Reactive Surfactant for Emulsion Polymerization
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Solution Overview
Problem
Existing reactive surfactant compositions for emulsion polymerization exhibit broad distribution of alkylene oxide addition molar numbers, leading to surfactants with insufficient surface activity, resulting in large particle diameters and poor water resistance of polymer coating films, necessitating high concentrations for effective micronization.
Innovation Solution
A reactive surfactant composition with a specific alkyleneoxy group distribution, represented by formula (1), is used for emulsion polymerization, where the average addition molar numbers of alkyleneoxy and ethyleneoxy groups are controlled to achieve optimal surface activity, reducing particle diameter and surfactant concentration while enhancing water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional reactive surfactants with broad alkylene oxide distribution are used, then emulsion polymerization can proceed, but the particle diameter becomes large and water resistance deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the alkylene oxide addition molar number distribution in the reactive surfactant. Specifically, it limits the proportion of components with addition molar numbers outside the range of (m-3) to (m+2) to less than 30%, thereby optimizing surface activity and achieving both small particle diameter and excellent water resistance in the polymer coating film.
Solution Approach 2:
The patent creates a composite surfactant system by combining multiple components with specific alkylene oxide chain lengths in a controlled distribution. This composite approach ensures optimal balance between hydrophobic and hydrophilic properties, enabling effective emulsion polymerization with improved particle size control and water resistance.
2Manufacturing precision
If high concentration of reactive surfactant is used to achieve micronization, then particle diameter decreases, but surfactant usage increases and cost rises
Solution Approach 1:
The patent changes the quality parameter of the surfactant from broad distribution to narrow controlled distribution of alkylene oxide addition molar numbers. This enhancement in surfactant efficiency allows achieving the same micronization effect at lower concentrations, reducing the required surfactant amount while maintaining small particle diameter.
Solution Approach 2:
By optimizing the surfactant structure to achieve higher efficiency, the patent reduces the quantity of surfactant needed, effectively replacing high-concentration requirements with a more efficient low-concentration formulation, thereby reducing material consumption and cost.
3Stability of the object's composition
If emulsifier is used in emulsion polymerization to ensure stability, then polymerization proceeds well, but water resistance and adhesiveness of the coating film deteriorate
Solution Approach 1:
The patent changes the chemical structure parameters of the emulsifier by controlling the alkylene oxide addition molar number distribution. This structural optimization allows the emulsifier to provide sufficient stability during polymerization while minimizing negative impact on the water resistance of the final coating film.
Solution Approach 2:
The patent extracts the essential function of the emulsifier (stability during polymerization) while removing the harmful effect (poor water resistance). By using a reactive surfactant with controlled alkylene oxide distribution, the emulsifier performs its stabilizing function but leaves minimal residual impact on the coating film's water resistance after polymerization completes.
4Ease of manufacture
If conventional surfactants are used, then emulsion polymerization can be performed, but the polymer coating film shows poor water resistance and weather resistance
Solution Approach 1:
The patent applies parameter changes to the surfactant's alkylene oxide addition molar number distribution, constraining it within a narrow range around the average value m. This parameter control optimizes the surfactant's performance, enabling easy emulsion polymerization while producing coating films with excellent water resistance and weather resistance.
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 reactive surfactant composition effectively micronizes the particle diameter of polymer emulsions, reduces surfactant usage, and produces polymer coating films with improved water resistance, suitable for various applications including aqueous coating materials and pressure-sensitive adhesives.
Implementation Method 1
a reactive surfactant composition for emulsion polymerization containing a reactive anionic surfactant
Implementation Method 2
AO represents an alkyleneoxy group having a carbon number of 3 or more and 18 or less; EO represents an ethyleneoxy group
Data Source
AI summary
The present invention is concerned with a reactive surfactant composition for emulsion polymerization, which is able to micronize the particle diameter of a polymer emulsion and to reduce the addition amount of the reactive surfactant composition to be used. The reactive surfactant composition for emulsion polymerization of the present invention contains a reactive anionic surfactant (component A) represented by the following formula (I):wherein AO represents an alkyleneoxy group having a carbon number of 3 or more and 18 or less; EO represents an ethyleneoxy group; p represents an integer of 1 or more and 15 or less; m′ represents an integer of 0 or more; n′ represents an integer of 0 or more; M+ represents a hydrogen ion or a cation; and plural kinds of AOs may coexist.