Source: http://www.google.com/patents/US7829640?dq=KOI-18
Timestamp: 2016-12-02 20:51:58
Document Index: 273725231

Matched Legal Cases: ['Application No. 200780027076', 'Application No. 09012412', 'Application No. 10154282', 'Application No. 200780000114', 'Application No. 12', 'Application No. 7709980']

Patent US7829640 - Recirculation loop reactor bulk polymerization process - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsA process for producing polymer and more particularly adhesive using a recirculating loop reactor. In one embodiment the reactor includes one or more mixers to mix feed stock with the polymerized material recirculating in the reactor. In another embodiment a planetary roller extruder (PRE) may be used...http://www.google.com/patents/US7829640?utm_source=gb-gplus-sharePatent US7829640 - Recirculation loop reactor bulk polymerization processAdvanced Patent SearchTry the new Google Patents, with machine-classified Google Scholar results, and Japanese and South Korean patents.Publication numberUS7829640 B2Publication typeGrantApplication numberUS 11/845,807Publication dateNov 9, 2010Filing dateAug 28, 2007Priority dateAug 30, 2006Fee statusPaidAlso published asCA2661231A1, CA2661231C, EP2057197A1, EP2057197B1, EP2371868A1, US20080058483, WO2008027858A1, WO2008027858B1Publication number11845807, 845807, US 7829640 B2, US 7829640B2, US-B2-7829640, US7829640 B2, US7829640B2InventorsMark D. Barbieri, Richard W. St. Coeur, John K. Tynan, Jr., Mark A. LewandowskiOriginal AssigneeIntertape Polymer Corp.Export CitationBiBTeX, EndNote, RefManPatent Citations (85), Non-Patent Citations (22), Referenced by (1), Classifications (29), Legal Events (6) External Links: USPTO, USPTO Assignment, EspacenetRecirculation loop reactor bulk polymerization process
US 7829640 B2Abstract
f) subjecting the remaining portion of the polymerized intermediate to further reaction to form polymerized product.
g) subjecting the remaining portion of the polymerized intermediate to additional reaction to form a polymerized product.
7. The process of claim 6 wherein the polymerized product is a self-adhesive composition which comprises the polymerization reaction product of at least one alkyl acrylate monomer.
f) subjecting the remaining portion of the polymerized intermediate to an additional reaction in a planetary roller extruder to reduce the unreacted monomer and form a polymerized product.
11. The process of claim 10 wherein the polymerized product is a self-adhesive composition which comprises the polymerization reaction product of at least one alkyl acrylate monomer.
a supply of at least one monomer and at least one initiator,
a reactor loop including at least one mixer for mixing the feed stock with a stream of polymerized intermediate recirculating in the reactor loop, and
a removal stream for removing polymerized product from the reactor;
wherein the reactor loop includes a junction where the removal stream diverges from the stream of polymerized intermediate and includes a mixer for cooling located in the recirculating stream between the junction and the at least one mixer that is mixing the feed stock with the stream of recirculating polymerized intermediate to cool the polymerized intermediate below an initiation temperature;
wherein the removal stream includes at least a static mixer or a dynamic mixer for further reacting the polymerized intermediate to form a polymer product.
15. The reactor of claim 14 wherein at least one mixer is a static mixer.
16. A polymerization reactor comprising a feed stock containing:
wherein the removal stream includes at least a static mixer or a dynamic mixer for further reacting the polymerized intermediate to form a polymer product;
wherein at least one mixer is a dynamic mixer.
19. The reactor of claim 16 wherein the reactor includes a dynamic mixer in the removal stream for further reacting the intermediate to form a polymer product.
21. The reactor of claim 16 wherein the removal stream includes a dynamic mixer, and the dynamic mixer is a planetary roller extruder. Description
Polymerization reaction temperatures may be selected based upon the type of monomer material used, the decomposition temperature of the initiator material and/or the desired polymer product desired. For example, a polymerization reaction may be carried out at a temperature of about 100 to about 140° C. when initiator 15 is AIBN.
The static mixer/heater 35 may mix the low viscosity monomers/initiator with the high viscosity polymer. At 70° C., the initiator (AIBN) and monomers are present together but they do not react. Recirculation stream 48 may be 0.042 m3/hr, 900 kg/m3, 700 Pas; Stream 30 may be 0.00833 m3/hr, 900 kg/m3, 0.01 Pas; Stream 32 may be 0.05 m3/hr, 900 kg/m3, 583 Pas. Static mixer/heater 35 may be CSE-X/8, DN 49.5, 18 elements, Δp=ca. 21 bar, shear rate 10.5 s−1, residence time 104 s, length approximately 900 mm, as shown in FIG. 2.
The homogenized mixture 38 of monomer/polymer/initiator may be heated in the mixer/heat exchanger 40. By increasing the temperature from about 70° C. to about 120° C. the polymerization reaction may be induced. The exothermic heat generated may be partly absorbed by the bulk polymer and the temperature rise due to the reaction may, for example, be about 20 to about 40° C. Heating may be performed with Marlotherm® L heat transfer fluid supplied to the reactor jacket 39 (e.g., at about 120° C.). Once the reaction starts the reactor jacket 39 may operate as a cooler, thereby keeping the temperature under control. Mixture data (stream 41) may be 0.005 m3/hr, 900 kg/m3, 700 Pas, Cp (heat capacity) of 2,300 J/kg/° K, λ (latent heat) of 0.15 W/m/° K. Mixer/heat exchanger 40 may be a CSE-XR, DN 80, 8 elements, Δp=ca. 5 bar, shear rate 4 s−1, residence time 170 s, length approximately 750-1,100 mm as shown in FIG. 2.
Marlotherm® LH is a high-performance synthetic, organic heat-transfer medium for use in the liquid phase in closed forced circulation unpressurized heat transfer systems at working temperatures from about 0° to about 280° C. The Marlotherm® heat transfer fluid is supplied by Sasol Olefins & Surfactants (Marl, Germany). A reaction temperature of about 120° C. may be suitably selected for the AIBN initiator, although alternatively, different thermal initiators or mixtures of thermal initiators may require a different reaction temperature.
Vessel 42 may be a double jacketed mixer and may be capable of providing additional residence time and mixing performance in order to increase the yield and the product quality. The polymer streams 41, 44 may be kept at a constant temperature (e.g., 120° C.). Mixture data (stream 44) may be characterized as 0.05 m3/hr, 900 kg/m3, 700 Pas. Mixer/heat exchanger 42 may be characterized as CSE-X/4, DN 80, 15 elements, Δp=ca. 3 bar, shear rate 1.6 s−1, residence time 390 s, length approximately 1,200 mm, as illustrated in FIG. 2.
The monomer/polymer/initiator mixture may be cooled in the recirculation loop by vessel 50 from about 120° C. down to about 70° C., thereby reducing or preventing further polymerization. The cooling of vessel 50 may be performed with Marlotherm® L supplied to the jacket 54 of the vessel 50 (e.g., at about 60° C.). Mixture data (stream 48) may be 0.005 m3/hr, 900 kg/m3, 700 Pas, Cp of 2,300 J/kg/° K, λ of 0.15 W/m/° K. Mixer/heat exchanger 50 maybe a CSE-XR, DN 80, 18 elements, Δp=ca. 11 bar, shear rate 4 s−1, residence time 390 s, length approximately 1,600 mm, as illustrated in FIG. 2.
The feed stream 200 is carried into the first planetary roller barrel 270 and combined with a recycled polymer stream 370 (having a recirculation flowrate R in FIG. 3), and heated to about 25 to about 240° C. to initiate the free-radical reaction process. In this embodiment, the mixture 300 is fed into a second planetary roller extruder barrel 280 and a third planetary roller barrel 290, where a preset residence time is provided to minimize the residual monomer content of the finished polymer stream 300. Individual monomers 120, 130, 140 as well as the feed stream 200 can be injected into the PRE anywhere along the length but most preferably using injection valves inserted into a spray ring before the first PRE barrel. Alternatively, it could also be injection valves inserted into any dispersion rings before and after any PRE barrels or a side port directly into a barrel or other internal and external delivery mechanisms. The recycle polymer stream 370 can be introduced into the PRE anywhere along its length but most preferably using a recirculation port in the side of a PRE barrel. Alternatively, it could also be introduced at any injection valves specially designed to handle such viscosity material at the same rings as monomer additions or other internal or external delivery mechanisms. To those skilled in the art, it is understood that the use of a three barrel PRE is only an example and barrels may be added or subtracted depending on the product desired. Temperature control is maintained within zones 270, 280, 290 for example by heating/cooling medium through the barrel walls 220, 230, 240 as well as through a central bore 250 in the central spindle 260. In one embodiment, the polymer process temperature is maintained below 240° C. (e.g., the minimum degradation temperature for acrylic polymers and copolymers).
Y 3=1−(C′ 3 /C o)
Zn=1−(C″ n /C″ o)
Stream 750 having a conversion Z2 is carried into the first planetary roller barrel 760 and heated to about 25 to about 240° C. to continue the free-radical reaction process. The mixture is carried into a second planetary roller barrel 770 and a third planetary roller barrel 780, where a preset residence time is provided to minimize the residual monomer content of the finished polymer stream 840. Accurate temperature control can be maintained within barrels 760, 770, 780 by conducting heating/cooling medium through the barrel walls 790, 800, 810, respectively and close to the intermeshing surfaces, as well as through a central bore 830 in the central spindle 820. The polymer process temperature is maintained below the polymeric materials degradation temperature (i.e., 240° C. for butyl acrylic polymers). Planetary roller barrels 760, 770, 780 convert stream 750 having a flowrate P at a conversion Z2 into stream 840 having a flowrate P at a conversion Z3.
Typical tackifying resins may include, but are not limited to partially or fully hydrogenated wood, gum or tall oil rosins, esterified wood, gum or tall oil rosins, alpha and beta pinene resins and polyterpene resins. The resins may be introduced in solid, liquid, i.e. including, but not limited to solutions and dispersions and/or molten form. Typical anti-degradents include antioxidants, ultraviolet absorbers and ultraviolet stabilizers. Typical crosslinking agents may include peroxides, ionic, thermally-activated resins, isocyanates, UV, and/or EB activated curing agents. Typical colorants may include titanium dioxide and other various metal pigments. In the event that the use of solvents is desired, typical solvents may include liquid carboxylates such as ethyl acetate and n-butyl acetate, ketones such as acetone, dimethyl ketone and cyclohexanones, aromatic hydrocarbons such as benzene, toluene, and the xylenes, liquid aliphatic and cyclo-aliphatic hydrocarbons such as petroleum fractions having boiling points of about 50 and 150° C. and in particular about 60 and 100° C., cyclohexane, and others such as dioxane, tetrahydrofuran and di-t-butyl ethers or mixtures thereof. Particularly useful solvents for the polymeric composition of this disclosure may include ethyl acetate, cyclohexane, and mixtures of acetone with petroleum ether (e.g., having a boiling point of about 60 to about 95° C.).
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