Zwitterionic Ethylene Copolymer via Ion Pair Compound
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Solution Overview
Problem
The production of traditional ionomers like Surlyn requires corrosion-resistant equipment due to the use of toxic and corrosive methacrylic acid, and involves energy-intensive solvent evaporation and incomplete neutralization, leading to residual acid groups and processing challenges.
Innovation Solution
The development of an ion pair compound consisting of a specific cation and anion formula, which allows for the production of a zwitterionic ethylene copolymer without the need for a neutralization step, thereby eliminating the use of corrosive materials and reducing processing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional ionomer production using methacrylic acid is employed, then ionomer can be produced, but corrosion-resistant equipment is required and the process becomes complex
Solution Approach 1:
The patent extracts and eliminates the corrosive methacrylic acid from the production process by using an ion pair compound where the acid is pre-neutralized. This removes the need for corrosion-resistant equipment and simplifies the manufacturing process while still producing functional ionomer.
Solution Approach 2:
The ion pair compound is prepared in advance with the acid already neutralized by a base, performing the neutralization action before the actual ionomer production. This preliminary action prevents corrosion issues during processing and eliminates the need for complex corrosion protection measures.
2Reliability
If neutralization step is performed in solution, then neutralization is achieved, but solvents need to be evaporated which increases energy consumption
Solution Approach 1:
The patent removes the solvent evaporation step entirely by using an ion pair compound that can be processed without requiring solvent removal. The neutralization is achieved through the ion pair compound itself, eliminating the energy-intensive evaporation process while maintaining complete neutralization.
3Ease of manufacture
If neutralization is performed in melt, then processing is simplified, but unreacted neutralizing salt remains in the ionomer
Solution Approach 1:
The ion pair compound acts as an intermediary that provides both the acid and base components in a controlled manner. This ensures complete neutralization without leaving unreacted salts, as the ion pair structure guarantees stoichiometric balance while maintaining processing simplicity.
4Reliability
If Surlyn is used, then ionomer properties are achieved, but materials need to be dried thoroughly before extruding
Solution Approach 1:
The patent removes the drying step from the processing sequence by using an ion pair compound that does not introduce moisture-absorbing acid groups. This eliminates the need for thorough drying before extrusion while maintaining ionomer performance, significantly simplifying the processing complexity.
5Productivity
If methacrylic acid is used in production, then ionomer can be produced, but equipment corrosion occurs
Solution Approach 1:
The patent converts the potentially harmful corrosive acid into a beneficial neutralized ion pair compound. The acid is pre-neutralized by a base to form an ion pair that provides the necessary ionic properties without the corrosive effects, turning a harmful factor into a beneficial one.
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
This approach results in a zwitterionic ethylene copolymer with enhanced mechanical properties and improved processing characteristics, such as reduced moisture sensitivity and absence of corrosion issues in processing equipment, while maintaining high dielectric constants and resistivity.
Implementation Method 1
an ethylene copolymer of ethylene and an ion pair compound consisting of a cation of formula (I) and an anion selected from formulas (II), (III), (IV), (V) and (VI)
Data Source
AI summary
The invention relates to an ethylene copolymer obtained by copolymerizing ethylene and an ion pair compound consisting of a cation of formula (I) and an anion selected from formulas (II), (III), (IV) and (V), wherein (I) where R1=H or C1-C10 alkyl; X═O or NH; R2=C1-C40 alkyl; R3, R4=H or C1-C10 alkyl which can be connected through a cyclic structure, R5=H or C1-C20, (II) (III) (IV) (V) where R6, R7, R9=H or C1-C10 alkyl; R8, R10=C1-C40 alkyl; Y, V, W═O or NH; n=1 to 20; Z═—SO3 or —C(O)O.