Superabsorbent Resin Particle Size Distribution and Surface Crosslinking
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Solution Overview
Problem
Conventional superabsorbent polymer resins have limitations in absorption rate and water permeability, despite advancements in their development for various applications.
Innovation Solution
A method involving the preparation of superabsorbent polymer resins with a specific particle size distribution and surface crosslinking, where agglomerated fines are increased to 15% by weight, and the content of larger particles is adjusted to improve absorption rate and permeability, involving steps like thermal or photo-polymerization, drying, milling, classification, blending, and surface crosslinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional superabsorbent polymer resins are used, then absorption capacity is achieved, but absorption rate and water permeability are limited
Solution Approach 1:
The patent applies parameter changes by precisely controlling particle size distribution parameters and agglomerated fines content (15-30 wt%) to simultaneously improve absorption rate and water permeability. The particle size is controlled within specific ranges (600-850 μm, 300-600 μm, 150-300 μm) to optimize both speed and reliability parameters.
Solution Approach 2:
The patent creates a composite particle structure by blending normal particles with agglomerated fines (15-30 wt%). This composite approach combines particles of different sizes and structures to achieve both high absorption rate and improved water permeability, resolving the contradiction between speed and reliability.
2Speed
If particle size distribution is optimized to improve absorption rate, then permeability may be compromised
Solution Approach 1:
The patent uses parameter changes by defining specific particle size ranges (600-850 μm, 300-600 μm, 150-300 μm) and agglomerated fines content (15-30 wt%) to simultaneously achieve high absorption rate and maintained permeability, resolving the contradiction between speed and ease of manufacture.
3Reliability
If surface crosslinking is performed to improve absorption properties, then particle structure and permeability may be affected
Solution Approach 1:
The patent applies local quality by performing surface crosslinking only on the outer layer of particles rather than throughout the entire particle structure. This localized treatment improves absorption properties while preserving the internal particle structure and maintaining permeability, thus resolving the contradiction between reliability and device complexity.
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 resulting superabsorbent polymer resins exhibit significantly improved absorption rate and permeability, as demonstrated by reduced absorption time and enhanced saline flow conductivity compared to conventional resins.
Implementation Method 1
preparing a hydrogel phase polymer by thermal- or photo-polymerizing a composition comprising an acrylic acid monomer and a polymerization initiator
Implementation Method 2
preparing a hydrogel phase polymer by thermal- or photo-polymerizing a composition comprising an acrylic acid monomer and a polymerization initiator
Implementation Method 3
mixing and reassembling the particles less than 450 μm in size with water at a weight part ratio of 100 : 50 to 300 for 30 seconds to 5 minutes in a rotating mixer
Implementation Method 4
mixing and reassembling the particles less than 450 μm in size with water at a weight part ratio of 100 : 50 to 300 for 30 seconds to 5 minutes in a rotating mixer
Implementation Method 5
The absorption mechanism of SAPs is governed by interactions of various factors including the osmotic pressure attributed to a difference in the electric attraction shown by a charge of a polymer electrolyte
Implementation Method 6
the affinity between water and the polymer electrolyte
Implementation Method 7
the expansion restraint due to cross-link bonds
Data Source
Figure 1
Figure 2
AI summary
Disclosed herein are a superabsorbent polymer resin comprising agglomerated particles with a size of 450 µm or less, and a method for preparing the same. The superabsorbent polymer resin exhibits significant improvement in absorption rate and permeability.