Pre-Active Polyamide Monomer Granules for Simplified Polymerization

Solution Overview

Problem

Conventional anionic polymerization processes for producing polyamide moldings require the incorporation of catalysts and activators into molten lactam, which is complex and costly due to the need to exclude oxygen, carbon dioxide, and water to prevent premature polymerization.

Innovation Solution

A process that creates a stable monomer composition comprising lactams or lactones, a catalyst, and an activator, which can be mixed and cooled to form a ready-to-use solid composition that can be stored and polymerized later at elevated temperatures, eliminating the need for additional catalysts and activators during the molding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If catalyst and activator are added to molten lactam during reactive molding, then polymerization can occur, but the process becomes complex and costly due to the need to exclude oxygen, carbon dioxide, and water

Engineering Contradiction:

Improvepolymerization controlVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The catalyst and activator are pre-incorporated into the lactam monomer during granule production, creating a pre-active monomer composition. This preliminary action eliminates the need for separate catalyst and activator addition steps during molding, and removes the requirement for complex atmospheric control systems to exclude oxygen, carbon dioxide, and water.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention merges the monomer, catalyst, and activator into a single integrated material composition. By combining these components into one pre-formulated granulate, the process eliminates multiple handling steps and the need for complex mixing equipment and atmospheric control systems that would otherwise be required.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If catalyst and activator are incorporated into molten lactam, then polymerization can proceed, but the handling and processing become complicated requiring absolute exclusion of water

Engineering Contradiction:

Improvepolymerization rateVSAvoidhandling simplicity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The catalyst and activator are pre-incorporated into the lactam monomer during granule production, creating a pre-active monomer composition. This preliminary action eliminates the need for separate catalyst and activator addition steps during molding, and removes the requirement for complex atmospheric control systems to exclude oxygen, carbon dioxide, and water.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses a stable, pre-formulated granulate composition that can be stored and handled like conventional thermoplastics. This disposable-like approach to monomer preparation eliminates the need for complex, expensive atmospheric control equipment and simplifies handling to levels comparable with standard plastic processing.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Quantity of substance

If monomer melt is charged to molding apparatus, then lower viscosity allows higher filler loadings, but the need to add catalyst and activator during processing increases complexity

Engineering Contradiction:

Improvefiller loadingVSAvoidprocessing complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The invention merges the monomer, catalyst, and activator into a single integrated material composition. By combining these components into one pre-formulated granulate, the process eliminates multiple handling steps and the need for complex mixing equipment and atmospheric control systems that would otherwise be required.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The catalyst and activator are pre-incorporated into the lactam monomer during granule production, creating a pre-active monomer composition. This preliminary action eliminates the need for separate catalyst and activator addition steps during molding, and removes the requirement for complex atmospheric control systems to exclude oxygen, carbon dioxide, and water.

Inventive Principle:

Principle #10Preliminary action

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 process simplifies the production of high-quality polyamide moldings with low residual monomer content, allows for higher filler loadings, and reduces production costs by enabling straightforward handling and processing using standard machinery, while minimizing contamination and odor.

Implementation Method 1

ring-opening, anionic polymerization

Methodology Applied

Scientific EffectRing-opening polymerization: Chemical Bonding

Implementation Method 2

mixing of the components (M), (K), and (A), and also optionally further components, to give a monomer composition which is initially stable with respect to polymerization

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentUS10538624B2Process for producing monomer compositions and use of these for producing a polyamide molding

Publication Date: 2020.01.21 BASF SE

AI summary

A process for producing an activated monomer composition comprising at least one lactam and/or lactone, one catalyst, and one activator permits storage of the resultant monomer composition, since this is stable with respect to polymerization. Said monomer composition is used inter alia in producing a polyamide molding via ring-opening, anionic polymerization.