Sulfonated Polyarylene Ether Sulfone Particle Formation With Low Fines
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Solution Overview
Problem
Existing processes for manufacturing sulfonated polyarylene(ether)sulfones face challenges in producing particles of manageable size with low fines content and high residual sulfuric acid content, while also generating significant waste washing liquids.
Innovation Solution
A process involving a tooth rim dispersion machine is used to mix a solution of sulfonated polyarylene(ether)sulfone and sulfuric acid with water, employing a rotor/stator design to control particle size and reduce fines, followed by solid-liquid separation and washing to minimize residual sulfuric acid and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyarylene(ether) sulfones are sulfonated by conventional methods (chlorosulfonic acid or sulfur trioxide in sulfuric acid), then sulfonated polyarylene(ether) sulfones can be produced, but the process requires sophisticated equipment and specialized knowledge due to the harsh reaction conditions
Solution Approach 1:
The patent changes the chemical parameters of the sulfonation process by using gaseous sulfur trioxide instead of liquid chlorosulfonic acid or sulfur trioxide dissolved in sulfuric acid. This parameter change allows the reaction to proceed under milder conditions, eliminating the need for sophisticated equipment while maintaining production reliability
Solution Approach 2:
The patent employs a simple glass reactor that can be easily disposed of or replaced, rather than requiring expensive, specialized equipment designed to withstand harsh conditions. The simplicity of the equipment reduces both initial investment and maintenance requirements
2Reliability
If polyarylene(ether) sulfones are sulfonated by conventional methods, then sulfonated polyarylene(ether) sulfones can be produced, but the process is troublesome and time-consuming due to lengthy procedures and strict process control requirements
Solution Approach 1:
The patent implements a continuous sulfonation process where gaseous sulfur trioxide is continuously passed through the polyarylene(ether) sulfone at elevated temperatures. This continuous action eliminates the need for lengthy procedural steps and strict process control intervals, significantly reducing the overall process time while maintaining reliable production
Solution Approach 2:
The patent performs preliminary preparation of gaseous sulfur trioxide and pre-heats it to the reaction temperature before contact with the polymer. This preliminary action ensures that when the sulfonation begins, the conditions are already optimal, eliminating the need for lengthy process adjustments and control during the reaction
3Reliability
If polyarylene(ether) sulfones are sulfonated by conventional methods, then sulfonated polyarylene(ether) sulfones can be produced, but the products have poor solubility and require complex purification procedures
Solution Approach 1:
The patent changes the sulfonation parameters by conducting the reaction in a solvent-free system with gaseous sulfur trioxide at controlled temperatures. This parameter change produces sulfonated polyarylene(ether) sulfones with improved solubility characteristics, eliminating the need for complex purification procedures while ensuring reliable product obtainability
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 process achieves sulfonated polyarylene(ether)sulfone particles with controlled size distribution, low fines content, and reduced sulfuric acid residuals, suitable for industrial-scale production with minimal waste generation.
Implementation Method 1
a process which comprises reacting polyarylene(ether) sulfone with sulfur trioxide in a gas phase
Data Source
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AI summary
A process for the manufacture of a sulfonated polyarylene(ether)sulfone comprising feeding of a solution (S1) comprising a sulfonated polyarylene(ether) sulfone and sulfuric acid into a tooth rim dispersion machine, wherein the solution (S1) is thereby contacted with a liquid (L1) compris- ing water, particles essentially consisting of a sulfonated polyarylene(ether)sulfone having a foam structure and uses of said particles.