Sulfonated Graft Copolymers Reducing Homopolymer Phase Separation

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Solution Overview

Problem

Existing sulfonated graft copolymers produced by grafting sulfonate groups onto sugars result in high levels of synthetic homopolymers, leading to phase separation and reduced functionality, particularly in calcium binding, and require high amounts of synthetic monomers derived from petroleum resources.

Innovation Solution

Development of sulfonated graft copolymers with a high weight percent of saccharide components, achieved through radical graft copolymerization of synthetic monomers with hydroxyl-containing naturally derived materials like monosaccharides, disaccharides, oligosaccharides, and polysaccharides, reducing synthetic homopolymer levels and enhancing biodegradability and renewable resource utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mercaptan chain transfer agents are used to graft sulfonate groups onto sugars, then grafting occurs, but synthetic homopolymers form and phase separation occurs

Engineering Contradiction:

Improvegrafting efficiencyVSAvoidphase separation

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent removes mercaptan chain transfer agents from the grafting process. This extraction of the harmful component eliminates the mechanism that causes synthetic homopolymer formation and subsequent phase separation, while maintaining effective grafting through alternative initiation methods

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical parameters of the grafting process by substituting mercaptan chain transfer agents with alternative initiation systems. This parameter change fundamentally alters the polymerization mechanism to prevent homopolymer formation while preserving grafting efficiency

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If higher amounts of saccharide are used in the copolymer, then renewable content increases, but functionality decreases

Engineering Contradiction:

Improvesaccharide contentVSAvoidfunctionality

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent converts the previously harmful effect of high saccharide content (which caused phase separation and reduced functionality) into a benefit by eliminating mercaptan-induced homopolymer formation. This allows high saccharide content materials to maintain both renewability and functionality through improved grafting efficiency

Inventive Principle:

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

Solution Approach 2:

The patent creates a true graft copolymer composite structure where synthetic sulfonated chains are covalently bonded to saccharide backbones. This composite structure ensures that high saccharide content materials maintain functionality because the saccharide units are effectively grafted rather than merely mixed, preventing phase separation

Inventive Principle:

Principle #40Composite materials

3Reliability

If more synthetic monomers are used, then polymer performance is maintained, but environmental friendliness decreases

Engineering Contradiction:

Improvepolymer performanceVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the compositional parameters of the copolymer by reducing synthetic monomer content while maintaining performance. This is achieved through improved grafting efficiency that eliminates waste of synthetic monomers in homopolymer formation, allowing lower synthetic content to deliver equivalent performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces long-lived synthetic polymers with biodegradable graft copolymers having high saccharide content. The improved grafting process ensures that even with reduced synthetic monomer content, the material maintains sufficient performance while gaining environmental benefits from biodegradability and renewability

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 sulfonated graft copolymers exhibit performance comparable to synthetic polymers in dispersancy and scale inhibition applications, while minimizing synthetic monomer usage, offering cost-effective, environmentally friendly, and biodegradable solutions for water treatment, detergents, and oil field applications.

Implementation Method 1

sulfonated graft copolymer obtained by radical graft copolymerization of one or more synthetic monomers in the presence of hydroxyl-containing naturally derived materials

Methodology Applied

Scientific EffectRadical graft copolymerization: Chemical Bonding

Data Source

PatentUS8674021B2Sulfonated graft copolymers

Publication Date: 2014.03.18 AKZO NOBEL CHEMICALS INTERNATIONAL BV

AI summary

Sulfonated graft copolymer obtained by radical graft copolymerization of one or more synthetic monomers in the presence of hydroxyl-containing naturally derived materials. The graft copolymer includes 0.1 to 100 wt %, based on weight of the total synthetic monomers, of at least one monoethylenically unsaturated monomer having a sulfonic acid group, monoethylenically unsaturated sulfuric acid ester or salt thereof, with the monomer and hydroxyl-containing naturally derived materials present in a weight ratio of 5:95 to 95:5.