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The hard template method for the preparation of monodisperse mesoporous silica microspheres (MPSMs) has been established in recent years. In this process, in situ-generated silica nanoparticles (SNPs) enter the porous organic template and control the size and pore parameters of the final MPSMs. Here, the sizes of the deposited SNPs are determined by the hydrolysis and condensation rates of different alkoxysilanes in a base catalyzed sol–gel process. Thus, tetramethyl orthosilicate (TMOS), tetraethyl orthosilicate (TEOS), tetrapropyl orthosilicate (TPOS) and tetrabutyl orthosilicate (TBOS) were sol–gel processed in the presence of amino-functionalized poly (glycidyl methacrylate-co-ethylene glycol dimethacrylate) (p(GMA-co-EDMA)) templates. The size of the final MPSMs covers a broad range of 0.5–7.3 µm and a median pore size distribution from 4.0 to 24.9 nm. Moreover, the specific surface area can be adjusted between 271 and 637 m2 g−1. Also, the properties and morphology of the MPSMs differ according to the SNPs. Furthermore, the combination of different alkoxysilanes allows the individual design of the morphology and pore parameters of the silica particles. Selected MPSMs were packed into columns and successfully applied as stationary phases in high-performance liquid chromatography (HPLC) in the separation of various water-soluble vitamins.
Determination of the gel point of formaldehyde-based wood adhesives by using a multiwave technique
(2023)
Determining the instant of gelation of formaldehyde-based wood adhesives as an assessment parameter for their curing rate is important for optimizing the curing behavior. Due to the stoichiometrically imbalanced networks of formaldehyde-based adhesives, the crossover point of storage G′ and loss modulus G″ cannot unconditionally be assumed as the gel point in oscillatory time sweeps as the material response is frequency-dependent. This study aims to determine the gel point of selected adhesives by the isothermal multiwave oscillatory shear test. A thorough comparison between the gel and the crossover point of G′ and G″ is performed. Rheokinetic analysis showed no significant difference between the activation energies calculated at the gel point determined by a multiwave test and the crossover point obtained by the time sweep test. Hence, for resins with similar curing reactions, a reliable determination of gel point by applying a multiwave test is needed for a comparison of their reactivity.
Sol-gel-controlled size and morphology of mesoporous silica microspheres using hard templates
(2023)
Mesoporous silica microspheres (MPSMs) represent a promising material as a stationary phase for HPLC separations. The use of hard templates provides a preparation strategy for producing such monodisperse silica microspheres. Here, 15 MPSMs were systematically synthesized by varying the sol–gel reaction parameters of water-to-precursor ratio and ammonia concentration in the presence of a porous p(GMA-co-EDMA) polymeric hard template. Changing the sol–gel process factors resulted in a wide range of MPSMs with varying particle sizes from smaller than one to several micrometers. The application of response surface methodology allowed to derive quantitative predictive models based on the process factor effects on particle size, pore size, pore volume, and specific surface area of the MPSMs. A narrow size distribution of the silica particles was maintained over the entire experimental space. Two larger-scale batches of MPSMs were prepared, and the particles were functionalized with trimethoxy(octadecyl) silane for the application as stationary phase in reversed-phases liquid chromatography. The separation of proteins and amino acids was successfully accomplished, and the effect of the pore properties of the silica particles on separation was demonstrated.
Mesoporous silica microspheres (MPSMs) find broad application as separation materials in high liquid chromatography (HPLC). A promising preparation strategy uses p(GMA-co-EDMA) as hard templates to control the pore properties and a narrow size distribution of the MPMs. Here six hard templates were prepared which differ in their porosity and surface functionalization. This was achieved by altering the ratio of GMA to EDMA and by adjusting the proportion of monomer and porogen in the polymerization process. The various amounts of GMA incorporated into the polymer network of P1-6 lead to different numbers of tetraethylene pentamine in the p(GMA-co-EDMA) template. This was established by a partial least squares regression (PLS-R) model, based on FTIR spectra of the templates. Deposition of silica nanoparticles (SNP) into the template under Stoeber conditions and subsequent removal of the polymer by calcination result in MPSM1-6. The size of the SNPs and their incorporation depends on the pore parameters of the template and degree of TEPA functionalization. Moreover, the incorporated SNPs construct the silica network and control the pore parameters of the MPSMs. Functionalization of the MPSMs with trimethoxy (octadecyl) silane allows their use as a stationary phase for the separation of biomolecules. The pore characteristics and the functionalization of the template determine the pore structure of the silica particles and, consequently, their separation properties.
Hybrid organic/inorganic nanocomposites combine the distinct properties of the organic polymer and the inorganic filler, resulting in overall improved system properties. Monodisperse porous hybrid beads consisting of tetraethylene pentamine functionalized poly(glycidyl methacrylateco-ethylene glycol dimethacrylate) particles and silica nanoparticles (SNPs) were synthesized under Stoeber sol-gel process conditions. A wide range of hybrid organic/silica nanocomposite materials with different material properties was generated. The effects of n(H2O)/n(TEOS) and c(NH3 ) on the hybrid bead properties particle size, SiO2 content, median pore size, specific surface area, pore volume and size of the SNPs were studied. Quantitative models with a high robustness and predictive power were established using a statistical and systematic approach based on response surface methodology. It was shown that the material properties depend in a complex way on the process factor settings and exhibit non-linear behaviors as well as partly synergistic interactions between the process factors. Thus, the silica content, median pore size, specific surface area, pore volume and size of the SNPs are non-linearly dependent on the water-to-precursor ratio. This is attributed to the effect of the water-to-precursor ratio on the hydrolysis and condensation rates of TEOS. A possible mechanism of SNP incorporation into the porous polymer network is discussed.
For optimization of production processes and product quality, often knowledge of the factors influencing the process outcome is compulsory. Thus, process analytical technology (PAT) that allows deeper insight into the process and results in a mathematical description of the process behavior as a simple function based on the most important process factors can help to achieve higher production efficiency and quality. The present study aims at characterizing a well-known industrial process, the transesterification reaction of rapeseed oil with methanol to produce fatty acid methyl esters (FAME) for usage as biodiesel in a continuous micro reactor set-up. To this end, a design of experiment approach is applied, where the effects of two process factors, the molar ratio and the total flow rate of the reactants, are investigated. The optimized process target response is the FAME mass fraction in the purified nonpolar phase of the product as a measure of reaction yield. The quantification is performed using attenuated total reflection infrared spectroscopy in combination with partial least squares regression. The data retrieved during the conduction of the DoE experimental plan were used for statistical analysis. A non-linear model indicating a synergistic interaction between the studied factors describes the reactor behavior with a high coefficient of determination (R²) of 0.9608. Thus, we applied a PAT approach to generate further insight into this established industrial process.
Monodisperse porous poly(glycidyl methacrylate-co-ethylene glycol dimethacrylate) particles are widely applied in different fields, as their pore properties can be influenced and functionalization of the epoxy group is versatile. However, the adjustment of parameters which control morphology and pore properties such as pore volume, pore size and specific surface area is scarcely available. In this work, the effects of the process factors monomer:porogen ratio, GMA:EDMA ratio and composition of the porogen mixture on the response variables pore volume, pore size and specific surface area are investigated using a face centered central composite design. Non-linear effects of the process factors and second order interaction effects between them were identified. Despite the complex interplay of the process factors, targeted control of the pore properties was possible. For each response a response surface model was derived with high predictive power (all R2 predicted > 0.85). All models were tested by four external validation experiments and their validity and predictive power was demonstrated.
Metalworking fluids (MWFs) are widely used to cool and lubricate metal workpieces during processing to reduce heat and friction. Extending a MWF’s service life is of importance from both economical and ecological points of view. Knowledge about the effects of processing conditions on the aging behavior and reliable analytical procedures are required to properly characterize the aging phenomena. While so far no quantitative estimations of ageing effects on MWFs have been described in the literature other than univariate ones based on single parameter measurements, in the present study we present a simple spectroscopy-based set-up for the simultaneous monitoring of three quality parameters of MWF and a mathematical model relating them to the most influential process factors relevant during use. For this purpose, the effects of MWF concentration, pH and nitrite concentration on the droplet size during aging were investigated by means of a response surface modelling approach. Systematically varied model MWF fluids were characterized using simultaneous measurements of absorption coefficients µa and effective scattering coefficients µ’s. Droplet size was determined via dynamic light scattering (DLS) measurements. Droplet size showed non-linear dependence on MWF concentration and pH, but the nitrite concentration had no significant effect. pH and MWF concentration showed a strong synergistic effect, which indicates that MWF aging is a rather complex process. The observed effects were similar for the DLS and the µ’s values, which shows the comparability of the methodologies. The correlations of the methods were R2c = 0.928 and R2P = 0.927, as calculated by a partial least squares regression (PLS-R) model. Furthermore, using µa, it was possible to generate a predictive PLS-R model for MWF concentration (R2c = 0.890, R2P = 0.924). Simultaneous determination of the pH based on the µ’s is possible with good accuracy (R²c = 0.803, R²P = 0.732). With prior knowledge of the MWF concentration using the µa-PLS-R model, the predictive capability of the µ’s-PLS-R model for pH was refined (10 wt%: R²c = 0.998, R²p = 0.997). This highlights the relevance of the combined measurement of µa and µ’s. Recognizing the synergistic nature of the effects of MWF concentration and pH on the droplet size is an important prerequisite for extending the service life of an MWF in the metalworking industry. The presented method can be applied as an in-process analytical tool that allows one to compensate for ageing effects during use of the MWF by taking appropriate corrective measures, such as pH correction or adjustment of concentration.
The isothermal curing of melamine resin is investigated by in-line infrared spectroscopy at different temperatures. The infrared spectra are decomposed into time courses of characteristic spectral patterns using Multivariate Curve Resolution (MCR). It was found that depending on the applied curing temperature, melamine films with different spectral fingerprints and correspondingly different chemical network structures are formed. The network structures of fully cured resin films are specific for the applied curing temperatures used and cannot simply be compensated by changes in the curing time. For industrial curing processes, this means that cure temperature is the main system determining factor at constant M:F ratio. However, different MF resin networks can be specifically obtained from one and the same melamine resin by suitable selection of the curing time and temperatures profiles to design resin functionality. The spectral fingerprints after short curing time as well as after long curing time reflect the fundamental differences in the thermoset networks that can be obtained with industrial short-cycle and multi-daylight presses.
Melamine-formaldehyde (MF) resins are widely used as surface finishes for engineered wood-based panels in decorative laminates. Since no additional glue is applied in lamination, the overall residual curing capacity of MF resins is of great technological importance. Residual curing capacity is measured by differential scanning calorimetry (DSC) as the exothermic curing enthalpy integral of the liquid resin. After resin synthesis is completed, the resulting pre-polymer has a defined chemical structure with a corresponding residual curing capacity. Predicting the residual curing capacity of a resin batch already at an early stage during synthesis would enable corrective measures to be taken by making adjustments while synthesis is still in progress. Thereby, discarding faulty batches could be avoided. Here, by using a batch modelling approach, it is demonstrated how quantitative predictions of MF residual curing capacity can be derived from inline Fourier Transform infrared (FTIR) spectra recorded during resin synthesis using partial least squares regression. Not only is there a strong correlation (R2 = 0.89) between the infrared spectra measured at the end of MF resin synthesis and the residual curing capacity. The inline reaction spectra obtained already at the point of complete dissolution of melamine upon methylolation during the initial stage of resin synthesis are also well suited for predicting final curing performance of the resin. Based on these IR spectra, a valid regression model (R2 = 0.85) can be established using information obtained at a very early stage of MF resin synthesis.