Polyurethane Particulate Preparation Using Inorganic Suspension Stabilizer
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Solution Overview
Problem
Existing methods for preparing polyurethane particulates result in amorphous forms, high manufacturing costs, and complex processes, with organic suspension stabilizers leading to impurity issues and pigment removal during washing.
Innovation Solution
A process using an inorganic metal compound as a suspension stabilizer to disperse compounds with isocyanate and active hydrogen groups, allowing for the production of thermoplastic and thermosetting polyurethane particulates with controlled size and form, minimizing foam generation and pigment separation during washing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If organic suspension stabilizer is used in polyurethane particulate preparation, then the particulate can be formed, but impurities are generated and pigment is removed during washing
Solution Approach 1:
The patent changes the chemical nature of the suspension stabilizer from organic to inorganic, specifically using metal salts (such as aluminum sulfate, ferric chloride, or zinc sulfate) at controlled concentrations (0.1-5% by weight). This parameter change eliminates the impurity and pigment removal issues associated with organic stabilizers while maintaining effective particulate formation during the polyurethane synthesis process.
2Ease of manufacture
If mechanical grinding is used to prepare polyurethane particulate, then solid state processing is achieved, but the particles are amorphous and additional processing is required
Solution Approach 1:
The patent applies preliminary action by incorporating the inorganic suspension stabilizer into the reaction mixture before polymerization occurs. This stabilizer pre-establishes the spherical morphology during the formation process itself, eliminating the need for subsequent mechanical grinding or shaping operations that would be required if particles were formed without such preliminary stabilization.
Solution Approach 2:
The patent utilizes phase transition principles by controlling the polymerization reaction in a suspension medium where the inorganic stabilizer facilitates uniform nucleation and growth. This results in spherical particles forming directly in the desired shape during the phase change from liquid monomer to solid polymer particulate, rather than requiring post-processing mechanical deformation.
3Reliability
If complex washing processes are used to remove organic stabilizer, then impurities can be reduced, but the process becomes complicated and costly
Solution Approach 1:
The patent employs inexpensive inorganic metal salts as suspension stabilizers that can be easily and completely removed through simple washing with water. These inorganic stabilizers serve their purpose during particle formation and then can be discarded through straightforward washing procedures, eliminating the need for complex multi-step purification processes required for organic stabilizer removal.
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 process enables the production of polyurethane particulates with uniform spherical form, stable color, and reduced manufacturing costs, maintaining desired particle size and form without additional grinding processes, and exhibiting superior scratch-resistance and solvent-resistance properties.
Implementation Method 1
a process for preparing a polyurethane particulate using a compound having at least one isocyanate group and a compound having at least one active hydrogen in the presence of a suspension stabilizer
Implementation Method 2
confirming that almost no foam is generated in a washing process by using an inorganic metal compound as the suspension stabilizer compared with an organic suspension stabilizer
Implementation Method 3
reacting the suspension solution... using a compound having at least one isocyanate group and a compound having at least one active hydrogen
Data Source
AI summary
Disclosed is a process for preparing polyurethane particulate and polyurethane particulate prepared therefrom. The polyurethane particulate has properties such that it is easy to control to a spherical form, the polyurethane particulate can be prepared in a desired particle size, the color thereof is stably exhibited, a washing process thereof is easy because almost no foam is generated in the washing process, and the preparation cost can be lowered because the particles do not lump and a separate grinding process is not needed, by using an inorganic suspension stabilizer in the manufacture process of the polyurethane particulate.