Emulsion copolymer cation exchange resins

Claim 2

A liquid cation exchange material comprising an emulsion of submicroscopic, approximately spherical beads of previously isolated, crosslinked emulsion copolymer having diameters within the range from about 0.01 to about 1.5 micrometers, and bearing from about 0.7 to about 1.5 cation exchange functional groups per monomer unit, the cation exchange functional groups being selected from the group consisting of strongly acidic functional groups and the free acid form of weakly acidic functional groups.

Claim 3

The liquid cation exchange material of claim 1 wherein the cation exchange functional groups are strongly acidic functional groups.

Claim 4

The liquid cation exchange material of claim 2 wherein the copolymer is an aromatic copolymer.

Claim 5

The liquid cation exchange material of claim 3 wherein the copolymer is an styrene copolymer.

Claim 6

The liquid cation exchange material of claim 4 wherein the styrene copolymer is a copolymer of styrene and divinylbenzene.

Claim 7

The liquid cation exchange material of claim 1 wherein the cation exchange functional groups are the free acid form of weakly acidic functional groups.

Claim 8

The liquid cation exchange material of claim 6 wherein the copolymer is an acrylic copolymer.

Claim 9

A weakly acidic cation exchange composition derived from the liquid cation exchange material of claim 6, comprising approximately spherical beads of crosslinked emulsion copolymer having diameters within the range from about 0.01 to about 1.5 micrometers and bearing from about 0.7 to about 1.5 weakly acidic cation exchange functional groups in the free acid form per monomer unit.

Claim 10

The liquid cation exchange material of claim 1 wherein the beads have a mean diameter of from about 0.01 to about 0.5 micrometers.

Claim 11

A process for preparing submicroscopic cation exchange resin particles comprising approximately spherical beads of crosslinked copolymer having diameters within the range from about 0.01 to about 1.5 micrometers and bearing from about 0.7 to about 1.5 strongly acidic cation exchange functional groups per monomer unit, which process comprises the steps of: (a) emulsion polymerizing a mixture of a major amount of a monoethylenically unsaturated monomer and a minor amount of a polyethylenically unsaturated monomer to form an emulsion of crosslinked copolymer beads, (b) adding the emulsion to a coagulant liquid to form coagulum particles of the copolymer beads, (c) separating the coagulum particles, from the emulsion polymerization medium, (d) functionalizing the coagulum particles with strongly acidic cation exchange functional groups, and (e) subsequently resuspending the coagulum of copolymer beads in a liquid medium to form an emulsion.

Claim 12

A process for preparing submicroscopic cation exchange resin particles comprising approximately spherical beads of crosslinked copolymer having diameters within the range from about 0.01 to about 1.5 micrometers and bearing from about 0.7 to about 1.5 strongly acidic cation exchange functional groups per monomer unit, which process comprises the steps of: (a) emulsion polymerizing a mixture of a major amount of a monoethylenically unsaturated monomer and a minor amount of a polyethylenically unsaturated monomer to form an emulsion of crosslinked copolymer beads, (b) adding the emulsion to a coagulant liquid to form coagulum particles of the copolymer beads, (c) separating the coagulum particles, from the emulsion polymerization medium, (d) functionalizing the coagulum particles with strongly acidic cation exchange functional groups, and (e) subsequently resuspending the coagulum of copolymer beads in a liquid medium to form an emulsion.

Claim 13

The process according to claim 10 wherein the copolymer beads are functionalized with strongly acidic cation exchange functional groups by reacting them with concentrated sulfuric acid.

Claim 14

A process for preparing submicroscopic cation exchange resin particles comprising approximately spherical beads of crosslinked copolymer having diameters within the range from about 0.01 to about 1.5 micrometers and bearing from about 0.7 to about 1.5 weakly acidic cation exchange functional groups per monomer unit, the weakly acidic groups being in the free acid form, which process comprises the steps of: (a) emulsion polymerizing a major amount of an acrylic ester monomer and a minor amount of a polyethylenically unsaturated monomer to form an emulsion of crosslinked acrylic copolymer beads, (b) hydrolyzing the ester linkages of the acrylic copolymer beads with a strong acid to form carboxylic cation exchange functional groups in the free acid form, and to concurrently form a coagulum of the functionalized copolymer beads, and (c) resuspending the coagulum of functionalized copolymer beads to form an emulsion of the functionalized copolymer beads.

Claim 15

A process for preparing submicroscopic cation exchange resin particles comprising approximately spherical beads of crosslinked copolymer having diameters within the range from about 0.01 to about 1.5 micrometers and bearing from about 0.7 to about 1.5 weakly acidic cation exchange functional groups per monomer unit, the weakly acidic groups being in the free acid form, which process comprises the steps of: (a) emulsion polymerizing a major amount of an acrylic ester monomer and a minor amount of a polyethylenically unsaturated monomer to form an emulsion of crosslinked acrylic copolymer beads, (b) hydrolyzing the ester linkages of the acrylic copolymer beads with a strong acid to form carboxylic cation exchange functional groups in the free acid form, and to concurrently form a coagulum of the functionalized copolymer beads, and (c) resuspending the coagulum of functionalized copolymer beads to form an emulsion of the functionalized copolymer beads.

Claim 16

A process for preparing submicroscopic cation exchange resin particles comprising approximately spherical beads of crosslinked copolymer having diameters within the range from about 0.01 to about 1.5 micrometers and bearing from about 0.7 to about 1.5 weakly acidic cation exchange functional groups per monomer unit, the weakly acidic groups being in the free acid form, which process comprises the steps of: (a) emulsion polymerizing a major amount of an acrylic ester monomer and a minor amount of a polyethylenically unsaturated monomer to form an emulsion of crosslinked acrylic copolymer beads, (b) hydrolyzing the ester linkages of the acrylic copolymer beads with an alkali hydroxide to form carboxylic cation exchange functional groups in the alkali salt form, and (c) contacting the emulsion of functionalized copolymer beads with strongly acidic cation exchange resin in the free acid form, to convert the functionalized emulsion copolymer beads in the emulsion to the free acid form.

Claim 17

A process for preparing submicroscopic cation exchange resin particles comprising approximately spherical beads of crosslinked copolymer having diameters within the range from about 0.01 to about 1.5 micrometers and bearing from about 0.7 to about 1.5 weakly acidic cation exchange functional groups per monomer unit, the weakly acidic groups being in the free acid form, which process comprises the steps of: (a) emulsion polymerizing a major amount of an acrylic ester monomer and a minor amount of a polyethylenically unsaturated monomer to form an emulsion of crosslinked acrylic copolymer beads, (b) hydrolyzing the ester linkages of the acrylic copolymer beads with an alkali hydroxide to form carboxylic cation exchange functional groups in the alkali salt form, and (c) contacting the emulsion of functionalized copolymer beads with strongly acidic cation exchange resin in the free acid form, to convert the functionalized emulsion copolymer beads in the emulsion to the free acid form.

Claim 20

The method of claim 14 wherein the emulsion is removed from the liquid after removal of the impurities by adding a flocculating agent to the liquid to form a floc with the emulsion particles, and subsequently separating the floc from the liquid.

Claim 21

The liquid cation exchange material of claim 5 wherein the beads have from about 0.8 to about 1.2 cation exchange functional groups per monomer unit.