Hollow Polymer Particles with Phosphate Ester for Scratch Resistance
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Solution Overview
Problem
Conventional hollow porous polymer particles lack sufficient mechanical strength and are prone to deformation and breakage under external forces, making them unsuitable for applications as light diffusing agents or matting agents in optical films and paints.
Innovation Solution
Hollow polymer particles comprising a polymer with vinylic monomer units and phosphate ester monomer units, specifically designed with a volume average particle diameter of 0.5 to 1000 μm, a specific surface area of 1 to 30 m2/g, and a bulk specific gravity of 0.1 to 0.4 g/cm3, which are produced through suspension polymerization with a non-polymerizable organic compound and an alkaline earth metal phosphate dispersant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional hollow porous polymer particles are used, then they can function as light diffusing agents or matting agents, but they lack sufficient mechanical strength and are easily deformed and broken under external force
Solution Approach 1:
The patent applies composite materials by combining polymer particles with inorganic materials (such as silica, metal oxides, or hydroxides) to form a coating layer on the surface of the hollow porous polymer particles. This composite structure enhances the mechanical strength and durability of the particles, preventing them from being deformed or broken under external force while maintaining their light diffusing and matting properties
Solution Approach 2:
The patent employs a thin film approach by forming a coating layer on the surface of the hollow porous polymer particles. This coating layer acts as a protective shell that reinforces the particle structure, providing mechanical strength and resistance to deformation and breakage while preserving the underlying porous structure and optical functions
2Strength
If conventional hollow porous particles are used as light diffusing agents or matting agents, then they can provide optical functions, but the coating films formed are vulnerable to scratches
Solution Approach 1:
The patent uses composite materials by incorporating inorganic materials into the coating layer formed on the hollow porous polymer particles. This composite coating structure significantly improves scratch resistance and durability, making the coating films more resistant to mechanical damage while maintaining their optical properties
Solution Approach 2:
The patent applies local quality by concentrating the reinforcement in the coating layer on the particle surface. The inorganic materials are specifically positioned in this region to provide localized protection against scratches and mechanical stress, while the interior porous structure maintains its light diffusing and matting functions
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 resulting hollow polymer particles exhibit high mechanical strength, maintaining their shape and optical properties under external forces, enhancing scratch resistance and stability in coating films and light diffusion films.
Implementation Method 1
subjecting a monomer mixture containing 0.01 to 1 part by mass of a phosphate ester monomer unit based on 100 parts by mass of a vinylic monomer unit to suspension polymerization in the presence of a non-polymerizable organic compound and a dispersant
Data Source
AI summary
Hollow polymer particles comprising a polymer containing a vinylic monomer unit and a phosphate ester monomer unit, the hollow polymer particles having a volume average particle diameter of 0.5 to 1000 μm.