Super Absorbent Resin Particle Aggregation via Moisture Control
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Solution Overview
Problem
Existing methods for preparing super absorbent polymers (SAPs) face challenges in achieving high water holding capacity and fine powder aggregation strength without a decrease in absorbing power under pressure and penetrability, particularly in hygiene products like baby diapers, where fine powders can be problematic due to mobility and performance issues.
Innovation Solution
A method involving thermal or photo polymerization of ethylene-based unsaturated monomers, followed by drying and milling to create a reassembled SAP with a specific particle size distribution, where the second hydrogel polymer has higher water holding capacity and is mixed with fine powders to enhance aggregation strength and maintain absorbing power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fine powders are excluded or reassembled to normal particle size, then particle mobility and performance issues are reduced, but aggregation strength decreases and particles may be easily crushed again
Solution Approach 1:
The patent controls the moisture content of fine powders within a specific range (5-20 wt%) to optimize both aggregation strength and particle stability. By precisely adjusting this physical parameter, the reassembled particles achieve sufficient binding strength while maintaining resistance to crushing during handling and use.
Solution Approach 2:
The patent creates composite particles by reassembling fine powder with larger particles or unreacted monomer beads. This composite structure combines the high surface area of fine powders with the structural integrity of larger particles, achieving both good aggregation strength and resistance to crushing while maintaining high water absorption capacity.
2Strength
If moisture content of fine powders is increased to raise aggregation strength, then aggregation strength improves, but handling difficulty increases
Solution Approach 1:
The patent identifies and controls the moisture content parameter within an optimal range (5-20 wt%) to balance aggregation strength and handling ease. This precise parameter control ensures that the material has sufficient moisture for strong aggregation during processing, but not excessive moisture that would cause handling difficulties or clumping.
3Quantity of substance
If fine powders are included in the final product, then water holding capacity is maintained, but particle mobility and performance decrease
Solution Approach 1:
The patent creates composite particles by combining fine powder with larger particles or unreacted monomer beads. This composite structure retains the high water absorption capacity of fine powders while the larger component provides structural stability and prevents particle mobility issues, achieving both high water holding capacity and particle stability.
Solution Approach 2:
The patent applies different properties to different parts of the particle structure. The fine powder component provides high water absorption capacity, while the larger particle component or surface coating provides structural stability and prevents mobility issues. This local differentiation of properties allows both requirements to be satisfied simultaneously.
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 SAPs with high water holding capacity, fine powder aggregation strength, and maintained absorbing power under pressure and penetrability, addressing the issues of fine powder mobility and performance in hygiene products.
Implementation Method 1
preparing a first hydrogel polymer by carrying out a thermal polymerization or photo polymerization of a monomer composition including a water-soluble ethylene-based unsaturated monomer and a polymerization initiator
Implementation Method 2
preparing a first hydrogel polymer by carrying out a thermal polymerization or photo polymerization of a monomer composition including a water-soluble ethylene-based unsaturated monomer and a polymerization initiator
Implementation Method 3
Super absorbent polymer (SAP) is a synthetic polymer material having a function of absorbing water about 5 hundred times to about 1 thousand times of the weight of itself
Implementation Method 4
preparing a first hydrogel polymer by carrying out a thermal polymerization or photo polymerization of a monomer composition including a water-soluble ethylene-based unsaturated monomer
Data Source
AI summary
The present invention relates to a method of preparing a super absorbent polymer (SAP) and a SAP prepared therefrom. The method of the present invention includes the steps of preparing a first hydrogel polymer by carrying out a thermal polymerization or photo polymerization of a monomer composition including a water-soluble ethylene-based unsaturated monomer and a polymerization initiator; preparing a second hydrogel polymer by carrying out a thermal polymerization or photo polymerization of a monomer composition including a water-soluble ethylene-based unsaturated monomer and a polymerization initiator; drying and milling the first hydrogel polymer and distributing the first hydrogel polymer into a fine powder having a particle diameter below 150µm and a base resin having a particle diameter of 150µm to 850µm; fabricating a reassembled body of the fine powder by mixing the fine powder and the second hydrogel polymer; and mixing the reassembled body of the fine powder with the first hydrogel polymer, and drying and milling the same, wherein the second hydrogel polymer has higher water holding capacity than the first hydrogel polymer. According to the present invention, the SAP having high water holding capacity and fine powder aggregation strength without decrease of absorbing power under pressure and penetrability can be obtained.