Organoborane Amine Complexes for Room Temperature Polymer Particle Synthesis
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Solution Overview
Problem
Current methods for producing polymer microparticles are limited by the need for surfactants, organic solvents, and high temperatures, and do not efficiently produce submicron-sized particles, making them costly and energy-intensive.
Innovation Solution
A composition comprising free radical polymerizable monomers, organoborane amine complexes, and a poor or non-solvent is used to initiate polymerization at room temperature or below, forming uniform polymeric particles with average diameters less than 10 μm, which encapsulate active ingredients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional polymerization methods (emulsion, dispersion, precipitation, or suspension polymerization) are used to produce polymer microparticles, then polymer particles can be formed, but the process requires surfactants, organic solvents, or high temperatures, and cannot efficiently produce submicron-sized particles
Solution Approach 1:
The invention changes the chemical parameters of the polymerization system by using organoborane amine complexes as initiators instead of conventional peroxide or azo initiators. This allows polymerization to proceed at room temperature or below without requiring surfactants, organic solvents, or high temperatures, while efficiently producing submicron-sized particles through precipitation polymerization
Solution Approach 2:
The invention extracts and eliminates harmful components from the polymerization process. By using organoborane amine complexes as initiators, the method removes the need for surfactants, organic solvents, and high-temperature conditions required by conventional methods, thereby simplifying the process and enabling submicron particle production
2Ease of manufacture
If spray drying operation is used to recover microcapsules, then catalyst can be encapsulated in thermoplastic resin, but the process is costly and limited in particle size range
Solution Approach 1:
The invention extracts and eliminates the need for expensive spray drying equipment and operations. By using precipitation polymerization with organoborane amine complexes, microcapsules are formed directly in a simplified process that is less costly and not limited by particle size ranges
Solution Approach 2:
The invention replaces the mechanical spray drying system with a chemical precipitation polymerization system. Instead of using mechanical atomization and rapid evaporation, the method uses chemical reactions to directly form microparticles in solution, which are then recovered by simple filtration or centrifugation
3Manufacturing precision
If mechanical grinding or crushing is used to form fine particles, then bulk polymers can be processed, but the process is energy intensive and costly to implement and maintain
Solution Approach 1:
The invention performs preliminary action by forming microparticles directly during the polymerization process itself, rather than creating bulk polymer first and then mechanically processing it. The organoborane amine complex initiator and poor solvent conditions cause the polymer to precipitate as fine particles during synthesis, eliminating the need for subsequent energy-intensive grinding or crushing operations
4Productivity
If conventional free radical initiators (peroxide or azo) are used, then polymerization can be initiated, but elevated temperatures are required which increases energy consumption
Solution Approach 1:
The invention changes the chemical parameters by using organoborane amine complexes as initiators instead of conventional peroxide or azo initiators. These complexes can initiate free radical polymerization at room temperature or below, maintaining high polymerization rates without requiring elevated temperatures, thereby reducing energy consumption
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 method allows for the rapid and cost-effective production of submicron-sized polymer microparticles at lower temperatures, reducing energy consumption and eliminating the need for surfactants and organic solvents, while effectively encapsulating active ingredients.
Implementation Method 1
free radical polymerizable monomers, that polymerize or crosslink in the presence of an organoborane amine complex, upon exposure to an amine-reactive compound, or by exposure to heat or radiation
Implementation Method 2
The reaction is carried out in a medium containing at least one poor or non-solvent for the resulting polymer, in order to form microparticles
Data Source
AI summary
A polymerized product is obtained from a mixture containing (i) a free radical polymerizable monomer, oligomer or polymer; (ii) an organoborane amine complex, (iii) a poor or non-solvent for the polymerized product of (i); and (iv) an amine reactive compound. The mixture may include (v) an active ingredient to be encapsulated by the polymerized product, and (vi) an optional component(s). Polymer particles are obtained by (A) forming a composition containing components (i)-(iv); (B) agitating components (i)-(iv) in the presence of oxygen to initiate polymerization, at a rate and for a time sufficient to provide a uniform dispersion and reaction of the components; (C) allowing the reaction to proceed to completion at room temperature; and (D) recovering the polymer particles by removing component (iii). The composition may include (v) the active ingredient to be encapsulated by the polymer particles.