POLYMER BEADS AND METHOD FOR PREPARATION THEREOF

Abstract: The present invention relates to a process for producing polymer beads incorporating solid particles and to the novel polymer beads per se. The invention provides a process for producing polymer beads incorporating solid particulate material, which process comprises producing a dispersion having a dispersed phase including one or more monomers also including solid particulate material, and causing said one or more monomers to undergo a polymerisation reaction to form said polymer beads, wherein said dispersion further includes a solid phase dispersing agent for dispersing solid particles of material in the dispersed phase and wherein said solid phase dispersing agent reacts with at least one monomer to thereby become chemically incorporated in said polymer. The polymer beads comprise a polymer matrix having solid particulate material dispersed substantially uniformly therein and wherein the polymer matrix incorporates a solid phase dispersing agent chemically reacted into the polymeric matrix.

Description: POLYMER BEADS AND METHOD FOR PREPARATION THEREOF The present invention relates to a process for producing polymer beads incorporating solid particles. The polymer beads produced by the process of the present invention are particularly suitable for use as ion exchange resins. The invention further relates to the polymeric beads and to ion exchange resins incorporating the polymeric beads. Ion exchange is widely used as a technique for removing contaminants from water. Ion exchange techniques involve passing water through a packed bed or column of ion exchange resin. Contaminant materials are adsorbed onto the ion exchange resin. Ion exchange resins are particularly suitable for removing contaminants from water. Crosslinked polymer beads that are physically like ion exchange resins but without the ion-exchanging functional groups are also capable of adsorbing organic contaminants from water; one such resin used for this purpose is XAD resin. Some of the contaminant removal capacity of ion exchange resins observed in practice may be due to adsorption by the polymeric matrix of the resin. For ease of handling in use, the above crosslinked polymer beads with or without ion exchange functionality should be substantially spheroidal or ellipsoidal in form, ideally they should be substantially uniform in size and free of very small particles. This enhances the flow properties of the dry resin or a concentrated suspension in water so that the resin can be metered or pumped. Such beads can be made by polymerisation of a dispersed monomer phase. In addition, resin containing dispersed particulate material may enhance the ease of separation either by increasing the density of the resin bead or by providing another property such as magnetic susceptibility which can be used to separate the resin from the water. Resins incorporating magnetic particles flocculate and settle rapidly by magnetic attraction. Such particulate material should be incorporated into the resin bead in a manner that prevents its loss by erosion or dissolution during use. It is highly desirable that the particulate material should be dispersed evenly throughout the polymer bead. Improved mechanical strength is a further benefit of even particulate dispersion. This had been difficult to achieve until now. Processes for the manufacture of magnetic ion exchange resins have been described in some prior art patents. For example, United States Patent No. 2,642,514 assigned to American Cyanamid Company, discloses an ion exchange process using a mixed ion exchange resin. One of the ion exchange resins is a magnetic resin. The magnetic resin is produced by polymerising a reagent mix until a viscous syrup is obtained. Magnetite is added to the viscous syrup and the mixture is agitated to mix in the magnetite. The mixture is cured to form a hard resin that is subsequently ground to form irregular particles of magnetic resin. European Patent Application No. 0,522,856 in the name of Bradtech Limited also discloses the manufacture of magnetic ion exchange resins by grinding or crushing a polymer having magnetite dispersed throughout the polymer matrix The processes for producing magnetic ion exchange resins disclosed in U.S. 2,642^14 and EP 0,522,856 require a grinding step, which increases the cost and complexity of the process and increases losses due to the formation of polymer particles outside the desired particle size range during the grinding step. An alternative process for producing magnetic ion exchange resins is described in Australian Patent Application No. 60530/80 in the name of ICI Australia Ltd. In this process, magnetic porous crosslinked copolymer particles are produced by a dispersion polymerisation process. A mixture of polymerizable vinyl compounds, magnetic powder, polymerisation initiator and suspension stabilizer is dispersed in water and polymerised. A similar process for producing magnetic ion exchange resins is described in Japanese Patent Application No. 62141071 in the name of Mitsubishi Chemical Industries KJC In this process it is preferred to add an electron donor substance such as polyvinyl pyridine-styrene copolymer, polyacrylamide-styrene copolymer or polyvinyl imidazole copolymer to the mixture in order to stabilise the dispersion of magnetic powder. According to the patent, the dispersion treatment is important for stabilising the dispersed state so that the rate of settling of the magnetic powder is reduced by breaking up magnetic particles which have clumped together in secondary or larger particles into primary particles. Furthermore, it is necessary to use dispersion equipment which differs from normal mixing equipment, with special mixers being required. The suspension stabiliser described in the ICI Australia Ltd. patent application and in the Mitsubishi Chemical Industries K.K. patent application are not capable of reacting with the monomers used to form the resins and do not become chemically incorporated into the resin. Experiments by the present inventors using the process described in JP 62-141,071 showed that use of a polyvinyl pyridine-styrene copolymer, when used as a dispersing agent in a system containing 10.8% γ-Fe^ in a glycidyl methacrylate/divinyi benzene copolymer system, gave resin beads that encapsulated the magnetic oxide. However, the beads were irregular in shape, very polydisperse in size, poor in mechanical strength, had a relatively low loading of magnetic oxide which was poorly dispersed in the beads. It is an object of the present invention to provide an improved process for manufacturing polymer beads incorporating solid particles. In a first aspect, the present invention provides a process for producing polymer beads incorporating solid particulate material, which process comprises producing a dispersion having a dispersed phase including one or more monomers also including solid particulate material, and causing said one or more monomers to undergo a polymerisation reaction to form said polymer beads, wherein said dispersion further includes a solid phase dispersing agent for dispersing solid particles of material in the dispersed phase and wherein said solid phase dispersing agent reacts with at least one monomer to thereby become chemically incorporated in said polymer. The present invention provides a process which can produce polymer beads in which solid particulate material is evenly distributed throughout the polymer beads. In a preferred embodiment of the present invention, an organic phase is the dispersed phase and, for convenience, the invention will hereinafter be described with reference to the organic phase being the dispersed phase. However, it will be appreciated that the invention also encompasses an aqueous phase being the dispersed phase, in which case water soluble monomers are used to produce the polymer beads. Where an organic phase constitutes the dispersed phase, an oil-in-water dispersion is produced. The organic phase includes one or more monomers that react to form the polymer matrix of the polymer beads. It is especially preferred that the polymer matrix be a copolymer, which requires two (or more) monomers to be used. The polymer beads may have ion exchange properties and it is particularly preferred that the process provides for the production of ion exchange resins. Generally ion exchange resins require two types of monomers: (a) monomers which are able to provide crosslink points; and (b) monomers which are able to provide functional groups. Of course, the polymer chain may be a copolymer and the functional groups may be added by later reaction of one of the polymer monomer residues in the polymer resin. Accordingly, when the polymer beads are to be used as an ion-exchange resin, the organic phase should include a crosslinking monomer and a functional monomer that provides the necessary functional groups to give the polymer an ion- exchange capability or provides sites that may be later reacted to provide the required functional groups to confer ion-exchange capability to the polymer. Other monomers may be able to be included in the organic phase to copolymerise with the crosslinking monomer and the functional monomer, for example, a backbone monomer may be included. The cross-linking monomer may be selected from a wide range of monomers, including divinyl monomers such as divinyl benzene, ethyleneglycol dimethacrylate or poly(ethyleneglycol) dimethacrylate or methylene bisacrylamide, ethyleneglycol divinylether and polyvinyl ester compounds having two or more double bonds. This list is not exhaustive. A wide range of functional monomers may also be used in the process of the present invention. Suitable monomers include glycidyl methacrylate, vinyl benzyl chloride, dimethylaminoethyi methacrylate, N,N-dime yiaminopropyi acryiamide and methacryiamide, vinyl pyridine, diaUyiamine, and their quaternized derivatives, N-vinyl formamide and its hydrolized derivatives, and methyl acrylate and its derivatives. This list is not exhaustive. The backbone monomers include any monomer polymerizable by free radicals such as styrene, vinyl toluene, methyl methacrylate and other acryiates and methacryiates. This list is not exhaustive. In order to increase the efficiency of removal of contaminants from water being treated by the polymer beads, it is preferred that d e polymer beads are macroporous. This increases the total surface area of each bead available for contact. To produce macroporous polymer beads according to the present invention, the dispersed phase should include one or more porogens. The porogen becomes dispersed throughout the droplets that form the dispersed phase, but that porogen does not take part in die polymerisation reaction. Accordingly, after the polymerisation reaction is completed, the porogen can be removed from the polymer beads, for example by washing or steam stripping, to produce macroporosity in the polymer beads. Suitable porogens for use in the process of the present invention in which the organic phase is the dispersed phase include aromatic compounds such as toluene and benzene, alcohols such as butanol, iso-octanol, cyclohexanol, dodecanol, isoamyl alcohol and methyl iso-butyl carbinol, esters such as ethyl acetate and butyl acetate, saturated hydrocarbons such as n-heptane, iso-octane, halogenated solvents such as dichloroethane and trichloroethylene, plasticisers such as dioctylphthalate and dibutyi adipate, polymers such as polystyrene and polyvinyl acetate; and mixtures thereof. Mixtures of cyclohexanol with other porogens such as dodecanol or toluene have been found to be especially suitable for use as a porogen in the process of the present invention. It will be appreciated that d e above list of porogens is not exhaustive and that the invention encompasses the use of other porogens and other combinations of porogens. In one embodiment, incorporation of the solid particulate material into the polymer beads preferably results in the beads having a higher density than they otherwise would have if the solid particulate material was not present. As the polymer beads have increased density, settling time of the beads is decreased which allows for simpler separation of d e beads from a water sample being treated. The solid particulate material maybe described as a weighting agent and assist in promoting rapid settling of the polymeric beads. In this embodiment, the solid particulate material used in the present invention may be of any material that has a density higher than d e density of the polymer material in die absence of d e solids. The solid particulate material is preferably not soluble in water or in any solution or liquid to be treated by contact with the polymer beads. It is also preferred that d e solid particulate material does not react with solution or liquid to be treated. Some examples of suitable solid particulate material include titania, zirconia, barite, cassiterite, silica, aluminosilicates, nickel oxide, copper oxide, zinc oxide, zinc sulphide, and other oxides, sulphides, sulphates and carbonates of heavy metals. In an especially preferred embodiment, the solid particulate material is a magnetic material. Incorporation of a solid particulate magnetic material into d e polymer beads results in the beads becoming magnetic. Magnetic separation techniques may be used to conveniently separate the beads from a solution or liquid being treated. The solid particulate magnetic material used in this embodiment of die present invention may be any solid material that is magnetic. Examples include γ-iron oxide (γ-Fe^, also known as maghemite), magnetite (Fe 3 O 4 ), chromium dioxide, other metal oxides and more exotic magnetic materials, such as those based on niobium and other rare earth materials. Maghemite is especially preferred because it is inexpensive. The solid particulate material is added in the form of particles. The particle size of the particles may range up to a size that is up to one-tenth of the particle size of d e polymer beads formed in the process of d e present invention. Particles that are larger than that may be difficult to evenly disperse into the polymer beads. More preferably, the particles of solid material range in size from sub-micron (e.g.0.1um) to 500um, most preferably from 0.1 um to lOum. The process of the present invention includes a solid phase dispersing agent in die dispersed phase. The solid phase dispersing agent acts to disperse the solid material in d e droplets of d e dispersed phase to thereby form a stable dispersion (or suspension) of d e solid particles in the dispersed phase and d e solid phase dispersing agent reacts with one or more of d e monomers to become chemically reacted into d e polymer matrix. Both of these actions are necessary for d e effective dispersal of die solid particulate material in d e polymer beads. Use of a suitable solid phase dispersing agent results in polymer beads being formed in which die solid particulate material is evenly dispersed throughout die polymer bead and d e solid phase dispersing agent is chemically reacted with d e polymer matrix. This avoids, or at least alleviates, die problem of leaching of d e solid particulate material from d e polymer beads. This avoids, or at least alleviates, d e problem of erosion of the solid particulate material from d e polymer beads in service, as may happen if d e solid material was located only on die outer surface of die beads. Selection of die solid phase dispersing agent will depend upon die particular solid material being used and die monomers being used. The solid phase dispersing agent should have a good affinity for the surface of the solid material and be able to react with one or more of d e monomers. As one example, a silane methacrylate is a suitable solid phase dispersing agent for use with titania or zirconia particles. Persons skilled in die art should be readily able to select a desired solid phase dispersing agent for the specific reaction system employed. The polymerisation reaction taking place in die process of die present invention is a suspension polymerisation reaction and techniques known to those skilled in d e art to control and monitor such suspension polymerisation reactions apply to d e present invention. In order to maintain the dispersed phase in d e form of a suspension of droplets in the continuous phase whilst avoiding aggregation of die droplets, a stabilising agent is preferably used. Where d e dispersed phase is d e organic phase, the stabilising agent may be polyvinyl alcohol, gelatine, methyl cellulose or sodium polyacrylate. It is to be understood that d e invention extends to cover any stabilising agent that may be suitable for use. The stabilising agent is typically present in an amount of 0.01 to 5.0% by weight, and preferably 0.05 to 2.0% by weight, based on d e weight of d e whole mixture. It will also be generally necessary to use an initiator to initiate die polymerisation reaction. The initiator to be used depends upon the monomers present in d e reaction mixture and die choice of initiator and the amount required will be readily apparent to the skilled addressee. By way of example only, suitable initiators include azoisobutyronitrile, benzoyl peroxide, lauroyl peroxide and t-butyi hydroperoxide. The amount of initiator used is generally in die range of 0.01 to 5.0 wt %, more preferably 0.10 to 1.0%, calculated on die total weight of monomer(s). In a preferred embodiment of the present invention, the monomer mixture may include a functional monomer present in an amount of from 10 to 99% by weight, based upon the weight of total monomers, more preferably 50 to 90% by weight (same basis). The crosslinking monomers may be present in an amount of from 1 to 90% by weight, based on the weight of total monomers, more preferably 10 to 50% by weight (same basis). Additional monomers may be present in an amount of 0 to 60% by weight, more preferably 0 to 30% by weight, based on die weight of total monomers. The total monomers may constitute from 1.0 to 50%, more preferably 5.0 to 30% by weight of die whole suspension polymerisation mixture. The solid particles of material are preferably added in an amount of from 10 to 300 wt%, based on die weight of total monomers, more preferably 20 to 100% by weight (same basis). The solid phase dispersing agent is preferably added in an amount of 0.10 to 30.0% by weight, more preferably 1.0 to 10.0% by weight, based on d e weight of solid particles of material. The dispersion of the dispersed phase (which includes die monomer(s)) in die continuous phase is usually achieved by mixing die organic and aqueous phases and shearing die resulting mixture. The shear applied to die dispersion can be adjusted to control die size of die droplets of die dispersed phase. As die droplets of dispersed phase are polymerised to produce d e polymer beads, d e shear applied to die dispersion largely controls die particle size of d e polymer beads. Generally, the polymer beads are controlled to have a particle size in die range of 10-5000μm. Once a stable dispersion of dispersed phase in continuous phase is established, die polymerisation reaction is started by heating die dispersion to die desired reaction temperature. The dispersion may be held at die desired reaction temperature until d e polymerisation reaction is substantially complete. Once die polymerisation reaction is substantially complete, die polymer beads may be optionally treated to activate d e active sites in die polymer for ion exchange and die beads recovered. The activation of die active sites in die polymer for ion- exchange will be dependent on d e nature of the species to be separated from solution. For example, hydrolysis of poly(ethyi acrylate) beads will provide a weak acid cation ion exchange resin suitable for separating transition metal ions such as cadmium and zinc from solution. Amination or quaternization of die polymer beads may be used to provide an ion exchange resin suitable for d e removal of acidic organic materials from solution. It will be clear to those skilled in the art that die means for activation of die ion exchange sites maybe conveniendy selected dependent on die nature of d e compounds to be separated from solution. The beads may require cleaning before use. This may be achieved by a sequence of washing the beads or by steam stripping the beads. One method for cleaning the polymer beads includes die following steps: (a) add reaction product to a large excess of water, stir and allow to setde; (b) separate beads from the supernatant; (c) add separated beads to a large excess of water, stir and allow to setde before separating beads from die supernatant; (d) repeat step (c) several times; (e) disperse water washed beads in alcohol (ethanol); (f) separate beads from alcohol and dry. An alternative clean-up procedure is to steam strip the porogens and then wash die polymer beads to remove any free solid particulate material. The present invention provides a process which produces polymer beads in which solid particulate material is evenly distributed throughout d e polymer beads. In an especially preferred embodiment of the invention, a magnetic polymer bead is produced. The polymer is formed as a copolymer of glycidyl methacrylate and divinyl benzene. The monomers are present in the organic phase, which also includes a mixture of cyclohexanol with toluene or dodecanol as porogens. Polyvinyl alcohol is used as a stabilising agent. A free radical initiator such as "VAZO" 67 or Azoisobutyronitrile (AIBN) is added to the organic phase as a polymerisation initiator and γ-iron oxide is the magnetic material. The solid phase dispersing agent preferred for use in this system is a block copolymer of poly(hydroxystearic acid) and poly(ethyleneimine) and sold under the trade name SOLSPERSE 24000. This solid phase dispersing agent has a high affinity for d e surface of die γ-iron oxide and also reacts with d e epoxy group of the glycidyl methacrylate through its primary and secondary amino groups and then die vinyl groups from the methacrylate react with polymerising radicals to become covalentiy bound to die polymer matrix. All of die components of the organic phase are preferably pre-mixed in a separate tank and dispersed in water in die reaction tank. In another aspect, die present invention provides a process which produces polymer beads which incorporates a toughening agent. The toughening agents are selected to increase die impaα resistance of die polymer. The general techniques for increasing die toughness of polymer beads prepared in accordance with die present invention may readily be employed to produce bead with increased durability. For example, rubber toughening agents may be used to improve die strength and durability of styrene-based polymer beads. The use of these rubber toughening agents not only results in improved durability but increases d e serviceable life of t e polymer beads. The rubber toughening agents include low molecular weight rubbers which may be incorporated into die dispersed phase. A particularly preferred rubber toughening agent is sold under the trade designation Kraton D1102 although other commercially available rubber toughening agents are available. In another aspect, the present invention provides polymer beads comprising a polymer matrix having solid particulate material dispersed substantially uniformly therein and wherein die polymer matrix incorporates a solid phase dispersing agent chemically reacted into the polymeric matrix The polymer beads are preferably macroporous. The particle size of die polymer beads is preferably within die range of 30um to lOOOum. The particles of solid material may have a particle size in die range of sub-micron (e.g. 0.1 μm) to 500μm and more preferably from 0.1 um to lOum. The solid particulate material may act to increase the density, and hence d e weight of the polymer beads. Examples of solid particulate materials suitable for use in the present invention include titania and zirconia. In an especially preferred embodiment, die solid particulate material is of a magnetic material and accordingly the polymer beads will be magnetic The solid phase dispersing agent is a chemical compound or species that can react with the monomers used to produce the polymeric matrix such tiiat die solid phase dispersing agent is incorporated into the polymeric matrix Further, the solid phase dispersing agent should have a good affinity for die surface of the solid particles and preferably should be able to chemically bond to d e surface of the solid particles. The use of such an agent allows die solid particles to be dispersed throughout the polymeric matrix As die solid particles are dispersed throughout die polymer beads of die present invention, die solid particles are not easily removed from the beads and this allows the beads to be subjected to a number of handling operations, such as conveying, pumping and mixing, without substantial erosion of solid particles therefrom. In another aspect, the present invention provides polymer beads comprising a polymeric matrix having solid particulate material dispersed therein, wherein the polymeric matrix incorporates a solid phase dispersing agent which is chemically reacted into d e polymeric matrix and wherein die polymer beads incorporate a toughening agent The invention further provides ion exchange resins including polymeric beads in accordance with the present invention. Throughout this specification and d e claims which follow, unless the context requires otherwise, die word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not die exclusion of any other integer or group of integers. The invention will be further described with reference to die following non-limiting Examples. Example 1 Magnetic polymer beads were prepared in accordance with die process of die present invention using die following raw materials: 1. Water this is d e continuous medium in which die organic phase is dispersed and tiien reacted. 2. Gosenhol • GH 17: this is a high molecular weight polymeric surfactant, a polyvinyl alcohol, that disperses die organic phase in die water as droplets. 3. Teric • N9: this is a low molecular weight surfactant that is added to further reduce the particle size of the dispersed organic phase. 4. Cyclohexanol: this is die major porogen: it is a solvent for d e monomers, but a non-solvent for the polymer, and it promotes d e formation of voids and internal porosity in die resin beads. 5. Dodecanol: this is die minor porogen. 6. Solsperse * 24000. it is a solid phase dispersing agent and is a block copolymer of poly(hydraxystearic acid) and rx>ly(emyleneimine). 7. Pferrox • 2228HC γ-Fe D j j gamma - iron oxide (maghemite). This is the magnetic oxide that makes die resin beads magnetic. 8. DVB-50 (divinyl benzene): this is the monomer that crosslinks the beads. 9. GMA (glycidyl methacrylate): this is die monomer that is first polymerised to incorporate it into the beads, then it is quatemized to place quaternary ammonium groups into die beads, thereby creating the ion exchange sites: 10. AIBN: this is the catalyst that initiates polymerisation when die mixture is heated above 50°C. 11. Trirnethylarninc this is the amine that reacts with d e epoxy group of die glycidyl methacrylate to form quaternary ammonium ion exchange sites. 12. Hydrochloric acid: this is used to neutralise the high pH due to die trimethylamine. 13. EύianoL this is used as a rinse and as a wetting agent Method Water (63L) was charged to a 20L reactor and die stirrer and nitrogen purge started. Next Gosenhol • GH-17 (30g) and Teric • N9 (15g) were added, and the water phase heated to 80°C to dissolve the surfaαants. While the water was heating cyclohexanol (1755g) was charged to a separate stirred mix tank and die stirrer turned on. Dodencanol (195g), SOLSPERSE • 24000 (63g), Pferrox 2228 HC γ-F^O j (936g), divinylbenzene (410g), and glycidyl methacrylate (1541g) were added in turn. This mixture was stirred and sonicated for one hour. Azoisobutyronitrile (8g) was added and die mixture was stirred for a further five minutes before adding it to die heated water phase. The resulting dispersion was held at 80°C (±5°C) for two hours, during which time polymerisation occurs and die solid resin beads (2.95kg) were formed. The nitrogen purge is then stopped and die trime ylamine and the hydrochloric acid are added to aminate the resin. These two materials can either be pre-mixed (with great caution due to d e exotherm), or added in such a way as to maintain the pH between 6 and 8. The reaction mixture is tiien held at 80°C for three hours. The mixture is tiien cooled to room temperature, and the beads separated from the excess γ-Fe 2 θ 3 by repeated cycles of washing, settiing and decanting (the beads setde much faster than die free oxide particles). The resin beads are then filtered, redispersed in ethanol, then filtered and washed with additional ethanol, then acetone, and dried with an air stream. Photomicrographs of the polymer beads produced by this example are shown in Figures 1A and IB. As can be seen, especially from Figure IB which is a photomicrograph of cracked beads, die solid particles are evenly dispersed throughout the polymer beads. The maghemite was well dispersed throughout the resin beads produced in this Example. Comparative Example 1 The materials and method of Example 1 were used to make 58g of resin on a 300g scale, the sole difference being that the dispersant for die γ-Fe^, Solsperse 24000, was omitted from the preparation. After the polymerisation and quaternization, fine, dark brown beads were obtained. However, when d e beads were cracked open, their interiors were white and only the surfaces were brown. Photomicrographs of tiiese beads are shown in Figures 2A and 2B. Figure 2B is a photomicrograph of cracked beads and, as can be seen, the γ-FβjOj was only attached to the surface of die beads and not dispersed through the bulk. This means diat the beads are highly likely to lose γ-Fe^ in service. Examp1e 2 Magnetic macroporous weak acid cation exchanger beads are prepared in accordance with the process of the invention. The suspension polymerization described in Example 1 was repeated with the glycidyl methacrylate replaced by an equal weight of ethyl acrylate. At the end of the polymerization sodium hydroxide was added to the aqueous phase (1.5 moles per mole of ethyl acrylate) and die mixture gentiy stirred at 80 degrees. Samples were withdrawn at intervals and the beads washed by decantation with water and ethanol as described in Example 1, then packed into a glass column fitted with a porous glass frit and eluted with dilute hydrochloric acid to convert die sodium acrylate functional groups to acrylic acid groups. The beads were dien dried in a vacuum oven. The unhydrolyzed poly(ethyl acrylate) beads contained 40.3% iron oxide by weight After hydrolysis for 2 hours at 80 degrees the produα had a weak acid capacity of 2.1 milliequivalents per gram and contained 40 % iron oxide; after 7 hours' hydrolysis d e capacity was 2.9 meq/g and the iron oxide content 38.8%. Example 3 Magnetic polymer beads were prepared in accordance with the process of the present invention using the following raw materials: 1. Water this is die continuous medium in which the organic phase is dispersed and then reacted. 2. Gosenhol * GH 20: this is a high molecular weight polymeric surfactant, a polyvinyl alcohol, tiiat disperses die organic phase in the water as droplets. 3. Cyclohexanol: this is the major porogen: it is a solvent for the monomers, but a non-solvent for the polymer, and it promotes the formation of voids and internal porosity in the resin beads. 4. Toluene: this is the minor porogen. 5. Solsperse • 2400ft it is a solid phase dispersing agent and is a block copolymer of poly(hydroxystearic acid) and rx)ly(eώyieneimine). 6. Pferrox • 2228HC γ-Fe ^ gamma - iron oxide (maghemite). This is the magnetic oxide that makes die resin beads magnetic. 7. KRATON * D1102 this is a low molecular weight rubber, incorporated into the organic phase to toughen d e polymer beads. 8. DVB-50 (divinyl benzene): this is the monomer mat αosslinks die beads. 9. GMA (glycidyl methacrylate): this is die monomer that is first polymerised to incorporate it into the beads, then it is quatemized to place quaternary ammonium groups into the beads, thereby creating the ion exchange sites. 10. VAZO • 67: this is the catalyst that initiates polymerisation when die mixture is heated above 50°C. 11. Trirnediylarnine: this is die amine that reacts with die epoxy group of the glycidyl methacrylate to form quaternary ammonium ion exchange sites. 12. Hydrochloric acid: this is used to neutralise die high pH due to die trimediylamine. ethod Water (2333g) was charged to a 5 L reaαor and the stirrer and nitrogen purge started. Next Gosenhol GH20 (lOg) was added, and the water phase heated to 80°C. While the water was heating Toluene (130g), DVB-50 (130g) and a first portion of Cyclohexanol (130g) were charged to a separate mix tank and the stirrer turned on. The Solsperse 24000 (21.84g) and the Pferrox 2228 HC γ-Fe j (325g) were added in turn, then the mixture was stirred and sonicated for 20 minutes to thoroughly disperse the magnetic oxide. Kraton D1102 was then added and the mixture stirred for a further hour to dissolve the toughening agent. Glycidyl methacrylate (520g), the remaining Cyclohexanol (390g) and the VAZO 67 (2.65g) were then added and the mixture was stirred for a further five minutes before adding it to the heated water phase. The resulting dispersion was then stirred and held at 80°C for two hours. The nitrogen purge was stopped and a mixture of trimethyiamine (687g; 25% w/w) and hydrochloric acid (294 g; 36% w/w) added, then the mixture was men stirred and held at 80°C for a further three hours. The mixture was then cooled and the resulting polymer beads cleaned as in Example 1. A photomicrograph of the beads is shown in Figure 3A Figures 3B and 3C are photomicrographs showing the beads crushed between two microscope slides. Some of d e beads are broken revealing their interiors. This illustrates that die solid magnetic oxide is well dispersed throughout the beads, and d e beads are qualitatively tougher than those of Example 1. Further, the size distribution of the polymer beads was relatively narrow. Example 4 Magnetic polymer beads were prepared in the manner of Example 3, except that die temperature of polymerization was 70°C. Polymer beads similar to those of Example 3 were produced. Example 5 Magnetic polymer beads were prepared in the manner of Example 3, except that the temperature of polymerization was 90°C, and that the mixture of monomers, porogens and magnetic oxide was gradually fed to the water phase over sixty minutes. Polymer beads with excellent magnetic oxide dispersion and strength resulted, however the distribution of polymer bead sizes was relatively broad. - 19 - Example 6 Magnetic polymer beads were prepared in the manner of Example 3, except that the initiator was Lauroyl Peroxide. The resulting polymer beads were not homogeneous. In some instances the distribution of magnetic oxide was acceptable however there was varying extents of separation of die magnetic oxide from the polymer matrix Some beads contained no magnetic oxide. Example 7 Magnetic polymer beads were prepared in the manner of Example 3, except that the initiator was Benzoyl Peroxide. While die resulting polymer beads had acceptable magnetic oxide distribution, die beads had a very broad size distribution, and many were irregular, rather than spherical, in shape. Example s Magnetic polymer beads were prepared in the manner of Example 3, except that the amount of Solsperse 24000 was one third that in Example 3. The resulting beads had a poor distribution of magnetic oxide, with internal regions that were white due to a lack of oxide, similar to Comparative Example 1. There was much magnetic oxide not incorporated into the beads. Example 9 Magnetic polymer beads were prepared in the manner of Example 3, except that the amount of Solsperse 24000 was three times that in Example 3. While the resulting polymer beads generally had acceptable magnetic oxide distribution, die beads also frequendy included smaller white beads that were free of oxide, and were fragile, rather than tough. - 20 - Fxaτnply r 10 Magnetic polymer beads were prepared in the manner of Example 3, except that the amount of Gosenhol GH20 was one third that in Example 3. While the resulting polymer beads generally had acceptable magnetic oxide distribution, the beads also frequendy included smaller white beads that were free of oxide, but were tough, unlike Example 9. Example 11 Magnetic polymer beads were prepared in d e manner of Example 3, except that the amount of Gosenhol GH20 was three times that in Example 3. The resulting polymer beads had good magnetic oxide distribution and were tough. However, the beads occasionally included smaller white beads that were free of oxide, but were hard and tough, unlike Example 9. It will be appreciated that die invention described herein is susceptible to variations and modifications other than those specifically described. It is to be understood that die invention encompasses all such variations and modifications that fall within me spirit and scope.

Claims: CLAIMS: 1. A process for producing polymer beads incorporating solid particulate material, which process comprises producing a dispersion having a dispersed phase including one or more monomers also including solid particulate material, and causing said one or more monomers to undergo a polymerisation reaction to form said polymer beads, wherein said dispersion further includes a solid phase dispersing agent for dispersing solid particles of material in the dispersed phase and wherein said solid phase dispersing agent reacts with at least one monomer to thereby become chemically incorporated in said polymer. 2. A process according to Claim 1 wherein the dispersed phase is an organic phase. 3. A process according to either Claim 1 or Claim 2 wherein the polymer beads are ion exchange resins. 4. A process according to Claim 3 wherein the ion exchange resins are produced from crosslinking monomers which are able to provide CTOSslinking points and are functional monomers which are able to provide ion exchange functional groups. 5. A process according to Claim 4 wherein the αcβslinking monomers are selected from the group consisting of divinyl monomers such as divinyl benzene, ethyleneglycol dimethacrylate or poly(ethyleneglycol) dimethacrylate or methylene bisacryiamide, ethyleneglycol drvinyiether and polyvinyl ester compounds having two or more double bonds. 6. A process according to either Claim 4 or Claim 5 wherein the functional monomers are seleαed from the group consisting of glycidyl methacrylate, vinyl benzyl chloride, dimemylaminoethyl methacrylate, aαylamide and methaαylamide, vinyl pyridine, diallylamine, and their quatemized - 22 - derivatives, N-vinyl formamide and its hydrolized derivatives. 7. A process according to any one of Claims 1 to 6 wherein the dispersed phase further includes one or more porogens. 8. A process according to Claim 7 wherein said porogens are seleαed from the group consists of aromatic compounds such as toluene and benzene, alcohols such as butanol, iso-oαanol, cyclohexanol, dodecanol, isoamyl alcohol and methyl iso- butyi carbinol, esters such as ethyl acetate and butyl acetate, saturated hydrocarbons such as n-heptane, iso-oαane, halogenated solvents such as dichloroethane and trichloroed ylene, plasticisers such as dioctylphthalate and dibutyi adipate, polymers such as polystyrene and polyvinyl acetate; and mixtures thereof. 9. A process according to Claim 7 wherein said porogens are mixtures of cyclohexanol with other porogens such as dodecanol or toluene. 10. A process according to any one of Claims 1 to 9 wherein said solid particulate material is a weighting agent. 11. A process according to Claim 10 wherein said solid particulate material is seleαed from the group consisting of titania, zirconia, barite, cassiterite, silica, aluminosilicates, nickel oxide, copper oxide, zinc oxide, zinc sulphide, and other oxides, sulphides, sulphates and carbonates of heavy metals. 12. A process according to any one of Claims 1 to 9 wherein said solid particulate material is a magnetic material. 13. A process according to Claim 12 wherein said solid particulate material is seleαed from the group consisting of γ-iron oxide also known as maghemite), magnetite (Fe 3 O ), chromium dioxide, other metal oxides and more exotic magnetic materials, such as those based on niobium and other rare earth materials. 14. A process according to any one of Claims 1 to 13 wherein said solid particulate material ranges in size from sub-micron (e.g.O.lum) to 500um. 15. A process according to any one of Claims 1 to 14 wherein said solid particulate material is in the range of from 0.1 μm to lOum. 16. A process according to any one of Claims 1 to 15 wherein said dispersion further includes a stabilizing agent. 17. A process according to Claim 16 wherein said stabilizing agent is seleαed from the group consisting of polyvinyl alcohol, gelatine, methyl cellulose or sodium polyacrylate. 18. A process according to either Claim 16 or Claim 17 wherein said stabilizing agent is present in an amount of 0.01 to 5.0% by weight of die whole mixture. 19. A process according to any one of Claims 16 to 18 wherein said stabilizing agent is present in an amount of 0.05 to 2.0% by weight, based on the weight of die whole mixture. 20. A process according to any one of Claims 1 to 19 wherein said dispersion further includes an initiator. 21. A process according to Claim 20 wherein said initiator is seleαed from the group consisting of azoisobutyronitrile, benzoyi peroxide, lauroyl peroxide and t- butyl hydroperoxide. 22. A process according to either Claim 20 or Claim 21 wherein said initiator is present in die range of 0.01 to 5.0 wt% based on the total weight of monomers. 23. A process according to any one of Claims 20 to 22 wherein said initiator is present in the range of 0.1 to 1.0 wt% based on the total weight of monomers. 24. A process according to any one of Claims 4 to 23 wherein said functional monomers are present in an amount of from 10 to 99% by weight based upon the total monomers, said αosslinking monomers may be present in an amount of from 1 to 90% by weight based upon the total monomers and additional monomers may be present in an amount of up to 60% by weight based upon the total monomers. 25. A process according to any one of Claims 4 to 23 wherein said functional monomers are present in an amount of from 50 to 90% by weight based upon the total monomers, said CTOSslinking monomers may be present in an amount of from 10 to 50% by weight based upon the total monomers and additional monomers may be present in an amount of up to 30% by weight based upon the total monomers. 26. A process according to any one of Qaims 4 to 25 wherein total monomers are present in an amount of from 1.0 to 50% by weight of the suspension polymerization mixture. 27. A process according to any one of Qaims 4 to 26 wherein total monomers are present in an amount of from 5.0 to 30% by weight of the suspension polymerization mixture. 28. A process according to any one of Qaims 1 to 27 wherein the solid particulate material is present in an amount of from 10 to 30% based upon the weight of the total monomers. 29. A process according to any one of Qaims 1 to 28 wherein the solid particulate material is present in an amount of from 20 to 100% based upon the weight of the total monomers. 30. A process according to any one of Qaims 1 to 29 wherein said solid phase dispersing agent is present in an amount of from 0.10 to 30.0% by weight of the solid particulate material. 31. A process according to any one of Qaims 1 to 30 wherein said solid phase dispersing agent is present in an amount of from 1.0 to 10.0% by weight of the solid particulate material. 32. A process according to any one of Qaims 4 to 31 wherein the polymer beads are treated to activate the active sites in die polymer for ion-exchange. 33. A process according to Qaim 32 wherein the polymer beads are treated by hydrolysis, amination or quaternization. 34. A process according to any one of Qaims 1 to 33 wherein the polymer beads are subjeαed to a subsequent cleaning step. 35. A process according to any one of Qaims 1 to 34 wherein all the components of the dispersal phase are premixed and subsequendy dispersed in the continuous phase. 36. A process according to any one of Qaims 1 to 35 wherein said dispersed phase further includes a toughening agent 37. Polymer beads produced according to the process of any one of Qaims 1 to 36. 38. Polymer beads comprising a polymer matrix having solid particulate material dispersed substantially uniformly therein and wherein d e polymer matrix incorporates a solid phase dispersing agent chemically reaαed into the polymeric matrix 39. Polymer beads according to Claim 38 wherein said polymer beads are in d e range of from 30um to lOOOum. 40. Polymer beads according to eitiier Qaim 38 or 39 wherein the solid particulate material is a magnetic material. 41. Polymer beads comprising a polymeric matrix having solid particulate material dispersed therein, wherein the polymeric matrix incorporates a solid phase dispersing agent which is chemically reaαed into die polymeric matrix and wherein the polymer beads incorporate a toughening agent 42. Polymer beads according to Qaim 41 wherein said polymer beads are in the range of from 30μm to lOOOum. 43. Polymer beads according to either Qaim 41 or 42 wherein the solid particulate material is a magnetic material. 44. A process for producing polymer beads substantially as hereinbefore described with reference to any one of d e Examples and/or Figures. 45. Polymer beads substantially as hereinbefore described with reference to any one of the Examples and/or Figures

Inventors: BALLARD MATHEW JOHN, BATES JAMES SYDNEY, ELDRIGDE ROBERT JAMES, BALLARD, MATHEW, JOHN, BATES, JAMES, SYDNEY, ELDRIGDE, ROBERT, JAMES
Applicants: BALLARD MATHEW JOHN, BATES JAMES SYDNEY, COMMW SCIENT IND RES ORG, ELDRIGDE ROBERT JAMES, ICI AUSTRALIA OPERATIONS, BALLARD, MATHEW, JOHN, BATES, JAMES, SYDNEY, COMMONWEALTH SCIENTIFIC AND INDUSTRIAL RESEARCH OR, ELDRIGDE, ROBERT, JAMES, ICI AUSTRALIA OPERATIONS PROPRIETARY LIMITED
Application year: 1995
Main classification: C08F2
IPC codes: C08F2, C08F6, C08F8, C08F16, C08F18, C08F20, C08F26, C08J3, C08K3, C08L25, C08L33