Superabsorbent Polymer Aggregation Strength via Controlled Reassembly
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Solution Overview
Problem
Super absorbent polymer particles with fine powder aggregates exhibit reduced physical properties and are undesirable in hygiene products due to low aggregation strength, leading to reassembly issues and potential re-crushing into fine powder.
Innovation Solution
A method involving thermal or photopolymerization of a monomer composition, followed by classification, reassembly with controlled water mixing, and surface cross-linking to enhance the aggregation strength of super absorbent polymer particles, maintaining water retention capacity and absorbency under pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the hydrogel polymer is pulverized to produce fine powder, then the polymer can be processed and classified, but the fine powder has low aggregation strength and may be crushed again during handling
Solution Approach 1:
The patent applies parameter changes by controlling the water temperature (5-30°C) and water content (50-200 parts by weight per 100 parts of fine powder) during the reassembly process. These parameter adjustments optimize the aggregation strength of fine powder particles while maintaining their classified size distribution, preventing re-crumbling during subsequent handling.
Solution Approach 2:
Water serves as an intermediary substance in the reassembly process. By adding controlled amounts of water at specific temperatures to the fine powder, the water acts as a binding medium that enhances aggregation strength without compromising the particle size classification achieved during pulverization.
2Strength
If reassembly is performed to aggregate fine powder, then aggregation strength may improve, but the polymer may be crushed into fine powder again due to low aggregation strength
Solution Approach 1:
The patent utilizes parameter changes by optimizing water temperature (5-30°C) and water content (50-200 parts by weight per 100 parts of fine powder) to achieve maximum aggregation strength. These controlled parameter adjustments ensure that aggregated particles maintain their integrity and do not crumble into fine powder during subsequent handling and processing.
Solution Approach 2:
The reassembly process is performed as a preliminary action before final product formation. By conducting reassembly under optimized conditions (controlled water temperature and content) before subsequent processing steps, the fine powder particles are pre-aggregated with sufficient strength to withstand handling without re-crumbling.
3Strength
If surface cross-linking is performed to enhance aggregation strength, then fine powder stability improves, but water retention capacity and absorbency under pressure must be maintained
Solution Approach 1:
Surface cross-linking applies local quality changes by modifying only the surface layer of the polymer particles while preserving the internal structure. This localized modification enhances aggregation strength at the particle surface without significantly affecting the bulk water retention capacity and absorbency properties of the superabsorbent polymer.
Solution Approach 2:
The patent creates a composite structure through surface cross-linking, where the cross-linked surface layer provides enhanced mechanical strength and aggregation stability, while the inner polymer matrix maintains its water absorption and retention capabilities. This composite approach allows simultaneous improvement of strength and preservation of water-related properties.
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 improves the aggregation strength of super absorbent polymer particles, reducing the occurrence of fine powder reassembly and maintaining water retention and absorbency, thus enhancing their physical properties and handling in hygiene products.
Implementation Method 1
carrying out a thermal polymerization or a photopolymerization of a monomer composition
Implementation Method 2
carrying out a thermal polymerization or a photopolymerization of a monomer composition
Implementation Method 3
A super absorbent polymer (SAP) is a synthetic polymeric material capable of absorbing water five hundred up to one thousand times the mass of its own
Implementation Method 4
to form a hydrogel polymer
Data Source
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AI summary
The present invention relates to a manufacturing method of a super absorbent polymer. The manufacturing method of a super absorbent polymer according to the present invention may include: carrying out a thermal polymerization or a photopolymerization of a monomer composition including a water-soluble ethylene-based unsaturated monomer and a polymerization initiator to form a hydrogel polymer; drying the hydrogel polymer; pulverizing the dried polymer; classifying the pulverized polymer into a fine powder having a particle diameter of less than 150 µm and a polymer having a particle diameter of 150 to 850 µm according to the particle diameter; performing reassembly by mixing and wetting the fine powder with 5 to 30°C water in a content of 50 to 200 parts by weight with respect to 100 parts by weight of the fine powder having a particle size of 150 µm or less, to form a fine powder reassembly; and mixing the polymer having a particle diameter of 150 to 850 µm with the fine powder reassembly, followed by surface cross-linking, and may obtain a super absorbent polymer having a high fine aggregation strength.