Hollow PVC Microparticles for Polymer Composites

Solution Overview

Problem

Existing technologies using hollow glass microspheres in polymer compounds face challenges such as high material costs and reduced polymer-to-filler compatibility, leading to inferior mechanical properties and compatibility issues.

Innovation Solution

The development of hollow polyvinyl chloride (PVC) microparticles formed through a double emulsion polymerization process, which offers lower material costs, improved compatibility with polymer matrices, and enhanced mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If hollow glass microspheres are used in polymer compounds, then weight reduction is achieved, but material cost increases and polymer-to-filler compatibility decreases

Engineering Contradiction:

Improveweight reductionVSAvoidmaterial cost

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The patent replaces expensive hollow glass microspheres with inexpensive hollow polymer microspheres made from polyvinyl chloride. The hollow structure is created through a double emulsion process using cheap polymer materials, achieving weight reduction without the high material costs associated with glass ceramics.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent uses polymeric hollow microspheres that are chemically similar to the polymer matrix, creating homogeneity between filler and matrix. This polymeric-to-polymeric compatibility improves interfacial adhesion and mechanical properties compared to ceramic glass microspheres, which are chemically incompatible with organic polymer matrices.

Inventive Principle:

Principle #33Homogeneity

2Weight of moving object

If hollow glass microspheres are used in polymer compounds, then weight reduction is achieved, but polymer-to-filler compatibility decreases

Engineering Contradiction:

Improveweight reductionVSAvoidpolymer-to-filler compatibility

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent uses polymeric hollow microspheres that are chemically similar to the polymer matrix, creating homogeneity between filler and matrix. This polymeric-to-polymeric compatibility improves interfacial adhesion and mechanical properties compared to ceramic glass microspheres, which are chemically incompatible with organic polymer matrices.

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The patent creates a composite system where hollow polyvinyl chloride microspheres are dispersed in a polymer matrix. The composite structure combines the lightweight hollow sphere morphology with chemically compatible polymeric material, achieving both weight reduction and improved compatibility with the surrounding polymer matrix.

Inventive Principle:

Principle #40Composite materials

3Weight of stationary object

If hollow glass microspheres are used in polymer compounds, then density reduction is achieved, but mechanical properties deteriorate

Engineering Contradiction:

Improvedensity reductionVSAvoidmechanical properties

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The patent uses polymeric hollow microspheres that are chemically similar to the polymer matrix, creating homogeneity between filler and matrix. This polymeric-to-polymeric compatibility improves interfacial adhesion and mechanical properties compared to ceramic glass microspheres, which are chemically incompatible with organic polymer matrices.

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The patent modifies the physical and chemical parameters of the filler material by using polymeric hollow microspheres instead of glass ceramics. The polymeric filler has similar thermal expansion, flexibility, and chemical compatibility parameters to the polymer matrix, resulting in improved mechanical properties while maintaining density reduction.

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 use of hollow PVC microparticles results in a lower density polymer composite with improved mechanical properties, durability, and increased water and stain resistance compared to glass microspheres.

Implementation Method 1

double emulsion polymerization process comprises (a) forming an intermediate water-in-oil emulsion having a discontinuous phase of alkaline water in a continuous phase of vinyl chloride monomer and lipophilic surfactant(s) and initiator(s)... (c) ripening via agitation the double emulsion to form microparticles having a monomeric polyvinyl chloride shell and an aqueous core

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 2

double emulsion polymerization process comprises (a) forming an intermediate water-in-oil emulsion having a discontinuous phase of alkaline water in a continuous phase of vinyl chloride monomer... (c) ripening via agitation the double emulsion to form microparticles having a monomeric polyvinyl chloride shell and an aqueous core

Methodology Applied

Scientific EffectEmulsion: Emulsion

Implementation Method 3

drying the microparticles to remove water from the core of the microparticles

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS12234353B2Low density polyvinyl chloride microparticles

Publication Date: 2025.02.25 MEXICHEM SPECIALTY RESINS INC

AI summary

Hollow microparticles of polyvinyl chloride are disclosed, having low volumetric densities useful for reducing mass per unit volume of polymer or inorganic articles and apparatus having such microparticles compounded into thermoplastic or thermoset polymers. A double emulsion polymerization process is also disclosed as the process to produce the hollow microparticles.