Phosphate Emulsion Binder for Stable High-Phosphorus Dispersions
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Solution Overview
Problem
Existing polymer compositions containing more than 5 wt.% of phosphorous-containing monomers suffer from stability issues during emulsion polymerization, leading to coagulation and poor storage stability, which limits their effectiveness as flame retardants.
Innovation Solution
A monomer composition comprising 5 wt.% to 15 wt.% of a phosphorous-containing monomer, 70 wt.% to 95 wt.% of straight-chained or branched C1-18 alkyl (meth)acrylates, and a base such as 2-amino-2-methyl-1-propanol in a specific molar ratio, which stabilizes the polymerization process and prevents coagulation, resulting in stable polymer dispersions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the content of phosphorous-containing monomer is increased to enhance flame-retardant performance, then the flame-retardant properties are improved, but the stability during emulsion polymerization deteriorates, leading to coagulation and poor storage stability
Solution Approach 1:
The patent applies parameter changes by carefully controlling the pH value within the specific range of 4.0-6.0 and maintaining the phosphorous-containing monomer content within 5-20 wt% of total monomers. These parameter optimizations enable the system to achieve both high flame-retardant performance and stable emulsion polymerization without coagulation, resolving the contradiction between improved flame resistance and maintained stability.
2Object-affected harmful factors
If the content of phosphorous-containing monomer is increased to improve flame-retardant performance, then the flame-retardant properties are enhanced, but the coagulation during polymerization increases, leading to poor product quality
Solution Approach 1:
The patent utilizes parameter changes by optimizing the pH value to 4.0-6.0 and controlling the phosphorous-containing monomer content at 5-20 wt% of total monomers. These parameter adjustments prevent coagulation during polymerization while maintaining high flame-retardant properties, effectively resolving the contradiction between enhanced flame resistance and reduced coagulation.
3Object-affected harmful factors
If the content of phosphorous-containing monomer is increased to enhance flame-retardant performance, then the flame-retardant properties are improved, but the storage stability deteriorates, limiting effectiveness
Solution Approach 1:
The patent applies parameter changes by maintaining the pH value within 4.0-6.0 and controlling the phosphorous-containing monomer content at 5-20 wt% of total monomers. These optimized parameters ensure both enhanced flame-retardant performance and improved storage stability, resolving the contradiction between higher flame resistance and longer storage stability.
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 solution enables the production of stable polymer dispersions with high phosphorous content, maintaining stability for at least one month at 60°C and enhancing flame-retardant performance.
Implementation Method 1
a base selected from the group consisting of ammonia and 2-amino-2-methyl-1-propanol being present in the composition in a molar ratio of (a) to (d) = 1:1.1 to 1:1.2
Implementation Method 2
a process for preparing a polymer dispersion from said monomer composition
Implementation Method 3
During the emulsion polymerization, HEMA-P is copolymerized with several other unsaturated monomers by a radical polymerization
Implementation Method 4
The binder consists of a dispersion of an acrylic copolymer (small particles) in water. The dispersion is stabilized by surfactants used already during the emulsion polymerization
Data Source
AI summary
The present invention relates to a monomer composition comprising 5 wt.% to 15 wt.% of a phosphorus-containing monomer and a process for preparing a polymer dispersion from said monomer composition.