Silylated Polymer Backmixing for Viscosity Control

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Solution Overview

Problem

Conventional processes for producing silylated polymers face issues such as viscosity creep, variability in mechanical properties, and the need for large excesses of silylating agents, leading to inefficiencies and unwanted color formation due to incomplete reactions and unreacted functional groups.

Innovation Solution

A continuous process involving a silylation step with backmixing, where a prepolymer is reacted with a silylating agent in a tubular reaction unit, with a portion of the silylated polymer composition being backmixed to adjust upstream process parameters, and optionally including stabilization or quenching steps to enhance reaction completion and reduce color formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a conventional continuous process is used to react prepolymer with silylating agent, then production efficiency is maintained, but the reaction does not reach completion resulting in unreacted functional groups and viscosity creep

Engineering Contradiction:

Improveproduction efficiencyVSAvoidreaction completion

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The continuous process is segmented into multiple reaction zones or stages, allowing the reaction to progress through different conditions. This enables the reaction to reach completion while maintaining continuous operation, resolving the conflict between productivity and reaction completeness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The process maintains continuous operation throughout the reaction sequence, ensuring uninterrupted production while using backmixing to ensure complete reaction. The continuous action is preserved while eliminating the harmful effect of incomplete reaction through strategic recirculation.

Inventive Principle:

Principle #20Continuity of useful action

2Reliability

If large excesses of silylating agent are used to force reaction completion, then reaction completeness improves, but process efficiency decreases and unwanted color formation increases

Engineering Contradiction:

Improvereaction completenessVSAvoidprocess efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The backmixing mechanism creates a feedback loop where unreacted material is recirculated back to the reaction zone. This feedback ensures complete reaction without requiring excess reagents, eliminating the trade-off between completeness and efficiency.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The process changes parameters such as residence time, temperature, or mixing conditions in the backmixing zone to optimize reaction completion. By adjusting these parameters strategically, the reaction reaches completion using stoichiometric amounts of reagents rather than large excesses.

Inventive Principle:

Principle #35Parameter changes

3Speed

If conventional processing conditions are used, then production speed is maintained, but color formation increases due to incomplete reactions and unreacted groups

Engineering Contradiction:

Improveproduction speedVSAvoidcolor formation

Core Design Contradiction:

SpeedVSObject-generated harmful factors

Solution Approach 1:

The backmixing process converts what would normally be waste (unreacted material leaving the reactor) into a beneficial resource by recirculating it for further reaction. This eliminates the source of color formation (unreacted groups) while maintaining production speed.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 ensures reduced variability in mechanical properties, minimizes the use of silylating agents, prevents viscosity creep, and reduces color formation, resulting in a more efficient and stable silylated polymer production process.

Implementation Method 1

Backmixing delivers at least a portion of the silylated polymer composition upstream to adjust an upstream process parameter

Methodology Applied

Scientific EffectBackmixing:

Implementation Method 2

a prepolymer having reactive functional groups is reacted with a silylating agent, having groups reactive with the prepolymer, to produce a silylated polymer

Methodology Applied

Scientific EffectSilylating reaction: Chemical Bonding

Data Source

PatentUS10336857B2Process for the preparation of silylated polymers employing a backmixing step

Publication Date: 2019.07.02 KOOKMIN BANK NEW YORK BRANCH AS ADMINISTATIVE AGENT

AI summary

A continuous process for preparing a silylated polymer comprising a silylation step where a prepolymer having reactive functional groups, a first intermediate product, is reacted continuously with a silylating agent in an endcapping tubular reaction unit to form a second intermediate product, and where at least a portion of the second intermediate product is backmixed continuously with the first intermediate product to form the silylated polymer. The continuous process may further comprise a stabilization step, a quenching step or both a stabilization step and a quenching step.