Superabsorbent Polymer Reassembly Process for Residual Monomer Reduction
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Solution Overview
Problem
Existing methods for preparing superabsorbent polymers face challenges in achieving high aggregation strength and improved water holding capacity while minimizing residual monomers, particularly in the reassembling process, which affects the quality of the final polymer product.
Innovation Solution
A method involving the reassembly of a mixture of polymerized ethylene-based unsaturated monomers, a compound represented by Chemical Formula 1, and water, followed by drying and pulverization, to produce a superabsorbent polymer with enhanced aggregation strength and reduced residual monomer content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the reassembling process is carried out under wet condition to increase aggregation strength, then the aggregation strength of fine powders increases, but it becomes difficult to handle the fine powders
Solution Approach 1:
The patent applies parameter changes by controlling the water content of fine powders within a specific range (30-70 wt%) before reassembling. This optimized parameter range enables the fine powders to achieve sufficient aggregation strength while maintaining manageable handling characteristics, resolving the contradiction between strength and ease of operation.
2Ease of manufacture
If only water is used for reassembling, then the process is simple, but improvement in physical properties such as water holding capacity and residual monomer content is difficult to achieve
Solution Approach 1:
The patent employs composite materials by combining water with at least one compound selected from specific chemical groups (carboxylic acids, alcohols, sugars, or salts thereof) to create a reassembling medium. This composite approach enhances water holding capacity and reduces residual monomer content while maintaining process feasibility, thus resolving the contradiction between manufacturing simplicity and physical properties improvement.
3Manufacturing precision
If fine powders are excluded or reassembled to prevent them in final product, then product quality improves, but additional processing steps and complexity are required
Solution Approach 1:
The patent merges the reassembling process with the fine powder aggregation step, performing both functions in a single operation. By adding the reassembling medium containing water and specified compounds, fine powders are simultaneously aggregated into larger particles and incorporated into the final product, eliminating the need for separate exclusion or reassembling steps and reducing overall process complexity while maintaining product quality.
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 effectively increases the water holding capacity and aggregation strength of superabsorbent polymers while reducing residual monomer content, resulting in a higher-quality final product with improved handling and physical properties.
Implementation Method 1
a compound having a reducing action on the polymerization initiator, wherein the compound has a chemical formula 1
Implementation Method 2
capable of absorbing moisture from about 500 to 1000 times its own weight
Data Source
AI summary
Provided is a method of preparing a superabsorbent polymer. In the method of preparing the superabsorbent polymer according to the present disclosure, a polymer resulting from polymerization of ethylene-based unsaturated monomers is subjected to a reassembling process by mixing with a compound of a particular Chemical Formula and water. According to the preparation method of the present disclosure, provided is a method of preparing a superabsorbent polymer having improved water holding capacity and a reduced content of residual monomers, thereby improving quality of final polymer products.