Oxidized Polyolefin Wax Preparation via Solid-State Oxidation
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Solution Overview
Problem
Existing methods for producing oxidized polyolefin waxes via solid state oxidation result in inconsistent emulsification and low clarity due to variations in feedstock particle size distribution, leading to poor emulsification performance and gritty products.
Innovation Solution
A method involving the use of a uniform polyolefin resin feedstock with a narrow particle size distribution (177 µm to 595 µm and a standard deviation of less than 125 µm) is oxidized in a solid state to produce a wax with a higher and more uniform acid number, facilitating uniform dispersion in an aqueous emulsion and enhancing emulsification and clarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid state oxidation is used to produce oxidized waxes from high molecular weight polyolefins, then the method avoids cross-linking and can process high molecular weight materials, but the emulsion clarity and emulsification consistency are poor
Solution Approach 1:
The invention changes the particle size parameter of the polyolefin feedstock to a specific range (10-100 mesh, approximately 1.7-1.77mm diameter) and maintains a narrow particle size distribution. This parameter optimization enables consistent oxygen diffusion rates during solid state oxidation, producing oxidized waxes with uniform acid numbers (20-40) that form clear, consistent emulsions without the grittiness associated with wider particle distributions.
Solution Approach 2:
The invention performs preliminary size classification of the polyolefin feedstock before oxidation to ensure all particles fall within the optimal size range. This preliminary action prevents the problems of inconsistent oxidation rates and poor emulsion clarity that would result from using feedstock with wide particle size variations, thereby ensuring consistent emulsification performance.
2Quantity of substance
If wide particle size distribution feedstock is used in solid state oxidation, then material utilization is maximized, but oxidation uniformity and emulsion quality deteriorate
Solution Approach 1:
The invention optimizes the particle size parameter to a specific range (10-100 mesh) that balances surface area for oxidation with mechanical handling properties. This specific parameter range, combined with a narrow distribution, ensures uniform oxidation across all particles while maintaining efficient material utilization. The consistent surface area-to-volume ratio across particles enables uniform acid number development.
3Productivity
If oxygen diffusion is enhanced in melt phase oxidation, then oxidation rate increases, but viscosity increases due to cross-linking and emulsification becomes difficult
Solution Approach 1:
The invention maintains the polyolefin in the solid state throughout the oxidation process rather than melting it. By conducting oxidation below the melting point of the polyolefin, the process avoids cross-linking reactions that occur in the melt phase. The solid state particles maintain their shape and size, enabling consistent oxygen diffusion and producing oxidized waxes that emulsify readily without the viscosity and cross-linking problems of melt phase oxidation.
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 method produces oxidized waxes that are highly emulsifiable and possess high clarity, with improved acid number uniformity and emulsification performance, resulting in clear and stable emulsions suitable for various applications.
Implementation Method 1
oxidizing said high molecular weight polyolefin resin particles in a solid state to produce a wax
Implementation Method 2
the oxygen diffusion is very slow and impractical on a commercial scale
Data Source
AI summary
A method for producing an oxidized wax comprising (a) providing a uniform high molecular weight polyolefin resin feedstock having an average particle size smaller than about 30 mesh and a standard deviation in particle size of not greater than about 125 µm; and (b) oxidizing the resin particles in their solid state to produce a wax having a predetermined acid number.