Over-Neutralized Fatty Acid Polymerization Process
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Solution Overview
Problem
The existing methods for forming highly neutralized polymers are inefficient due to the difficulty in mixing liquid fatty acids with resin-like copolymers, leading to time-consuming reactions.
Innovation Solution
A method involving the reaction of a neutralization agent with fatty acid to form an over-neutralized compound, which is then mixed with an acid copolymer to create a highly neutralized polymer, utilizing magnesium oxide or hydroxide to achieve the desired level of neutralization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a copolymer and fatty acid are mixed directly and then a neutralization agent is added, then the neutralization reaction can proceed, but the process becomes time consuming due to the difficulty in mixing liquid fatty acid with resin-like copolymer
Solution Approach 1:
The patent applies preliminary action by first reacting the neutralization agent with the fatty acid to form an over-neutralized fatty acid compound before mixing with the copolymer. This pre-reaction ensures complete neutralization and creates a reactive intermediate that accelerates the subsequent polymerization, thereby reducing the overall reaction time while maintaining reliable neutralization.
Solution Approach 2:
The over-neutralized fatty acid compound serves as an intermediary substance that facilitates the reaction between the neutralization agent and the copolymer. This intermediate compound contains reactive groups that promote efficient mixing and reaction with the resin-like copolymer, solving the problem of difficult mixing while ensuring complete neutralization.
2Manufacturing precision
If a neutralization agent is added to neutralize fatty acid, then the polymer neutralization can be achieved, but the process complexity increases due to the need to control neutralization levels
Solution Approach 1:
The patent applies partial or excessive action by intentionally adding an excess amount of neutralization agent to the fatty acid, creating an over-neutralized fatty acid compound. This excessive neutralization simplifies the process control by ensuring complete neutralization even with variations in mixing conditions, and the excess neutralization agent is subsequently consumed during the polymerization reaction, achieving precise neutralization level control without complex process monitoring.
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 simplifies the process and enhances the formation of highly neutralized polymers, resulting in a more efficient and effective production of thermoplastic materials suitable for golf balls with improved properties.
Implementation Method 1
reacting a predetermined amount of magnesium oxide with a predetermined amount of oleic acid to form an over-neutralized oleic acid compound
Implementation Method 2
reacting a predetermined amount of an acid copolymer compound with the over-neutralized oleic acid compound to form a highly neutralized polymer
Data Source
AI summary
A method for forming highly neutralized polymers for use in games balls and the like is disclosed herein. The method includes mixing oleic acid with a predetermined amount of magnesium oxide which is greater than the amount necessary to fully neutralize the oleic acid. The over-neutralized oleic acid particulate is mixed with an acid copolymer compound to form a highly neutralized polymer.