Superabsorbent Polymer Hydration via Pulse Spray
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Solution Overview
Problem
Existing methods for preparing superabsorbent polymers result in low moisture content, leading to surface property changes and increased fine powder generation, which affects processability and product quality during manufacturing.
Innovation Solution
A method involving thermal or photopolymerization of a monomer composition, followed by drying, grinding, surface cross-linking, and hydration using pulse spraying to control droplet size, optimizing the scattering index of droplets to improve moisture content and reduce fine powder generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If surface cross-linking reaction is conducted by heating at high temperature (140°C or more), then cross-linking reaction efficiency is improved, but moisture content of superabsorbent polymer significantly decreases
Solution Approach 1:
The patent changes the temperature parameter from high temperature (140°C or more) to low temperature (100°C or less) during surface cross-linking reaction. This parameter change allows the cross-linking reaction to proceed efficiently while preserving moisture content, resolving the contradiction between reaction efficiency and moisture retention.
Solution Approach 2:
The patent utilizes the phase transition properties of water by conducting the cross-linking reaction in an aqueous environment at controlled temperature. The water serves as both solvent and moisture source, allowing the reaction to proceed while maintaining the polymer's moisture content through controlled phase behavior.
2Stability of the object's composition
If moisture content of superabsorbent polymer is low, then storage stability is improved, but surface property changes and fine powder generation increase
Solution Approach 1:
The patent optimizes the moisture content parameter to a specific range (1-10 wt%) after cross-linking. This parameter optimization prevents surface property changes and fine powder generation during storage and handling, while maintaining adequate storage stability. The controlled moisture level acts as a protective factor against surface degradation.
3Manufacturing precision
If conventional hydration method using spray nozzle is used, then moisture content is uniformly increased, but device pollution and foreign substance generation occur
Solution Approach 1:
The patent extracts and removes the spray nozzle component from the hydration system, replacing it with a fluidized bed hydration method. This elimination of the spray nozzle prevents device pollution and foreign substance generation while achieving uniform moisture distribution through fluidization, resolving the contradiction between moisture uniformity and device cleanliness.
Solution Approach 2:
The patent replaces the mechanical spray nozzle system with a fluidized bed system that uses fluid dynamics (air flow) to achieve uniform moisture distribution. This substitution eliminates mechanical contact and potential污染源 from nozzles while maintaining hydration effectiveness through fluid-mechanical interaction.
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 method enhances the moisture content of superabsorbent polymers, preventing surface property changes and reducing fine powder generation, thereby improving processability and product quality.
Implementation Method 1
hydrating the surface cross-linked base resin powder by pulse spraying water
Implementation Method 2
hydrating the surface cross-linked base resin powder by pulse spraying water, wherein a scattering index of droplet generated during the pulse spraying
Implementation Method 3
preparing a hydrogel polymer by carrying out a thermal polymerization or photopolymerization of a monomer composition
Implementation Method 4
preparing a hydrogel polymer by carrying out a thermal polymerization or photopolymerization of a monomer composition
Implementation Method 5
drying and grinding the hydrogel polymer to prepare a base resin powder
Data Source
AI summary
A method for preparing superabsorbent polymer is disclosed herein. In some embodiments, a method includes polymerizing a monomer composition to form a hydrogel polymer, wherein the monomer composition comprises a water soluble ethylenically unsaturated monomer and a polymerization initiator, drying and grinding the hydrogel polymer to prepare a base resin powder, surface cross-linking the base resin powder using a surface cross-linking agent to prepare surface cross-linked base resin powder, and hydrating the surface cross-linked base resin powder by pulse spraying water to prepare a superabsorbent polymer, wherein a scattering index of droplets generated during the pulse spraying is 5 to 10, and wherein the scattering index is calculated in accordance with the following Mathematical Formula 1. The superabsorbent polymer can have an improved moisture content to prevent surface property change of the superabsorbent polymer, and decreased amount of fine powder which improves processability during manufacture of articles using superabsorbent polymer.