Super Absorbent Polymer Preparation Reducing Fine Powder
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Solution Overview
Problem
The conventional preparation method of super absorbent polymers generates a significant amount of fine powder, which deteriorates the physical properties of the final product and increases energy consumption and equipment load due to the need for reassembly and drying processes.
Innovation Solution
A method involving the cross-linking polymerization of a water-soluble ethylene-based unsaturated monomer with an internal cross-linking agent and polymerization initiator, followed by mixing with a carboxylic acid-based additive, pulverization, and drying using a paddle-type dryer to reduce fine powder generation and improve particle size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the hydrogel polymer is dried and then pulverized into polymer particles, then the super absorbent polymer can be obtained in particle form, but a large amount of fine powder is generated which deteriorates physical properties
Solution Approach 1:
The patent applies preliminary action by mixing the hydrogel polymer with a surfactant solution before drying. This pre-treatment prevents fine powder generation during subsequent pulverization by reducing surface tension and improving particle coherence, thereby resolving the contradiction between obtaining particles and avoiding fine powder.
Solution Approach 2:
The surfactant acts as an intermediary substance between the hydrogel polymer and the environment. It coats the polymer particles and modifies their surface properties, preventing excessive fragmentation during drying and pulverization, thus reducing fine powder generation while maintaining particle form.
2Loss of substance
If fine powder is reassembled by mixing with water and agglomerating, then the fine powder can be reused, but energy consumption during drying increases and device load increases
Solution Approach 1:
The patent extracts the problematic step of water-based fine powder reassembly from the conventional process. By using surfactant solution instead of water for agglomeration, it eliminates the need for subsequent drying of fine powder, thereby removing the energy consumption burden while still achieving fine powder reuse.
Solution Approach 2:
The patent changes the parameter of the liquid medium from water to surfactant solution. This parameter change modifies the surface tension and wetting properties, enabling fine powder agglomeration without requiring extensive drying, thus reducing energy consumption while maintaining material reuse.
3Quantity of substance
If the super absorbent polymer particles are contained in multiple layers in pulpless hygienic materials, then the absorption capacity can be increased, but the requirement for fast absorption rate and high absorption performance becomes more stringent
Solution Approach 1:
The patent applies preliminary action by treating the hydrogel polymer with surfactant solution before particle formation. This pre-treatment ensures that the particles maintain their structural integrity and porosity, which is crucial for maintaining high absorption performance and fast absorption rate when used in multiple layers.
Solution Approach 2:
The surfactant serves as an intermediary that preserves the hydrogel polymer's internal structure during processing. It prevents collapse of the porous network, ensuring that the particles retain their high absorption capacity and fast absorption kinetics even when densely packed in multiple layers.
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 significantly reduces fine powder production, enhances the absorption performance of super absorbent polymers, and improves manufacturing efficiency by suppressing agglomeration and energy consumption.
Implementation Method 1
mixing the hydrogel polymer with a carboxylic acid-based additive, followed by pulverization to prepare a pulverized product containing hydrous super absorbent polymer particles
Implementation Method 2
drying the pulverized product with a paddle-type dryer to prepare super absorbent polymer particles
Implementation Method 3
a step of polymerizing a monomer to prepare a hydrogel polymer containing a large amount of moisture
Data Source
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AI summary
The present disclosure relates to a preparation method of a super absorbent polymer. More specifically, it relates to a preparation method of a super absorbent polymer capable of significantly reducing the amount of fine powder generated during the process by mixing a hydrogel polymer with an additive having a specific structure, pulverizing it, and then drying it with a paddle-type dryer.