Super Absorbent Polymer Coarse Particle Preparation
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Solution Overview
Problem
The generation of fine powder during the pulverization of super absorbent polymers leads to environmental issues and increased process loads, while increasing the surface area for higher absorption rates weakens structural strength, necessitating a method to reduce fine powder generation while maintaining physical properties.
Innovation Solution
A method involving crosslinking polymerization of water-soluble ethylenically unsaturated monomers, followed by drying and controlled pulverization to produce particles with a diameter of 710 μm or more, reducing fine powder generation through secondary pulverization, thereby improving the preparation of super absorbent polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the surface area of super absorbent polymer is increased to exhibit fast absorption rate, then the absorption rate is improved, but the structural strength becomes weak and fine powder is generated in the coarse pulverizing process
Solution Approach 1:
The patent changes the particle size parameter to 710 μm or more, which is significantly larger than conventional sizes. This parameter change reduces the surface area to volume ratio, thereby maintaining structural strength while still providing adequate absorption performance. The coarse particle size prevents the structural weakness and fine powder generation associated with high-surface-area fine particles.
Solution Approach 2:
Instead of increasing surface area by reducing particle size (conventional approach), the patent inverts the approach by using large particle sizes (710 μm or more) and achieving absorption performance through other means such as porous internal structure or surface modification. This inversion resolves the contradiction by decoupling absorption rate from particle size reduction.
2Speed
If the surface area is increased to exhibit fast absorption rate, then the absorption rate is improved, but fine powder is generated in the coarse pulverizing process
Solution Approach 1:
The patent specifies particle diameter of 710 μm or more, which is a significant parameter change from conventional fine particles. This coarse particle size prevents fine powder generation during pulverizing while maintaining absorption functionality through the large particle's internal structure or surface properties.
Solution Approach 2:
The patent inverts the conventional wisdom that fine particles are needed for fast absorption. By using coarse particles (710 μm or more), the patent eliminates fine powder generation problems while achieving absorption performance through alternative mechanisms such as porous structure or surface modification of the coarse particles.
3Quantity of substance
If super absorbent polymer particles are contained in multiple layers in hygienic materials, then the absorption capacity is improved, but the structural strength of each particle becomes weak
Solution Approach 1:
The patent uses particle diameter of 710 μm or more, which provides sufficient mechanical strength to withstand multiple layer configurations in hygienic materials. The large particle size with appropriate strength can be stacked in multiple layers without breaking, while the total absorption capacity is achieved through the quantity and arrangement of these strong coarse particles.
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 method effectively reduces fine powder generation during the pulverization process, minimizing environmental impact and process loads while maintaining the physical properties and absorption capabilities of the super absorbent polymers.
Implementation Method 1
performing crosslinking polymerization of a water-soluble ethylenically unsaturated monomer having an acidic group of which at least a part is neutralized, in the presence of an internal crosslinking agent and a polymerization initiator to form a hydrogel polymer containing a first crosslinked polymer
Implementation Method 2
Super absorbent polymer (SAP) is a synthetic polymer material capable of absorbing moisture from about 500 to about 1,000 times its own weight
Data Source
AI summary
The method for preparing a super absorbent polymer according to the present disclosure reduces the generating amount of a fine powder while realizing the same particle size distribution in the process of pulverizing the dried polymer, thereby reducing the load of the fine powder reassembly, drying, pulverizing and classifying steps.