Viscosity Modifier for Polyesters Using Carrier Resin
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Solution Overview
Problem
Current methods for increasing melt viscosity of condensation polymers, such as using chain extenders, face challenges like volatility, toxicity, gel formation, and handling difficulties, leading to inconsistent results and processability issues in recycling and reprocessing of condensation polymers.
Innovation Solution
A viscosity modifier comprising a chain extender with reactive and vinyl monomers, combined with a non-condensation carrier resin, is used to enhance melt viscosity without gel formation, ensuring consistent mixing and maintaining mechanical and thermal properties, achieved through emulsion polymerization and specific weight ratios of chain extender and carrier resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If chain extenders are used to increase melt viscosity, then melt viscosity increases, but gel formation occurs and handling becomes difficult
Solution Approach 1:
The patent uses a carrier resin as an intermediary substance to deliver the chain extender to the condensation polymer. The carrier resin acts as a medium that prevents direct contact between the chain extender and polymer, eliminating gel formation while still enabling viscosity increase. The carrier resin melts at processing temperatures to release the chain extender gradually, solving both the viscosity enhancement need and the handling difficulty.
Solution Approach 2:
The patent changes the physical state and delivery mechanism of the chain extender by encapsulating it in a carrier resin matrix. This transforms the chain extender from a free-flowing liquid or powder that causes handling issues into a stable, processable solid composite material that can be easily handled and dosed while maintaining its chain-extending functionality.
2Temperature
If chain extenders are used to increase melt viscosity, then melt viscosity increases, but gel formation occurs
Solution Approach 1:
The carrier resin serves as a mediator that controls the interaction between the chain extender and the condensation polymer. By embedding the chain extender in the carrier resin matrix, the patent prevents uncontrolled aggregation and gel formation while still allowing the chain extender to function at appropriate concentrations as the carrier resin melts and releases it during processing.
3Temperature
If phosphite-based chain extenders are used, then melt viscosity increases, but volatility and hydrolysis susceptibility increase
Solution Approach 1:
The carrier resin acts as a protective intermediary that shields the phosphite-based chain extender from direct exposure to moisture and hydrolytic conditions. The carrier resin matrix provides a barrier that reduces water access to the chain extender, thereby decreasing hydrolysis susceptibility while still allowing the chain extender to perform its viscosity-enhancing function when released during processing.
4Temperature
If ethylene-based epoxy-functional chain extenders are used, then melt viscosity increases, but molecular weight increases causing gel formation
Solution Approach 1:
The carrier resin acts as a controlling intermediary that regulates the interaction between the high molecular weight chain extender and the condensation polymer. By releasing the chain extender gradually as the carrier resin melts, the patent prevents premature and excessive molecular weight buildup that would lead to gel formation, while still achieving the desired viscosity enhancement through controlled chain extension.
5Temperature
If isocyanate-based chain extenders are used, then melt viscosity increases, but toxicity and reactivity to moisture increase
Solution Approach 1:
The carrier resin serves as a protective intermediary that isolates the toxic isocyanate-based chain extender from direct contact with the environment and operators during handling and processing. The carrier resin matrix encapsulates the chain extender, reducing its volatility and exposure risk, while still enabling its viscosity-enhancing function when released under controlled processing conditions.
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 solution effectively increases melt viscosity of condensation polymers, improving processability and maintaining transparency and mechanical properties, while preventing gelation and bridging issues, thus enhancing the recycling and reprocessing of condensation polymers.
Implementation Method 1
a chain extender comprising at least one reactive monomer and at least one vinyl monomer copolymerizable with the reactive monomer
Implementation Method 2
achieved through emulsion polymerization and specific weight ratios of chain extender and carrier resin
Data Source
AI summary
A viscosity modifier for a condensation polymer may include a chain extender comprising at least one reactive monomer and at least one vinyl monomer copolymerizable with the reactive monomer, the chain extender being present in an amount ranging from 15 to 70 wt % of the viscosity modifier; and a non-condensation carrier resin present in an amount ranging from 30 to 85 wt % of the viscosity modifier. Condensation polymer compositions, methods of forming viscosity modifiers, and methods of molding condensation polymer compositions are also provided.