethylenically unsaturated C3-C6 carboxylic acid monomers, and (b) polymerized units of 20 to 78 wt % of one or more C1-C12 alkyl (meth)acrylate monomers, and has a weight-average molecular weight from 20,000 to 100,000; and the second polymer comprises polymerized units of 50 to 100 wt% of one or more monoethylenically unsaturated C3-C6 carboxylic acid monomers and has a weight-average molecular weight from 1,000 to 45,000. The first polymer comprises from 1 to 50 wt% of total weight of the first and second polymers. At least one first polymer at a pH from 3 to 4 with at least one second polymer at a pH from 2 to 4 are combined.