Polyester Elastic Aqueous Dispersion With Low Surfactant Bleeding
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Solution Overview
Problem
Existing aqueous dispersions of macromolecular elastic materials, such as styrene-type materials, suffer from inferior wear resistance, flex resistance, oil resistance, and weather resistance, and the methods used to produce them, including the use of organic solvents and thermal shear, pose environmental and adhesion issues.
Innovation Solution
An aqueous dispersion of a polyester-containing elastic material is developed, incorporating a non-ionic surface active agent at a specific ratio, which is emulsified within a temperature range between 40°C below and 100°C above the melting point of the material, resulting in a stable dispersion that minimizes bleeding of the surface active agent and enhances adhesiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aqueous dispersion of styrene-type elastic material is produced using conventional methods (organic solvent removal or thermal shear), then the material can be processed, but the molded article shows inferior wear resistance, flex resistance, oil resistance, and weather resistance
Solution Approach 1:
The patent changes the chemical composition parameters by substituting styrene-type elastic material with polyester-containing elastic material and adjusting the emulsifying agent composition (specific ratio of anionic to non-ionic surfactants), which fundamentally improves the molded article's resistance properties while maintaining manufacturability
Solution Approach 2:
The patent uses a composite emulsifying system combining specific anionic surfactants (e.g., alkyl sulfate, alkyl sulfonate) with non-ionic surfactants (e.g., polyethylene glycol alkyl ether) in controlled ratios, creating a synergistic effect that enhances both processing ease and final product performance
2Ease of manufacture
If organic solvents are used to dissolve macromolecular elastic material for aqueous dispersion, then the material can be processed, but significant environmental load is generated
Solution Approach 1:
The patent extracts and eliminates organic solvents from the processing system, replacing them entirely with aqueous media and surfactant-based emulsification, thereby removing the harmful environmental factor while maintaining full processability through alternative mechanisms
Solution Approach 2:
The patent introduces emulsifying agents (surfactants) as intermediary substances that mediate between the hydrophobic elastic material and hydrophilic aqueous medium, enabling dissolution and processing without requiring organic solvents
3Ease of manufacture
If thermal shear is applied to emulsify macromolecular elastic material at or above melting point, then aqueous dispersion can be achieved, but decomposition of the resin occurs
Solution Approach 1:
The patent changes the temperature parameter from high-temperature thermal shear (≥melting point) to mild temperature processing below the melting point, combined with surfactant-mediated emulsification, achieving effective dispersion without resin decomposition
4Stability of the object's composition
If emulsifying agents are used at high concentrations to achieve stable aqueous dispersion, then dispersion stability improves, but adhesiveness deteriorates
Solution Approach 1:
The patent optimizes the concentration parameter of emulsifying agents by precisely controlling the ratio of anionic to non-ionic surfactants, achieving adequate dispersion stability at lower total concentrations that preserve adhesiveness
Solution Approach 2:
The patent applies different types of surfactants (anionic and non-ionic) with complementary local functions: anionic surfactants provide primary emulsification while non-ionic surfactants enhance stability without interfering with adhesion, creating localized functional differentiation
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 a molded article with improved adhesiveness and reduced bleeding of the non-ionic surface active agent, maintaining the desirable properties of the polyester-containing elastic material, including heat resistance, flexibility, and mechanical strength.
Implementation Method 1
incorporating a non-ionic surface active agent at a specific ratio, which is emulsified within a temperature range
Implementation Method 2
emulsified within a temperature range between 40°C below and 100°C above the melting point of the material, resulting in a stable dispersion
Data Source
AI summary
The present invention provides an aqueous dispersion of a polyester-containing elastic material, the aqueous dispersion comprising an aqueous medium, a non-ionic surface active agent and a polyester-containing elastic material, wherein the aqueous dispersion comprises 1 to 20 parts by mass of the non-ionic surface active agent relative to 100 parts by mass of the polyester-containing elastic material. The present invention also provides: a method for producing an aqueous dispersion of a polyester-containing elastic material; a molded article produced from the aqueous dispersion; and a method for producing a molded article.