Super Absorbent Polymer Droplet UV Curing
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Solution Overview
Problem
Existing methods for producing super absorbent polymers (SAP) face challenges in controlling particle diameter and minimizing the recycling process, leading to deteriorated properties and increased complexity due to the formation of unnecessary particle size distributions and the need for multiple pulverization and drying steps.
Innovation Solution
A method involving spraying a monomer composition with a water-soluble ethylenic unsaturated monomer and a polymerization initiator onto a hydrophobic substrate, followed by UV polymerization on a continuously moving reactor with a slightly hydrophilic surface, allowing for the formation of fine droplet particles with controlled size and distribution, reducing the need for additional processing steps and maintaining the properties of the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the prior UV polymerization method is used to produce SAP, then the polymerization can be carried out quickly, but the particle diameter cannot be controlled properly and fine particles are generated requiring recycling processes
Solution Approach 1:
The invention divides the monomer composition into fine droplets (average diameter 5-50 μm) before polymerization by spraying through a nozzle. This segmentation of the liquid monomer mixture into discrete droplet particles enables controlled polymerization and prevents the formation of excessive fine particles, thereby resolving the contradiction between fast polymerization and particle diameter control.
Solution Approach 2:
The invention performs preliminary droplet formation by spraying the monomer composition onto a conveyor belt before UV irradiation. This preliminary action of creating uniformly sized droplets ensures that when polymerization occurs, the particles maintain consistent size without requiring subsequent recycling processes to remove fine particles.
2Manufacturing precision
If the prior method of gel-sizing, drying, and sizing is applied repeatedly to control particle diameter, then the particle size distribution can be adjusted, but the SAP properties deteriorate and the process becomes complicated
Solution Approach 1:
The invention performs preliminary droplet formation with controlled size distribution before polymerization by spraying the monomer composition through a nozzle onto a conveyor belt. This preliminary sizing action eliminates the need for subsequent gel-sizing and pulverizing processes, preventing property deterioration while achieving the desired particle size distribution in one step.
3Ease of manufacture
If the monomer composition is fed in liquid phase to a 2-dimensional curing system, then the polymerization can proceed, but the thickness is limited by light transmittance
Solution Approach 1:
The invention segments the liquid monomer composition into fine droplets (average diameter 5-50 μm) before polymerization. This segmentation transforms the thick liquid layer into numerous thin droplets, allowing UV light to penetrate effectively throughout each droplet and enabling polymerization of compositions that would be too thick for conventional 2-dimensional curing systems.
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 approach enables the production of SAP with improved uniformity and narrow particle diameter distribution, simplifying the drying and pulverizing processes, minimizing fine powder generation, and maintaining the product's properties, thus enhancing the efficiency and economic viability of the SAP production process.
Implementation Method 1
spraying said monomer composition on a substrate having a hydrophobic surface connected with a polymerization reactor to prepare a monomer mixture of fine droplet
Implementation Method 2
polymerizing said monomer mixture of fine droplet on a continuously moving polymerization reactor with UV rays to prepare a fine hydrogel polymer
Data Source
AI summary
The present invention relates to a method of preparing a super absorbent polymer (SAP), and more specifically to a method of preparing a SAP including the steps of spraying the monomer composition on a substrate having a hydrophobic surface of a certain tan angle and carrying out a UV polymerization on a polymerization reactor having a slightly hydrophilic surface. The present invention can improve the conversion rate of polymerization because the shape of the monomer solution is changed from prior sheet form to droplet form so that UV rays reach the deeper layer of the droplets, can minimize or simplify the recycling process because it is easy to control the particles of the prepared polymer, and can provides the SAP of high caliber by narrowing the particle diameter distribution and improving the uniformity.