Coagulated Latex Particle Production via Viscosity Control
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Solution Overview
Problem
Conventional methods for manufacturing coagulated particles from latex prepared by emulsion polymerization face challenges such as high fine particle content, low bulk specific gravity, and unsatisfactory powder properties, leading to issues like dust generation and increased facility costs.
Innovation Solution
The method involves discharging a latex with a thickener from a nozzle into a coagulating agent solution, followed by crushing the aggregates to control particle size and achieve high bulk specific gravity, eliminating the need for organic solvents and simplifying equipment requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional coagulation methods are used to recover graft copolymer from latex, then the polymer can be recovered in powder form, but the coagulated particles contain large amounts of fine powder and have low bulk specific gravity
Solution Approach 1:
The patent applies preliminary action by adding a thickener to the latex before coagulation to increase its viscosity. This pre-treatment modifies the latex properties in advance, enabling the formation of coagulated particles with improved bulk specific gravity and reduced fine powder content during the subsequent coagulation process
Solution Approach 2:
The patent changes physical parameters of the latex system by introducing a thickener that increases viscosity. This parameter change affects the coagulation behavior, leading to particles with better powder properties including higher bulk specific gravity and improved particle size distribution
2Ease of operation
If water is added to adjust polymer solid content to 10% or less before coagulation, then coagulated particles can be formed, but the fine particle content increases and bulk specific gravity decreases
Solution Approach 1:
Instead of changing the polymer solid content parameter by dilution, the patent changes the viscosity parameter by adding a thickener. This allows maintaining higher solid content while achieving proper coagulation behavior and improved bulk specific gravity
3Productivity
If gas-phase coagulation is used to coagulate latex, then coagulated particles can be produced, but the particle size becomes uneven and fine particle content increases
Solution Approach 1:
The patent applies preliminary action by increasing latex viscosity with a thickener before coagulation. This pre-treatment ensures that during gas-phase coagulation, the latex maintains better structural integrity, leading to more uniform particle size and reduced fine powder generation
4Ease of manufacture
If organic solvents are used in coagulation processes, then coagulated particles can be formed, but environmental problems arise due to remaining organic solvent in particles
Solution Approach 1:
The patent replaces persistent organic solvents with water-based thickeners that decompose harmlessly. The thickener serves its function during coagulation and then becomes an environmentally benign component, eliminating the harmful effects of organic solvent residues
Solution Approach 2:
The patent converts the potential harm of water-based coagulation (which can produce fine powder) into a benefit by adding a thickener. This transforms the coagulation process into one that uses water (environmentally friendly) while achieving improved particle properties through viscosity control
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
This approach efficiently produces coagulated particles with small fine particle and coarse particle contents, achieving a high bulk specific gravity and preferred powder properties for applications like impact modifiers in vinyl chloride resins.
Implementation Method 1
a method for manufacturing coagulated particles from a latex prepared by emulsion polymerization, characterized by comprising a step of discharging the latex prepared by emulsion polymerization having a viscosity of 10 mPa·s or more, from the nozzle
Implementation Method 2
discharging the latex prepared by emulsion polymerization having a viscosity of 10 mPa·s or more, from the nozzle to a solution containing a coagulating agent
Data Source
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AI summary
The present invention relates to a method for manufacturing coagulated particles from a latex prepared by emulsion polymerization, containing step of discharging the latex prepared by emulsion polymerization containing a thickener or the latex prepared by emulsion polymerization having a given viscosity into a solution containing a coagulating agent, to coagulate the latex prepared by emulsion polymerization, aggregates having an anisotropy shape obtained by discharging a latex prepared by emulsion polymerization containing a thickener into a solution containing a coagulating agent, and coagulated particles from the latex prepared by emulsion polymerization obtained by the method.