Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J41/00—Anion exchange; Use of material as anion exchangers; Treatment of material for improving the anion exchange properties
  • B01J41/08—Use of material as anion exchangers; Treatment of material for improving the anion exchange properties
  • B01J41/12—Macromolecular compounds
  • B01J41/13—Macromolecular compounds obtained otherwise than by reactions only involving unsaturated carbon-to-carbon bonds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J47/00—Ion-exchange processes in general; Apparatus therefor
  • B01J47/12—Ion-exchange processes in general; Apparatus therefor characterised by the use of ion-exchange material in the form of ribbons, filaments, fibres or sheets, e.g. membranes
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/20—Manufacture of shaped structures of ion-exchange resins
  • C08J5/22—Films, membranes or diaphragms
  • C08J5/2206—Films, membranes or diaphragms based on organic and/or inorganic macromolecular compounds
  • C08J5/2218—Synthetic macromolecular compounds
  • C08J5/2231—Synthetic macromolecular compounds based on macromolecular compounds obtained by reactions involving unsaturated carbon-to-carbon bonds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2333/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
  • C08J2333/18—Homopolymers or copolymers of nitriles
  • C08J2333/20—Homopolymers or copolymers of acrylonitrile

Definitions

• This invention relates to ion exchange polymer compositions, and more particularly, to crosslinked ion exchange polymer compositions and ion exchange materials prepared from these polymer compositions having low water content and good ion exchange capacity.
• Ion exchange materials are commonly employed to treat and remove ionizable components from fluids for a variety of applications.
• Flow-through beds or flow-through devices for fluid treatment may employ exchange material or components in the form of grains, fabrics or membranes.
• the ion exchange functionality operates to transport one type of ion across the material in an electric field, while substantially or effectively blocking most ions of the opposite polarity.
• Anion exchange polymers and materials carry cationic groups, which repel cations and are selective to anions.
• Cation exchange polymers and materials carry anionic groups, which repel anions and are selective to cations.
• Increasing crosslinking density in ion exchange polymers can improve the mechanical integrity of ion exchange materials prepared from the polymers and reduce water content, but increasing the crosslinking density can also reduce the ion exchange capacity of the material to unacceptable levels.
• U.S. Patent No. 7,968,663 which is incorporated herein by reference, discloses anion exchange polymers prepared from the polymerization of a crosslinked quaternary ammonium monomer (primary crosslinker).
• primary crosslinker crosslinked quaternary ammonium monomer
• an ion exchange polymer composition includes a primary crosslinker and a secondary crosslinker, wherein the primary crosslinker includes a crosslinked ionic monomer including a quaternary ammonium group.
• a method for making an ion exchange polymer composition includes polymerizing a primary crosslinker with a secondary crosslinker, wherein the primary crosslinker includes a crosslinked ionic monomer including a quaternary ammonium group.
• a membrane in another embodiment, includes an ion exchange polymer composition including a primary crosslinker and a secondary crosslinker, wherein the primary crosslinker includes a crosslinked ionic monomer including a quaternary ammonium group.
• the various embodiments provide ion exchange polymer compositions with increased crosslinking density that are chemically resistant and non-fouling.
• the compositions produce materials, such as membranes, at lower cost with improved mechanical properties, smooth surfaces, good ion exchange capacity and a low and more controllable water uptake.
• the Figure is a graph illustrating the ion exchange capacity (IEC) and water content of an ion exchange membrane vs. the mole ratio of a tertiary amine (DMAPMA) to cyclohexanedimethanol diglycidyl ether in the primary crosslinker.
• IEC ion exchange capacity
• DMAPMA tertiary amine
• an ion exchange polymer composition includes a primary crosslinker and a secondary crosslinker, wherein the primary crosslinker includes a crosslinked ionic monomer including a quaternary ammonium group.
• an ion exchange polymer composition may be an anion with cationic groups.
• the primary crosslinker includes a crosslinked ionic monomer.
• the ionic monomer includes at least one cationic quaternary ammonium group.
• the ionic monomer includes at least one vinyl group, such as an acrylic group.
• the ionic monomer includes at least two ionic functional groups and at least two vinyl groups.
• the crosslinked ionic monomer may be prepared by reacting a polyepoxide with a tertiary amine including an acrylic group in the presence of an acid.
• the tertiary amine may be an ethylenic tertiary amine.
• Examples of an ethylenic tertiary amine with acrylic groups include dimethylaminopropylmethacrylamide (DMAPMA), dimethylaminopropylacrylamide (DMAPAA), diethylaminopropylmethacrylamide (DEAPMA), or dimethylaminoethylmethacrylate (DMAEMA).
• DMAPMA dimethylaminopropylmethacrylamide
• DMAPAA dimethylaminopropylacrylamide
• DEAPMA diethylaminopropylmethacrylamide
• DMAEMA dimethylaminoethylmethacrylate
• the polyepoxide may be any type of polyepoxide including at least two epoxide groups.
• the polyepoxide is a diglycidyl ether or a triglycidyl ether.
• Diglycidyl ethers include, but are not limited to, diethylene glycol diglycidyl ether, diglycidyl 1 ,2-cyclohexanedicarboxylate, N,N-diglycidyl-4-glycidyloxyaniline, bisphenol A diglycidyl ether, brominated bisphenol A diglycidyl ether, bisphenol F diglycidyl ether, 1 ,4-butanediol diglycidyl ether, 1 ,4-butanediyl diglycidyl ether, 1 ,4-cyclohexanedimethanol diglycidyl ether, glycerol diglycidyl ether, resorcinol diglycidyl ether, bis[4-(glycidyloxy)phenyl]methane, bisphenol A propoxylate diglycidyl ether, dimer acid diglycidyl ester, ethylene glycol diglycidyl ether, brominated
• Triglycidyl ethers include, but are not limited to, tris(2,3-epoxypropyl)isocyanurate, trimethylolpropane triglycidyl ether, tris(4-hydroxyphenyl)methane triglycidyl ether 2,6- tolylene diisocyanate, tris(4-hydroxyphenyl)methane triglycidyl ether, glycerol propoxylate triglycidyl ether and trimethylolethane triglycidyl ether.
• the polyepoxide is a diepoxide.
• Diepoxides include, but are not limited to, 1,3-butadiene-diepoxide, 1,3-butadiene diepoxide, dicyclopentadiene dioxide, methyl cis,cis-l l,12;14,15-diepoxyeicosanoate.
• the acid may be any type of acid, such as a mineral acid.
• the acid includes, but is not limited to, hydrochloric acid, methane sulfonic acid, sulfuric acid or phosphoric acid.
• the acid is present in an amount of from about 75 percent by mole weight to about 125 percent by mole weight, based on the mole weight of the tertiary amine. In another embodiment, the acid is present in an amount of from about 75 percent by mole weight to about 100 percent by mole weight, based on the mole weight of the tertiary amine.
• the tertiary amine is quatemized and crosslinked in the reaction.
• the temperature ranges from about 40°C to about 150°C. In another embodiment, the temperature range is from about 60°C to about 110°C and in another embodiment, the temperature range is from about 75°C to about 100°C.
• the reaction time is from about 1 minute to about 2 hours. In another embodiment, the reaction time is from about 10 minutes to about 1 hour. In another embodiment, the reaction time is from about 20 minutes to about 45 minutes.
• the monomer is highly crosslinked.
• the polymer is crosslinked in the range of from about 50 to about 100 percent. In another embodiment, the polymer is fully crosslinked.
• the ionic polymer may be synthesized using a wide ratio range of the tertiary amine to the polyepoxide.
• the ratio is from about 1.0 to about 2.5 moles of the tertiary amine to each equivalent mole of the polyepoxide.
• the ratio is from about 1.5 to about 2.0 moles of the tertiary amine monomer per equivalent mole of the polyepoxide.
• the ratio is about 1.5 moles of the tertiary amine monomer per equivalent mole of the epoxide.
• the crosslinked ionic monomer has structure I:
• R is -[CH 2 -CH(OH)] 2 -W; Ri is hydrogen or a Ci-Ci 2 alkyl group; Z is oxygen or N- R 3 ; R 2 is -[CH 2 ] n -; R 3 is hydrogen or -[CH 2 ] m -CH 3 ; R4 and R 5 are each, independently, -[CH 2 ] m — CH 3 ; X is selected from the group consisting of CI, Br, I and acetate; W is a bridging group or atom; m is an integer from 0 to 20; and n is an integer from 1 to 20.
• Ri is a Ci-C 6 alkyl group. In another embodiment, Ri is methyl, ethyl, propyl, butyl or isobutyl.
• Z is ammonia, trimethylammonia or triethylammonia.
• W is a bridging group or atom.
• W is a hydrocarbon group, an inorganic group or inorganic atom.
• W is a Ci-C 3 o alkyl group, Ci-C 3 o alkyl ether group, C 6 -C 3 o aromatic group, C 6 -C 3 o aromatic ether group or a siloxane.
• W is a Ci-C 6 alkyl group, Ci-C 6 alkyl ether group, a C 6 -Cio aromatic group or a C 6 -Cio aromatic ether group.
• W is methyl, ethyl, propyl, butyl, isobutyl, phenyl, 1 ,2-cyclohexanedicarboxylate, bisphenol A, diethylene glycol, resorcinol, cyclohexanedimethanol, poly(dimethylsiloxane), 2,6-tolylene diisocyanate, 1,3- butadiene or dicyclopentadiene.
• n is an integer from 0 to 10. In another embodiment, m is an integer from 0 to 5. In another embodiment, n is an integer from 1 to 10. In another embodiment, n is an integer from 1 to 5.
• a secondary crosslinker copolymerizes with the primary crosslinker to produce an ion exchange polymer having increased crosslinking density.
• the secondary crosslinker may be a non-ionic monomer.
• the secondary crosslinker includes divinyllic functionality.
• the secondary crosslinker may be N- methacrylamidomethy acrylamide .
• the secondary crosslinker may be prepared by reacting an acrylamide compound with another acrylamide compound including hydroxyl groups.
• the acrylamide may be methacrylamide (MAA).
• the acrylamide including hydroxyl groups may be N-hydroxymethylacrylamide (NHMA).
• the reaction occurs in the presence of an acid. In another embodiment, the reaction may proceed at room temperature.
• the secondary crosslinker may be synthesized using a wide ratio range of the acrylamide and acrylamide including hydroxyl groups. In one embodiment, the ratio is from about 0.1 to about 1.5 moles of the acrylamide to the acrylamide including hydroxyl groups. In another embodiment, the ratio is from about 0.1 to about 0.5 moles of the acrylamide to the acrylamide including hydroxyl groups. In another embodiment, the ratio is from about 1.0 moles to about 1.5 moles of the acrylamide to the acrylamide including hydroxyl groups.
• the acid may be any type of acid, such as a mineral acid.
• the acid includes, but is not limited to, hydrochloric acid, methane sulfonic acid, sulfuric acid or phosphoric acid.
• the amount of acid may be in a ratio of from about 0.1 mole to about 1.5 moles of the acid to the acrylamide including the hydroxyl groups.
• the amount of acid may be in a ratio of from about 0.1 mole to about 1.0 mole of the acid to the acrylamide including the hydroxyl groups.
• the amount of acid may be in a ratio of from about 0.1 mole to about 0.5 mole of the acid to the acrylamide including the hydroxyl groups.
• a method for making an ion exchange polymer composition includes polymerizing a primary crosslinker with a secondary crosslinker, wherein the primary crosslinker includes a crosslinked ionic monomer including a quaternary ammonium group.
• the primary crosslinker and secondary crosslinker are described above.
• Polymerization of the primary and secondary crosslinkers may be carried out by any means suitable for polymerizing and covalently bonding the primary and secondary crosslinkers.
• the polymerization may be photochemically with the addition of a photoiniator.
• photoiniators include benzophenone, benzyl, antraquinone, eosin or methylene blue.
• the polymerization may be by heating the reactants and monomers to a suitable temperature and for a time sufficient to covalently crosslink the compounds.
• the temperature range is from about 40°C to about 150°C.
• the temperature range is from about 60°C to about 110°C and in another embodiment, the temperature range is from about 75°C to about 100°C.
• the reaction time is from about 1 minute to about 2 hours. In another embodiment, the reaction time is from about 10 minutes to about 1.5 hours. In another embodiment, the reaction time is from about 30 minutes to about 1.5 hours.
• Polymerization may be conducted in the presence of an acid.
• the acid is a mineral acid.
• the acid includes, but is not limited to, hydrochloric acid, methane sulfonic acid, sulfuric acid or phosphoric acid.
• the acid may be added in an amount of from about 1 percent by weight to about 5 percent by weight, based on the weight of the reaction mixture.
• a catalyst may be added to aid in polymerization.
• the catalyst may be spontaneously activated or activated by heat, electromagnetic radiation, electron beam radiation or by chemical promoters.
• the catalyst may be added in any amount suitable for aiding in polymerization.
• the catalyst is in an amount of from about 0.1 to about 5.0 percent by weight of the reaction mixture.
• the catalyst may be added in an amount of from about 0.5 percent by weight to about 3.0 percent by weight, based on the weight of the reaction mixture.
• the catalyst may be added in an amount of from about 0.5 percent by weight to about 1.0 percent by weight, based on the weight of the reaction mixture.
• the catalyst is a radical polymerization initiator or a
• the catalyst is a peroxide.
• the peroxide includes, but is not limited to, methyl ethyl ketone peroxide and dibenzoyl peroxide.
• the catalyst is a water soluble or oil soluble azo initiator.
• the azo initiator includes, but is not limited to, 2,2'-azobis[2-(2-imidazolin-2- yl)propane]dihydrochloride, 2,2'-azobis(N,N'-dimethylene isobutyramidine)
• chemical promoters refers to a substance, which increases the rate of polymerization either by itself or in combination with another catalyst.
• UV radiation polymerization agents can become more efficient in the presence of chemical promoters, which are photoinitiators or chemical compounds that generate free radicals.
• chemical promoters which are photoinitiators or chemical compounds that generate free radicals.
• methyl ethyl ketone peroxide can function as a catalyst itself, but its rate of initiation can be greatly increase by small amounts of transition metal salt chemical promoters, such as, for example, cobalt naphthenate.
• dibenzoyl peroxide can function as a catalyst itself, but its action be accelerated by a dimethylaniline chemical promoter.
• photoinitiating chemical promoters include
• the components are combined in the presence of a solvent.
• a solvent Any solvent is suitable for use in this embodiment, so long as the solvent is not itself
• Solvents suitable in this embodiment include, but are not limited to, water, polyethylene glycols, dimethylsulfoxide, 2-pyrrolidone, N-methyl pyrrolidone and mixtures thereof.
• the amount of solvent is added in any amount suitable for solubilizing the
• the amount of solvent is from about 10 to about 90 percent by weight based on the total weight of the reaction mixture. In another embodiment, the amount of solvent is from about 20 to about 70 percent by weight based on the total weight of the reaction mixture. In another embodiment, the amount of solvent is from about 25 to about 50 percent by weight based on the total weight of the reaction mixture.
• Ion exchange materials may be prepared from the ion exchange polymer
• the ion exchange material may be an ion exchange membrane.
• a membrane includes an ion exchange polymer composition including a primary crosslinker and a secondary crosslinker, wherein the primary crosslinker includes a crosslinked ionic monomer including a quaternary ammonium group. The ion exchange polymer composition, primary crosslinker and secondary crosslinker are described above.
• the ion exchange polymer composition may be applied to a base or support membrane to provide ionic functionality to the membrane.
• a membrane may be formed by reinforcing a support fabric with the ion exchange polymer composition.
• a liquid mixture of the primary crosslinker and secondary crosslinker may be applied to the fabric by casting the liquid mixture onto the fabric or by soaking the fabric in the liquid mixture using individual pieces of fabric, multiple pieces of fabric arranged in stacks or with fabric from a roll in a continuous process.
• the base or support membrane may have any thickness suitable for preparing the desired membrane.
• the thickness is from about 1 mil to about 75 mils. In another embodiment, the thickness is from about 1 mil to about 50 mils. In another embodiment, the thickness is from about 1 mil to about 20 mils. In another embodiment, the thickness is from about 1 mil to about 10 mils.
• Polymerization occurs between the primary and secondary crosslinkers to form a dual-crosslinked ion exchange membrane supported by a fabric.
• polymerization can occur photochemically.
• polymerization can occur upon heating the membrane.
• the temperature range is from about 40°C to about 150°C.
• the temperature range is from about 60°C to about 110°C and in another embodiment, the temperature range is from about 75°C to about 100°C.
• the reaction time is from about 1 minute to about 2 hours. In another embodiment, the reaction time is from about 10 minutes to about 1.5 hours. In another embodiment, the reaction time is from about 30 minutes to about 1.5 hours.
• the membrane may be formed by imbibing a porous plastic film, such as polyethylene, polypropylene or Teflon®, with the ion exchange polymer composition.
• a porous plastic film such as polyethylene, polypropylene or Teflon®
• a liquid mixture of a primary crosslinker and secondary crosslinker can be applied to the porous plastic film by casting the liquid monomer mixture onto the porous plastic film or by soaking the porous plastic film in the liquid mixture.
• Polymerization occurs between the crosslinkers to form a dual-crosslinked ion exchange membrane supported by a porous plastic film.
• polymerization can occur photochemically.
• polymerization can occur upon heating the membrane.
• the temperature range is from about 40°C to about 150°C.
• the temperature range is from about 60°C to about 110°C and in another embodiment, the temperature range is from about 75°C to about 100°C.
• the reaction time is from about 1 minute to about 2 hours. In another embodiment, the reaction time is from about 10 minutes to about 1.5 hours. In another embodiment, the reaction time is from about 30 minutes to about 1.5 hours.
• the primary and secondary crosslinkers can be polymerized into a solid mass, processed and pulverized into small particles.
• the small particles can then be blended in an extruder and heated with a melted plastic, such as polyethylene or polypropylene.
• the plastic and ion exchange mixture can then be extruded into thin sheets of ion exchange membranes.
• the water content is a measurement of the amount of water absorbed by an ionic membrane.
• the ion exchange membrane has a water content of from about 30% to about 50%.
• the membrane has a water content of from about 36% to about 47%.
• the membrane has a water content of from about 37% to about 45%.
• the membrane has a water content of from about 37% to about 39%.
• the membrane has a water content of about 38%.
• the membrane has an ion exchange capacity (IEC) of from about 1.2 meq/g to about 2.4 meq/g.
• the membrane has an IEC of from about 1.5 meq/g to about 2.4 meq/g. In another embodiment, the membrane has an IEC in the range of from about 1.7 meq/g to about 2.4 meq/g. In another embodiment, the membrane has an IEC of from about 2.1 meq/g to about 2.4 meq/g. In another embodiment, the IEC value is from about 2.2 meq/g to about 2.3 meq/g.
• the pre-curing solution was made from two solutions.
• Solution 1 was for the primary crosslinking monomer and solution 2 was for the secondary crosslinking monomer.
• the final mix was prepared by adding solution 2 to solution 1 and stirring the reaction mixture for about 10 min.
• the total mix quantity of the combined solutions was 100 g.
• a 6" x 6" mylar sheet was place onto a 6" x 6" glass plate and the solution mixture was spread onto the mylar sheet.
• An acrylic cloth was placed on the mylar sheet and the mix was allowed to spread across the cloth.
• Another 6" x 6" mylar sheet was placed on the cloth and excess solution mix was wiped off the cloth.
• Another 6" x 6" glass plate was placed on the second mylar sheet and the glass/mylar/cloth/mylar/glass sandwich structure was clamped using binder clips. The sandwich was placed in the oven at 85°C for 60 min for curing.
• the membrane envelope was removed from the oven, cooled for 15 min and the glass plates were pried open. The mylar sheets were then carefully separated from the membrane. The membrane was placed in deionized water for at least 4 hours and analyzed. IEC and water content were measured. Results are shown in the Figure.
• the ion exchange capacity (IEC) was expressed as milligram-equivalents per gram of dry ion exchange resin in the nitrate form (i.e., not including fabric).
• the water content (WC) was expressed as percent by weight of the wet ion exchange resin in the nitrate form (i.e., not including fabric).
• the smoothness factor was determined by visually comparing the membrane to a commercial membrane having a smoothness factor of 5.

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