Peroxide Dispersion Viscosity Control via Polyglyceryl Esters
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Highly concentrated aqueous dispersions of water-insoluble, solid organic peroxides with particle sizes below 10 µm are typically viscous and difficult to handle, making processing inefficient, especially when milling, as they form thick pastes that require prolonged rest periods to soften and become manageable.
Innovation Solution
The use of polyglyceryl esters of C6-C12 fatty acids as surfactants during the milling process reduces viscosity, allowing for the production of shear-thinning dispersions that remain flowable and pumpable, enabling efficient reduction of organic peroxide particle size to less than 10 µm without the need for frequent interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the particle size of water-insoluble solid peroxide is reduced to below 10 μm to improve performance, then the dispersion becomes extremely viscous and difficult to handle
Solution Approach 1:
A surfactant is introduced as an intermediary substance to mediate between the water-insoluble peroxide particles and the aqueous medium. The surfactant adsorbs at the particle-water interface, reducing interfacial tension and preventing excessive water absorption by the fine particles, thereby maintaining pumpable viscosity despite small particle size
Solution Approach 2:
The patent controls the water content parameter to be 40-65% by weight and optimizes the surfactant concentration to balance particle size reduction with viscosity control. By precisely controlling these parameters, the dispersion achieves both fine particle size and acceptable flow properties
2Productivity
If the concentration of organic peroxide is increased to improve efficiency, then the dispersion becomes more viscous and difficult to process
Solution Approach 1:
The surfactant acts as a lubricating intermediary between peroxide particles, preventing them from forming a rigid network structure even at high concentrations. This allows the dispersion to maintain pourability and pumpability while containing 35% or more organic peroxide by weight
Solution Approach 2:
The patent creates a composite dispersion system combining peroxide particles, water, and surfactant in specific proportions. This composite structure leverages the surfactant's amphiphilic nature to achieve synergistic effects, where the combination allows high peroxide loading while maintaining fluidity
3Manufacturing precision
If milling is continued to reduce particle size, then the dispersion forms thick pastes requiring interruption to soften
Solution Approach 1:
The surfactant enables continuous milling operation by preventing the dispersion from thickening into an unmillable paste. The surfactant continuously adsorbs at particle interfaces during milling, maintaining fluidity and allowing the milling process to proceed without interruption to achieve fine particle sizes
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 significantly improves processing efficiency by maintaining the dispersions as free-flowing liquids during milling, reducing the time required to achieve desired particle sizes and minimizing the risk of peroxide decomposition, while allowing for higher concentrations of organic peroxides in aqueous dispersions.
Implementation Method 1
b) a surfactant which is a polyglyceryl ester of one or more C6-C12 fatty acids
Implementation Method 2
The pastes are shear thinning or sufficiently flowable so as to be pumpable/pourable
Data Source
AI summary
The viscosity of aqueous dispersions of normally solid organic peroxides may be advantageously lowered through the use of surfactants which are polyglyceryl esters of C6-C12 fatty acids. The reduction in viscosity facilitates milling the peroxides to reduce particle size and also provides dispersions of small particle size peroxides which may be readily poured or pumped.