Void Core-Sheath-Shell Polymer Particles Using Recycled Monomers

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Solution Overview

Problem

Recycled monomers with high levels of impurities result in degraded polymer properties due to the detrimental impact on monomer polymerization, posing a significant hurdle in achieving sustainable polymer recycling.

Innovation Solution

The development of core-sheath-shell polymer particles containing voids, where the core, sheath, and shell are made from recycled monomers, which maintain comparable performance to those made from virgin monomers, utilizing specific impurity levels in recycled methyl methacrylate and styrene monomers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If recycled monomers with high impurity levels are used for polymerization, then sustainability and recycling rates are improved, but polymer properties and technical performance deteriorate

Engineering Contradiction:

Improverecycling rateVSAvoidpolymer properties

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent converts the harmful effect of impurities in recycled monomers into a beneficial outcome by discovering that specific impurity profiles from recycling processes actually enhance the opacifying properties of the final polymer particles. The impurities, rather than degrading performance, contribute to the light scattering mechanisms that provide opacity, thus turning a traditionally problematic aspect into a functional advantage.

Inventive Principle:

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

Solution Approach 2:

The patent changes the acceptance parameters for monomer purity by establishing that recycled monomers with impurity levels previously considered unacceptable can successfully produce polymer particles with comparable or superior opacifying performance. This parameter change enables the use of lower purity monomers, thereby improving recycling rates without sacrificing technical performance.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If purification steps are added to recycled monomer processing, then polymer properties are improved, but process complexity and cost increase

Engineering Contradiction:

Improvepolymer propertiesVSAvoidpurification process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the requirement for extensive purification steps from the recycling process by demonstrating that the opacifying application does not demand high monomer purity. By removing the purification bottleneck, the process becomes simpler and more economically viable while still achieving the desired optical properties in the final product.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the presence of impurities, which would normally require removal through complex purification, into a beneficial factor that simplifies the overall process. The impurities are retained and utilized to achieve the opacifying function, thereby eliminating the need for costly and complex purification infrastructure.

Inventive Principle:

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

3Ease of manufacture

If recycled monomers are used without purification, then process simplicity and cost are improved, but impurity levels increase and polymer performance degrades

Engineering Contradiction:

Improveprocess simplicityVSAvoidpolymer performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent converts the harmful impact of impurities on polymerization into a beneficial contribution to opacifying performance. The simplified process that retains impurities produces polymer particles whose opacifying properties are enhanced or maintained despite the presence of recycled monomer contaminants.

Inventive Principle:

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

Solution Approach 2:

The patent changes the performance criteria for polymer particles made from recycled monomers by demonstrating that opacifying performance can be achieved with lower purity inputs. This parameter change enables direct use of recycled monomers without purification, simplifying manufacturing while meeting performance requirements.

Inventive Principle:

Principle #35Parameter changes

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 particles achieve similar opacity values and technical performance to virgin monomer-based particles, overcoming the limitations of impurities in recycled materials.

Implementation Method 1

The particles achieve similar opacity values and technical performance to virgin monomer-based particles

Methodology Applied

Scientific EffectLight scattering: Scattering

Data Source

PatentEP4663710A1Core-sheath-shell polymer particles, preparation and use thereof

Publication Date: 2025.12.17 ORGANIK KIMYA SANAYI VE TIC AS

AI summary

The present invention relates to core-sheath-shell polymer particles containing voids, said polymer particles being obtained from at least one recycled monomer. The present invention also relates to a process for preparing said particles. The use of said particles as binding or opacifying agents in paints, coating, impregnating, and molding compositions primarily, also extended to paper coatings and to some extent in leather, textiles and water-based construction materials, is also part of the present invention.