Super Absorbent Polymer Chopper Die Shape Control

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Solution Overview

Problem

Existing methods for preparing super absorbent polymers face a trade-off between improving absorption rate, centrifuge retention capacity, and absorbency under load, where increasing one property often decreases the others, necessitating a method that enhances all simultaneously.

Innovation Solution

A method involving the controlled shape and size of chopper die holes during coarse pulverization of a hydrous gel phase polymer, combined with surface-crosslinking, to achieve a super absorbent polymer with high centrifuge retention capacity, absorbency under load, and a favorable ratio of absorbency under load at 5 minutes to 60 minutes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If a porous structure is formed on the particle surface by using a blowing agent, then the absorption rate is improved, but the centrifuge retention capacity and absorbency under load are relatively decreased

Engineering Contradiction:

Improveabsorption rateVSAvoidcentrifuge retention capacity and absorbency under load

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent employs a porous structure formed on the particle surface of the super absorbent polymer to enhance the absorption rate. The porous structure provides increased surface area and pathways for rapid fluid uptake, directly addressing the absorption rate improvement while maintaining the polymer's capacity through controlled porosity design.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent applies different structural characteristics to different regions of the polymer particle. The surface region contains the porous structure formed by the blowing agent for rapid absorption, while the internal structure maintains high density and crosslinking for retention capacity. This local differentiation allows simultaneous optimization of both absorption rate and reliability properties.

Inventive Principle:

Principle #3Local quality

2Speed

If the surface area of the super absorbent polymer is increased to improve absorption rate, then the absorption rate is improved, but there is a limit that the centrifuge retention capacity and absorbency under load are relatively decreased

Engineering Contradiction:

Improveabsorption rateVSAvoidcentrifuge retention capacity and absorbency under load

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent transitions from considering only surface area as a two-dimensional parameter to incorporating the porous structure's three-dimensional architecture. By creating a hierarchical porous system with pores at multiple scales, the patent increases the effective surface area for absorption while maintaining particle integrity and retention capacity through the volumetric support structure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If physical properties such as absorption rate, retention capacity, and absorbency under load are improved simultaneously, then all properties are enhanced, but the trade-off relation makes this difficult to achieve

Engineering Contradiction:

Improveabsorption rate, retention capacity, and absorbency under loadVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into a single integrated process step. The blowing agent incorporation, porous structure formation, and particle shaping are achieved simultaneously during the polymerization process rather than through separate post-processing steps. This merging approach enhances all physical properties while avoiding the complexity of multiple sequential operations.

Inventive Principle:

Principle #5Merging (Combining)

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 results in a super absorbent polymer with improved centrifuge retention capacity, absorbency under load, and a favorable absorbency ratio, effectively addressing the trade-off limitations of previous technologies.

Implementation Method 1

polymerizing a water-soluble ethylene-based unsaturated monomer to form a hydrous gel phase polymer

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 2

surface-crosslinking a base polymer prepared by polymerizing a water-soluble ethylene-based unsaturated monomer

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Implementation Method 3

capable of absorbing moisture from about 500 to about 1,000 times its own weight

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 4

absorbency under load (AUL) of more than 18 g/g

Methodology Applied

Scientific EffectOsmosis: Osmosis

Data Source

PatentUS10450425B2Super absorbent polymer and method for preparing the same

Publication Date: 2019.10.22 LG CHEM LTD

AI summary

The present invention relates to a super absorbent polymer and a method for preparing the same. The present invention has features that it is possible to prepare a super absorbent resin that can have an improved centrifuge retention capacity (CRC) and a high absorbency under load (AUL) by controlling the shape and size of the chopper die holes during coarse pulverization of a hydrous gel phase polymer.