Polycarboxylic Acid Copolymer Production via Redox Initiation
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Solution Overview
Problem
The production of polycarboxylic acid-based copolymers incorporating unsaturated polyalkylene glycol ether-based monomers and unsaturated carboxylic acid-based monomers faces challenges in achieving desired copolymerization ratios due to low copolymerization properties, leading to decreased polymer purity and increased production costs, which affects the performance of cement admixtures.
Innovation Solution
A production method involving the polymerization of unsaturated polyalkylene glycol ether-based monomers and unsaturated carboxylic acid-based monomers using peroxides and reductants as initiators, while controlling the pH to 3 or less in the presence of organic sulfonic acids, to enhance copolymerization properties and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unsaturated polyalkylene glycol ether-based monomer is used in copolymerization, then water-reducing performance of cement admixture is improved, but copolymerization property deteriorates leading to low polymer purity
Solution Approach 1:
The patent applies parameter changes by modifying the polymerization conditions, specifically using a water-soluble initiator system (potassium persulfate and sodium bisulfite) and controlling the polymerization temperature at 50-70°C. These parameter changes enable successful copolymerization of unsaturated polyalkylene glycol ether-based monomers with unsaturated carboxylic acid-based monomers, achieving both desired copolymerization ratio and high water-reducing performance.
2Manufacturing precision
If copolymerization is performed to achieve desired copolymerization ratio, then polymer quality is improved, but production cost increases due to low concentration condition
Solution Approach 1:
The patent changes the concentration parameter by performing copolymerization at relatively high monomer concentrations (total monomer content 30-80% by mass) instead of low concentration conditions. This is made possible by using a water-soluble initiator system and controlling temperature at 50-70°C, which enables efficient polymerization at higher concentrations, thereby reducing production costs while maintaining desired copolymerization ratio.
Solution Approach 2:
The patent substitutes the conventional organic-soluble initiator system with a water-soluble initiator system (potassium persulfate and sodium bisulfite). This substitution enables the use of water as the polymerization medium, allowing for easier handling, simpler purification processes, and reduced production costs while achieving the desired copolymerization ratio.
3Device complexity
If conventional copolymerization method is used, then production process is simple, but copolymerization property of unsaturated polyalkylene glycol ether-based monomer is insufficient
Solution Approach 1:
The patent applies parameter changes by introducing a specific initiator system (potassium persulfate as oxidant and sodium bisulfite as reductant) and controlling the polymerization temperature at 50-70°C. These parameter changes significantly improve the copolymerization property of unsaturated polyalkylene glycol ether-based monomers, enabling successful incorporation into the copolymer structure while maintaining a relatively simple aqueous-phase polymerization process.
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 method results in a high-performance cement admixture with reduced production costs and improved polymer quality, enabling unprecedented performance in cement compositions.
Implementation Method 1
monomer components including the monomer (a) and the monomer (b) are polymerized using a peroxide and a reductant as polymerization initiators
Implementation Method 2
polymerized using a peroxide and a reductant as polymerization initiators
Implementation Method 3
the pH during polymerization is controlled to 3 or less in the presence of a pH adjustor
Data Source
AI summary
The present application relates to a production method for a polycarboxylic acid-based copolymer including a structural unit (I) derived from an unsaturated polyalkylene glycol ether-based monomer (a) and a structural unit (II) derived from an unsaturated carboxylic acid-based monomer (b), in which monomer components including the monomer (a) and the monomer (b) are polymerized using a peroxide and a reductant as polymerization initiators in combination while the pH during polymerization is controlled to 3 or less in the presence of a pH adjustor. The present application also relates to a polycarboxylic acid-based copolymer for a high-performance cement admixture including a structural unit (I) derived from an unsaturated polyalkylene glycol ether-based monomer (a) and a structural unit (II) derived from an unsaturated carboxylic acid-based monomer (b), and a nonpolymerizable organic sulfonic acid having a molecular weight of 300 or less and/or a salt thereof.