Macroporous Copolymers with Interpenetrating Networks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current ion exchange resins, both gel and macroporous, face limitations in stability under osmotic changes and diffusion rates, leading to suboptimal performance in applications requiring rapid access to exchange sites and high physical strength.
Innovation Solution
Development of macroporous copolymers with interpenetrating polymeric networks (IPN) that combine large pore diameters with enhanced physical strength, achieved through a process involving multiple stages of monomer mixing and polymerization, including the use of pore-forming agents and crosslinking agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If gel type resins are used, then good flow velocity through tall column beds is achieved, but poor performance in stability to osmotic changes and great swelling/shrinking occurs
Solution Approach 1:
The patent applies porous materials by creating macroporous copolymers with controlled pore structures. The porous framework allows rapid fluid flow through the resin bed while the crosslinked network maintains structural integrity during osmotic changes, preventing the swelling/shrinking problems of gel resins.
Solution Approach 2:
The patent uses composite materials by forming interpenetrating polymeric networks (IPNs) where two or more polymer networks are combined. This composite structure provides both the flow characteristics of macroporous materials and the stability of crosslinked networks, resolving the contradiction between flow velocity and osmotic stability.
2Quantity of substance
If gel beads are used, then high volume capacities are achieved, but slow rate of diffusion into the resin beads occurs
Solution Approach 1:
The patent creates macroporous copolymers with large pore diameters (average pore diameter of at least 1,000 Å) that facilitate rapid diffusion of chemical species throughout the resin bead. The porous structure reduces the diffusion path length while maintaining high exchange capacity, solving the contradiction between volume capacity and diffusion rate.
3Speed
If small beads are used to reduce diffusion path length, then rapid access to exchange sites is achieved, but larger pressure drops and reduced flow rates occur
Solution Approach 1:
The patent segments the resin structure by creating macroporous copolymers with internal pore channels that divide the diffusion path into multiple segments. This allows rapid access to exchange sites through the pore network while maintaining larger bead sizes that reduce pressure drops and improve flow rates through the column bed.
4Speed
If macroporous resins with large pores are formed, then improved diffusion rates are achieved, but low physical strength occurs
Solution Approach 1:
The patent forms composite materials by creating interpenetrating polymeric networks where multiple polymer networks are combined within the macroporous structure. This composite approach provides both the large pore diameters needed for rapid diffusion and the enhanced mechanical strength from the interconnected networks, resolving the contradiction between diffusion rate and physical strength.
Solution Approach 2:
The patent applies local quality by creating regions of different network densities within the copolymer structure. The macroporous regions provide rapid diffusion pathways while the crosslinked network regions provide mechanical strength, allowing both properties to coexist in different parts of the same resin bead.
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 macroporous copolymers exhibit significantly improved diffusion rates and physical strength, enabling their use in a broader range of applications where standard resins are unsuitable, including efficient separation and purification processes.
Implementation Method 1
Copolymers and resins with extremely large and extraordinary pores and enormously increased strength have been formed by creating an IPN from porous starting copolymers
Implementation Method 2
mixing an aqueous suspension polymerization of a 1st monomer mixture comprising a monoethylenic monomer, a polyethylenic monomer, and a 1st pore-forming agent
Data Source
AI summary
The present invention provides a macroporous copolymer having large pores, typically in the range of 5,000-200,000 Å and a typical breaking weight of at least 175 g/bead. The macroporous copolymers can be made using an interpenetrating polymer network (IPN) techniques. These macroporous copolymers may also form macroporous resins. The present invention also provides methods of using the macroporous copolymers and resins.