Polyarylethersulfone Recycling via Trans-Etherification Reuse
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Solution Overview
Problem
Existing methods for recycling sulfone polymers are limited in their ability to recycle them back into their original applications, and off-specification polyarylethersulfone waste is often disposed of due to unsuitability for specific uses, leading to environmental impact and economic inefficiency.
Innovation Solution
A one-pot process that recycles polyarylethersulfone by incorporating recycled polymer recurring units into new polymer chains using a polar aprotic solvent, alkali salt-forming agent, and aromatic diol or dihalo monomers, allowing for the production of polyarylethersulfone identical in structure and properties to virgin materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If chemical recycling methods are used to convert plastic materials into smaller molecules, then the plastic waste can be repurposed into new petrochemicals and plastics, but the resulting products are structurally different and can only be used in applications other than originally targeted
Solution Approach 1:
The patent changes the chemical parameters of the recycling process by using trans-etherification reaction conditions (polar aprotic solvent, alkali salt-forming agent, elevated temperature) that preserve the polyarylethersulfone structure rather than breaking it down into smaller molecules. This allows the recycled polymer to maintain its original structural characteristics and be suitable for original applications.
Solution Approach 2:
Instead of following the conventional chemical recycling approach of depolymerization into monomers or oligomers, this patent inverts the approach by using the waste polymer itself as a reactant in a trans-etherification reaction. The recycled polymer chains are directly incorporated into new polymer chains without complete breakdown, thus preserving the original polymer structure while achieving recycling.
2Manufacturing precision
If off-specification polyarylethersulfone waste is disposed of due to unsuitability for specific uses, then product specifications are maintained, but environmental impact increases and economic efficiency decreases
Solution Approach 1:
The patent converts the previously harmful waste disposal problem into a beneficial recycling opportunity. Off-specification polyarylethersulfone waste that would have been disposed of is instead used as a reactant in the trans-etherification process, transforming it into valuable recycled polymer material and eliminating the environmental harm of waste disposal.
Solution Approach 2:
Rather than discarding the off-specification polyarylethersulfone waste, the patent recovers it by using it as a reactant source. The waste polymer is recovered and transformed into useful recycled polymer product, turning a disposal problem into a resource recovery solution.
3Manufacturing precision
If mechanical recycling is used for clean and homopolymeric-based material, then the material can be reused in manufacturing with minimal structural change, but the availability of such clean material is low
Solution Approach 1:
The patent changes the chemical parameters and reaction conditions to enable the use of a broader range of polymer sources. By using trans-etherification reaction in polar aprotic solvent with alkali salt-forming agent, the process can accept off-specification and mixed polyarylethersulfone materials that would not be suitable for conventional mechanical recycling, thus expanding material source acceptability while maintaining structural integrity.
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 process achieves near 100% efficiency in recycling polyarylethersulfone, reducing environmental footprint and improving production economics by enabling the reuse of off-specification waste in its original applications.
Implementation Method 1
adding a polar aprotic solvent (S) to a reactor vessel; adding a recycled polymeric material containing a polyarylethersulfone (P1) to the reactor vessel
Implementation Method 2
adding an alkali salt-forming agent (A) to the reactor vessel; heating the reaction medium to reach a reaction temperature of at least 150° C. to form a polyarylethersulfone (P2)
Implementation Method 3
heating the reaction medium to reach a reaction temperature of at least 150° C. to form a polyarylethersulfone (P2)
Data Source
AI summary
A process for the manufacture of a polyarylethersulfone “PAES” (P2) using recycled polymeric material, comprising heating a reaction medium (RM) comprising a recycled polymeric material containing a polyarylethersulfone “PAES” (P1), at least one monomer (M), an alkali salt-forming agent (A) and a polar aprotic solvent (S) to reach a reaction temperature of at least 150° C. to form a PAES (P2); and separating the forned PAES (P2) from the reaction medium. The PAES (P1) recycle ratio may be from 100 wt. % to 1 wt. %. The recycled polymeric material added to the reaction medium may further include other polymer(s), solid fillers, and/or additives. The monomer (M) may be at least one aromatic diol monomer (AA) and/or at least one aromatic dihalo monomer (BB). The diol (AA) may comprise bisphenol A, bisphenol S, biphenol, a 1,4:3,6-dianhydrohexitol sugar diol and/or tetramethyl bisphenol F, and the dihalo (BB) may comprise non-sulfonated and/or disulfonated dihalodiphenylsulfone.