A continuous production system, method and application for refined products

Abstract

This invention provides a continuous production system, method, and application for refined chemical products, relating to the field of cosmetic manufacturing technology. The continuous production system for refined chemical products of this invention includes a continuous tubular processor, automatic feeding equipment, extrusion equipment, continuous forming extrusion tooling, automatic slitting equipment, automatic packaging equipment, and discharge conveying device. It possesses continuous production capability, eliminating batch-to-batch quality fluctuations caused by intermittent processes. It facilitates the application of intelligent control systems and digital integration, enabling the overall process to have dynamic and stable quality control capabilities, resulting in high-quality products. Furthermore, this invention has the flexibility to start and stop the entire process at any time, eliminating time waste caused by coordination between processes in different production cycles, material waste caused by coordination between processes with different capacities, and waste from extra preparations to prevent quality abnormalities or waste from re-feeding production due to unprepared risks, thus facilitating resource conservation and cost reduction.

Description

Technical Field

[0001] This invention relates to the field of cosmetic manufacturing technology, and in particular to a continuous production system, method and application for refined chemical products. Background Technology

[0002] Traditional refined chemical products, including cosmetics and personal care products, currently utilize traditional batch production processes on a large scale. This processing method is characterized by its intuitiveness, phased nature, and ability to operate independently. Most traditional refined chemical products employ mixing containers (such as reaction vessels) as the main ingredient mixing and processing equipment. The simplest process can be expressed as follows: 1. Weigh each component; 2. Add each component (in a specific order) to the mixing container; 3. Mix the mixture in the mixing container for a certain period of time under specific temperature and pressure conditions; 4. Remove the mixture from the mixing container; 5. Transfer and / or shape the mixture.

[0003] However, the main problems with traditional intermittent production processes are: because equipment at each stage must operate intermittently, and the different processing capacities and cycles of each piece of equipment mean that the least efficient bottleneck stage limits overall process capacity and production cycle time, resulting in system waste. Furthermore, the hardware and software of equipment at each stage are not fully interconnected, necessitating phased data collection and quality control. These two problems caused by traditional intermittent processing processes are based on the logical principle of segmented processes and can only be minimized through process and technological improvements, but cannot be completely eliminated.

[0004] The above processes utilize different processing equipment and employ an intermittent processing technique. For example, since the mixing container can hold a maximum of 7kg of material at a time, while the weighing equipment can weigh a maximum of 5kg at a time, and each finished product weighs only 0.8kg, producing 20 products requires 16kg of material, involving 4 batching operations, 3 mixing operations, and 20 shaping operations. Furthermore, if there is even a single possibility of a defective product, it necessitates increased material input and carries the risk of waste, which in turn exacerbates the amount and likelihood of waste. Simultaneously, batch-to-batch quality variations are unavoidable.

[0005] Therefore, traditional intermittent processing technology has inherent disadvantages in terms of process stability and quality stability. Chinese patent CN209718735U discloses a wet powder extrusion device. It uses a first pressing cylinder to automatically press material from the storage chamber into the discharge chamber via a discharge pipe. A second pressing cylinder then presses the material from the discharge chamber into the extrusion chamber, and a second pressing plate acts as a material stopper. Sealing rings at both ends of the second pressing plate prevent material from escaping to the top. A feeding screw facilitates material conveying. However, this equipment primarily functions as product conveying and compaction, lacking mixing capabilities. Essentially, it remains a traditional intermittent processing technology and cannot solve the problems inherent in traditional intermittent production processes. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the present invention aims to provide a continuous production system for refined chemical products, encompassing the entire process from feeding and quantitative mixing to continuous production of finished or semi-finished products with stable quality and capacity. This objective is achieved through the following technical solution: A continuous production system for refined chemical products includes at least one continuous tubular processor and one or more of the following: automatic feeding equipment, extrusion equipment, continuous forming extrusion fixtures, automatic slitting equipment, automatic packaging equipment, and discharge conveying device.

[0007] Furthermore, the continuous tubular processor includes one or more of a mixing section, a kneading section, and a shearing section, which are located after the automatic feeding device and are used to mix and process materials; the continuous tubular processor and extrusion equipment include a screw extruder and / or a reciprocating screw extruder. Reciprocating screw extruders include, but are not limited to, Buss kneaders.

[0008] Furthermore, the mixing section includes a mixing chamber and a mixing screw. The mixing screw has through holes or notches along its helical direction, and the inner wall of the mixing chamber is provided with mixing columns and / or protrusions that obstruct the flow of materials.

[0009] The kneading section includes a kneading cavity, a kneading screw, and a kneading limiting port. The distance between the kneading screw and the kneading limiting port is adjustable.

[0010] The shearing section includes a shearing cavity, a shearing screw, a shearing column, and / or protrusions. The shearing section can be integrated with the mixing and kneading sections according to the needs of the actual application: by adjusting the thread density and the gap between the thread and the column and / or protrusions, the shearing effect of the mixing and kneading sections can be increased or decreased, simultaneously reducing or increasing their conveying capacity. The stronger the conveying capacity, the weaker the shearing effect. Through the separate or integrated design of the mixing, kneading, and shearing sections, more diverse process requirements can be accommodated.

[0011] Furthermore, the automatic feeding equipment includes a liquid feeding device and / or a solid feeding device;

[0012] The liquid feeding device and the solid feeding device include a feeding conveyor and an automatic metering feeder. The automatic metering feeder includes a feeding unit and a feeding control unit.

[0013] Furthermore, the feed conveyor of the liquid feeding device includes a pipe; the feeding control unit of the liquid feeding device includes a valve, which is used to control the flow rate and velocity of the liquid material;

[0014] The feeding control unit of the solid feeding device includes a loss-in-weight scale, which is equipped with a high-precision stable feeding control system and a loss-in-weight scale sensor.

[0015] Furthermore, the feed conveyor of the solid feeding device includes a conveyor belt;

[0016] The feeding section of the solid feeding device includes a hopper and a feeding screw located in the middle of the hopper.

[0017] Furthermore, the continuous production system for refined products also includes several monitoring sensors, which are installed in each piece of equipment in the continuous production system for refined products and are used to collect parameter signals of materials in each piece of equipment.

[0018] The parameter signals include one or more of the following: flow rate, temperature, pressure, viscosity, melt flow index, PVT coefficient, density, hardness, elastic modulus, Poisson's ratio, composition ratio, dispersibility, water content, filler content, foaming rate, porosity, color, gloss, transparency, refractive index, electrical conductivity, resistance, resistivity, dielectric constant, dielectric loss, thermal conductivity, specific heat capacity, coefficient of thermal expansion, and shrinkage rate.

[0019] By measuring the flow rate, temperature, pressure, viscosity, and other processing properties at a certain point in the system, the flow rate is preferably the weight flow rate or volume flow rate. The temperature can be the temperature at the heater or the temperature of the material. High pressure can damage the equipment and may cause instability in continuous operation. High viscosity can also damage the equipment, making it difficult to process and flow. This allows for easy monitoring of continuous production status and feedback signals, enabling the overall process to be automatically adjusted and stabilized.

[0020] By measuring parameters such as melt flow index (flow rate of material at a specific temperature, pressure, and pipe diameter), PVT coefficient (the relationship between pressure, volume, and temperature of material), density (mass per unit volume of material), hardness (the ability of material to resist penetration), elastic modulus (the ratio of material to dimensional change under a certain tensile force), shrinkage rate (the ratio of dimensional shrinkage during cooling and hardening of material), and Poisson's ratio (the ratio of dimensional change due to longitudinal stretching to dimensional shrinkage due to transverse shrinkage of material) in the material measurement system, subsequent processing parameters of the material can be obtained, which facilitates obtaining the performance that needs to be tested later in the production process, improves testing efficiency and timeliness, and enhances product quality control capabilities.

[0021] By measuring the composition ratio (the proportion between the components of the material), dispersibility (the uniformity between the components of the material), moisture content (the water content in the material), filling amount (the proportion of the unmelted part of the material during measurement), foaming rate (the volume ratio of the material containing air bubbles during measurement), and porosity (the volume ratio of the material containing voids during measurement), the quality performance of the material produced can be ensured by measuring the material composition ratio in a steady-state process. When the filling material flow is slow, it will gradually accumulate and block at a certain point, and the produced material will not meet the specifications. It can also obtain controlled addition of gas to form foam and uncontrolled cracking, which facilitates monitoring of the quality of material processing and timely adjustment of the process to ensure quality.

[0022] By measuring the color, gloss, transparency, refractive index, and other appearance parameters of the materials produced in the system, online measurement and feedback can be used to dynamically control the material's appearance quality and facilitate color matching. Measuring the electrical conductivity, resistance, resistivity, dielectric constant (a parameter for radio wave isolation), and dielectric loss (a parameter for radio wave penetration energy loss) of the materials produced in the system facilitates monitoring the product's electrical performance. Measuring the thermal conductivity, specific heat capacity, and coefficient of thermal expansion of the materials produced in the system facilitates monitoring the product's thermal performance.

[0023] Furthermore, the system also includes a central control device, which is electrically or wirelessly connected to monitoring sensors, automatic feeding equipment, continuous tubular processor, extrusion equipment, continuous forming extrusion tooling, automatic slitting equipment, automatic packaging equipment, and discharge conveying device.

[0024] Traditional refined chemical products, including cosmetics and personal care products, currently rely heavily on traditional intermittent production processes. This method is characterized by its intuitiveness, phased nature, and ability to operate independently. This invention, through the rational utilization and precise digital management, offers the possibility of achieving continuous, high-quality production of refined chemical products.

[0025] This invention enables continuous production of refined chemical products. This novel continuous production process for refined chemical products can achieve continuous production of finished or semi-finished products with stable quality and capacity, from feeding and quantitative mixing to finished product or semi-finished product output. It not only allows for real-time online monitoring of process parameters at each stage and output of real-time data, but also enables dynamic adjustment of process conditions at each stage, and even allows for start-up and complete shutdown at any time. It possesses both a high degree of continuous automation and high production flexibility. It is an innovation that propels the refined chemical product manufacturing industry from traditional manufacturing to intelligent manufacturing.

[0026] In this case, a loss-in-weight (DIW) device can be equipped for the continuous production system of refined chemical products. The DIW includes a high-precision, stable feeding control system to ensure that raw materials enter the single-screw extruder uniformly and continuously during feeding. A continuous conveying system can be installed on the DIW to continuously add material to it, ensuring that the DIW always contains the appropriate amount of raw material. Alternatively, one or more DIWs can be used, feeding material from the same or different screw positions within the continuous production system of refined chemical products. Simultaneously, sensors within the DIW can record and provide feedback on process conditions such as feeding speed and temperature, which are then adjusted by a central control unit.

[0027] Similarly, the continuous production system is also equipped with numerous sensors for temperature, pressure, and rotation speed, which record and feed back this information to the central control system. After processing by the continuous production system, various raw materials form a mixture with a certain degree of homogeneity. This mixture is then continuously extruded from the outlet of the extrusion equipment under screw pressure. This design can equip the outlet of the extrusion equipment with a temperature-adjustable continuous forming extrusion fixture, allowing the mixture to be continuously output as finished or semi-finished products in a fixed form, such as filaments, columns, or granules. If the mixture is continuously output in an uninterrupted form, a periodic automatic slitting device can be installed to achieve continuous slitting, forming, and filling. If the mixture is continuously output in a discrete form, a periodic collection device can be installed to achieve continuous filling. Finally, automatic packaging equipment and a discharge conveyor can be installed on the filled finished and semi-finished products to achieve continuous production of the final product.

[0028] The second objective of this invention is to provide a continuous production method for refined products. This objective is achieved through the following technical solution: a continuous production method for refined products, comprising the following steps:

[0029] A. The automatic feeding equipment transports the raw materials of refined products to the feeding position of the continuous production system of refined products. Different feeding positions are set with different conveying volumes or conveying frequencies according to the demand.

[0030] B. Different raw materials enter the continuous tubular processor through their respective automatic feeding equipment. The feeding control unit in the automatic feeding equipment is used to ensure that the rate at which raw materials enter the production equipment remains stable.

[0031] C. One or more continuous processes of mixing, kneading, shearing and chemical reaction of different raw materials in a continuous tubular processor, while pressurizing and pushing the resulting mixture.

[0032] D. The mixture is fed into a continuous forming extrusion fixture through an extrusion device to obtain a semi-finished or finished product through continuous forming.

[0033] E. After forming, the finished or semi-finished products are packaged by automatic cutting and packaging equipment and transported to the required location by automatic conveying devices.

[0034] F. All equipment in the continuous production system is equipped with sensors to provide real-time feedback on the process status of materials in each piece of equipment, such as flow rate, temperature, and pressure; the sensor signals are collected and sent to the central control device for unified adjustment.

[0035] Traditional batch production processes use different processing equipment for each step. Since the mixing container can hold a maximum of 7 kg of material at a time, and the weighing equipment can weigh a maximum of 5 kg at a time, and each finished product weighs only 0.8 kg, producing 20 products requires 16 kg of material, involving 4 batching processes, 3 mixing processes, and 20 shaping processes. Furthermore, if there is even a single possibility of a defective product, it necessitates increased material input and carries the risk of waste, which in turn exacerbates the amount and likelihood of waste. Simultaneously, batch-to-batch quality variations are unavoidable. Therefore, this invention proposes a novel continuous production process to replace the traditional batch processing process and solve the above problems.

[0036] The third objective of this invention is to provide an application of a continuous production system for refined products. The second objective of this invention is achieved through the following technical solution: an application of a continuous production system for refined products, wherein the continuous production system for refined products is applied in the field of cosmetics and daily necessities preparation, and the cosmetics and daily necessities are prepared.

[0037] The cosmetics include, but are not limited to, solid or liquid products such as lipstick, eyebrow pencil, lotion, and cream; the daily necessities include, but are not limited to, solid or liquid products such as toothpaste and soap.

[0038] This continuous production system and method for refined chemical products can be fully automatic or semi-automatic. Sensors and data feedback systems can be installed at all or some process nodes. The material state of the refined chemical products in this continuous production system can be either continuously combined or continuously dispersed. It can continuously realize various processing steps for refined chemical products, including but not limited to weighing, feeding, mixing, kneading, shearing, chemical reaction, extrusion, molding, packaging, and transportation.

[0039] Compared with the prior art, the present invention has the following beneficial effects:

[0040] (1) The refined product continuous production system of the present invention has continuous production capability by setting one or more of the following: automatic feeding equipment, continuous tubular processor, extrusion equipment, continuous forming extrusion tooling, automatic slitting equipment, automatic packaging equipment, and discharge conveying device. It integrates different processes into a continuous process, eliminates batch-to-batch quality fluctuations caused by intermittent processes. Since different processes are integrated into a continuous process, it is beneficial to apply intelligent control systems and digital integration. Since the independence of processes with different production capacities and production cycles is eliminated, the overall process has dynamic and stable quality control capability, resulting in high-quality products.

[0041] (2) The refined product continuous production system of the present invention has the flexibility to start and stop the entire process at any time, eliminates the time waste caused by the coordination between different production cycle processes, eliminates the material waste caused by the coordination between different capacity processes, eliminates the waste caused by the need for additional preparation due to the risk of abnormal finished product quality, or the waste caused by the failure to prepare additional materials due to the failure to prevent abnormal finished product quality, thus facilitating the saving of resources and reducing costs.

[0042] (3) The continuous production method of refined products of the present invention requires high-level continuous production equipment, as well as high-level informatization and automatic control capabilities. At the same time, it provides a new manufacturing mode for refined products. Continuous production can eliminate batch fluctuations, reduce waste caused by mismatch between cycle and capacity, reduce the risk of cost increase caused by quality abnormalities, and also help to concentrate scattered processes into overall control, which is convenient for intelligent transformation and intelligent management.

[0043] (4) The continuous production method for refined products of the present invention is novel in design but rich in process flexibility. In addition to single-screw extruders, other supporting equipment can be flexibly configured. Not only can the type of equipment be replaced, but the number of equipment can also be changed. Not only can the length of the entire continuous production process be increased, but also the individual continuous production links can be flexibly divided and combined.

[0044] (5) The continuous production method for refined products of the present invention also has strong processing capabilities, and can handle a wide range of raw materials and mixtures with viscosity, from emulsions to high-viscosity polymers. It can also realize chemical reactions between materials during the processing, and play the role of modifying materials, thereby making it possible to complete the continuous production from raw materials to final products. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of the continuous production system for refined products according to Embodiment 1 of the present invention;

[0046] Figure 2 This is a system block diagram of the refined product continuous production system of Embodiment 1 of the present invention;

[0047] Figure 3 This is a flowchart of the steps in a continuous production method for refined products according to Embodiment 2 of the present invention;

[0048] Reference numerals: 1. Automatic feeding equipment; 11. Liquid feeding device; 12. Solid feeding device; 13. Feeding section; 14. Feeding control section; 2. Continuous tubular processor; 3. Extrusion equipment; 4. Continuous forming extrusion fixture; 5. Automatic slitting equipment; 6. Automatic packaging equipment; 7. Discharge conveying device; 8. Monitoring sensor; 9. Central control device; 101. The automatic feeding equipment conveys the raw materials of refined products to the feeding positions of the continuous production system of refined products. Different feeding positions are set with different conveying volumes or conveying frequencies according to the demand; 102. Different raw materials enter the continuous tubular processor through their respective automatic feeding equipment. The feeding control section in the automatic feeding equipment is used to ensure the raw materials... 103. The material enters the production equipment at a stable rate; 104. Different raw materials undergo one or more continuous processes such as mixing, kneading, shearing, and chemical reaction in a continuous tubular processor, while the resulting mixture is pressurized and propelled; 105. The mixture passes through an extrusion device and enters a continuous forming extrusion fixture to obtain semi-finished or finished products through continuous forming; 106. After forming, the finished or semi-finished products are packaged by automatic slitting and automatic packaging equipment and transported to the required location by an automatic conveying device; 107. All equipment in the continuous production system is equipped with sensors to provide real-time feedback on the flow rate, temperature, pressure, and other process status of the materials in each device. The sensor signals are collected and uniformly adjusted by the central control device. Detailed Implementation

[0049] The following embodiments will help those skilled in the art to further understand the present invention, but do not limit the present invention in any way. In the following description, in order to clearly illustrate the structure and operation of the present invention, many directional terms will be used. However, terms such as "front," "back," "left," "right," "outer," "inner," "outward," "inward," "up," and "down" should be understood as convenient terms and not as limiting terms. In this document, "far," "near," "proximal," and "farthest" refer to the position of the operator, that is, "near" means closer to the operator and "far" means farther from the operator.

[0050] For those skilled in the art, various changes and modifications can be made without departing from the inventive concept, and all of these fall within the scope of protection of this invention. The endpoints and values ​​of the ranges disclosed herein are not limited to the precise ranges or values; these ranges or values ​​should be understood to include values ​​close to these ranges or values. Regarding numerical ranges, the endpoint values ​​of each range, the endpoint values ​​of each range and individual point values, and individual point values ​​can be combined to obtain one or more new numerical ranges. These numerical ranges should be considered as specifically disclosed herein. The invention will now be described in detail with reference to specific embodiments:

[0051] Example 1:

[0052] like Figure 1 As shown, this embodiment relates to a continuous production system for refined products, including a continuous tubular processor 2, an automatic feeding device 1, and an extrusion device 3. In a specific embodiment, there are three automatic feeding devices 1, a continuous tubular processor 2, and an extrusion device 3. The continuous tubular processor 2 includes several sets of mixing sections, kneading sections, and shearing sections, which are located after two automatic feeding devices 1 and are used to compound and blend multiple raw materials. The continuous tubular processor 2 and the extrusion device 3 include single-screw extruders and reciprocating single-screw extruders, which can be selected and combined as needed. The reciprocating single-screw extruder includes, but is not limited to, a Buss kneader.

[0053] In one specific embodiment, the mixing section includes a mixing chamber and a mixing screw. The mixing screw has through holes or notches evenly distributed along its helical direction. A mixing column is provided on the inner wall of the mixing chamber to ensure thorough mixing of the multi-purpose raw materials. The mixing column and the mixing screw should not interfere with each other. The kneading section includes a kneading chamber, a kneading screw, and a kneading limiting port. The distance between the kneading screw and the kneading limiting port is adjustable.

[0054] The automatic feeding device 1 includes a liquid feeding device 11 or a solid feeding device 12. Specifically, the three automatic feeding devices 1 include two solid feeding devices 12 and one liquid feeding device 11.

[0055] like Figure 2 As shown, the liquid feeding device 11 and the solid feeding device 12 include a feeding conveyor and an automatic metering feeder. The automatic metering feeder includes a feeding section 13 and a feeding control section 14. The feeding conveyor of the liquid feeding device 11 includes a pipe; the feeding section 13 of the liquid feeding device 11 includes a valve, which is used to control the flow rate and velocity of the liquid material.

[0056] The feeding control unit 14 includes a loss-in-weight scale, which is located above or to the side of the continuous tubular processor 2. The loss-in-weight scale is equipped with a high-precision stable feeding control system and a loss-in-weight scale sensor. The feed conveyor of the solid feeding device 12 includes a conveyor belt.

[0057] The feeding section 13 of the solid feeding device 12 includes a hopper and a feeding screw disposed in the middle of the hopper. The feeding screw is used to control the feeding rate.

[0058] In another embodiment, the continuous production system for refined products also includes a continuous forming extrusion fixture 4, an automatic slitting device 5, an automatic packaging device 6, a discharge conveying device 7, several monitoring sensors 8, and a central control device 9. The monitoring sensors 8 are installed in each piece of equipment in the system to collect the flow rate, temperature, and pressure signals of the material in each piece of equipment. The central control device 9 is electrically or wirelessly connected to the monitoring sensors 8, the automatic feeding device 1, the continuous tubular processor 2, the extrusion equipment 3, the continuous forming extrusion fixture 4, the automatic slitting device 5, the automatic packaging device 6, and the discharge conveying device 7.

[0059] Traditional refined chemical products, including cosmetics and personal care products, currently rely heavily on traditional intermittent production processes. This method is characterized by its intuitiveness, phased nature, and ability to operate independently. This invention, through the rational utilization and precise digital management, offers the possibility of achieving continuous, high-quality production of refined chemical products.

[0060] This invention enables continuous production of refined chemical products. This novel continuous production process for refined chemical products can achieve continuous production of finished or semi-finished products with stable quality and capacity, from feeding and quantitative mixing to finished product or semi-finished product output. It not only allows for real-time online monitoring of process parameters at each stage and output of real-time data, but also enables dynamic adjustment of process conditions at each stage, and even allows for start-up and complete shutdown at any time. It possesses both a high degree of continuous automation and high production flexibility. It is an innovation that propels the refined chemical product manufacturing industry from traditional manufacturing to intelligent manufacturing.

[0061] In this case, a loss-in-weight weighing device can be equipped for the continuous production system of refined chemical products. The loss-in-weight weighing device includes a high-precision, stable feeding control system to ensure that raw materials can enter the single-screw extruder uniformly and continuously during feeding. A continuous conveying system can be installed on the loss-in-weight weighing device to continuously add material, ensuring that there is always a suitable amount of raw material inside. Alternatively, one or more loss-in-weight weighing devices can be used, feeding material from the same or different screw positions in the continuous production system of refined chemical products. Simultaneously, sensors within the loss-in-weight weighing device can record and provide feedback on process conditions such as feeding speed and temperature, which are then adjusted by the central control unit 9.

[0062] Similarly, the continuous production system is also equipped with numerous sensors for temperature, pressure, and rotation speed, which record and feed back this information to the central control system. After processing by the continuous production system, various raw materials form a mixture with a certain degree of homogeneity. This mixture is then continuously extruded from the outlet of extrusion equipment 3 under screw pressure. This design can equip the outlet of extrusion equipment 3 with a temperature-adjustable continuous forming extrusion fixture 4, allowing the mixture to be continuously output as finished or semi-finished products in a fixed form, such as filaments, columns, or granules. If the mixture is continuously output in an uninterrupted form, a periodic automatic slitting device 5 can be installed to achieve continuous slitting, forming, and filling. If the mixture is continuously output in a discrete form, a periodic collection device can be installed to achieve continuous filling. Finally, the filled finished and semi-finished products can be equipped with automatic packaging equipment 6 and a discharge conveyor device 7 to achieve continuous production of the final product.

[0063] Example 2:

[0064] like Figure 3 As shown, this embodiment relates to an automated laser cutting production method, including the following steps:

[0065] Step A: The automatic feeding device 1 transports the raw materials of the refined products to the feeding position of the continuous production system of refined products. Different feeding positions are set with different conveying volumes or conveying frequencies according to the demand.

[0066] Step B: Different raw materials enter the continuous tubular processor 2 through their respective automatic feeding devices 1. The feeding control unit 14 in the automatic feeding device 1 is used to ensure that the rate at which the raw materials enter the production equipment remains stable.

[0067] Step C: Different raw materials undergo one or more continuous processes such as mixing, kneading, shearing, and chemical reaction within the continuous tubular processor 2, while the resulting mixture is pressurized and propelled.

[0068] In one specific embodiment, the following steps are also included:

[0069] Step D: The mixture passes through the extrusion equipment 3 and enters the continuous forming extrusion fixture 4 to obtain a semi-finished product or a finished product in a continuous forming manner;

[0070] Step E: After forming, the finished or semi-finished product is packaged by the automatic cutting equipment 5 and the automatic packaging equipment 6, and then transported to the required location by the automatic conveying device.

[0071] Step F: All equipment in the continuous production system is equipped with sensors to provide real-time feedback on parameters such as the flow rate, temperature, and pressure of materials in each piece of equipment; the sensor signals are collected and sent to the central control device 9 for unified adjustment.

[0072] The parameter signals also include pressure, viscosity, melt flow index, PVT coefficient, density, hardness, elastic modulus, Poisson's ratio, composition ratio, dispersibility, water content, filler content, foaming rate, porosity, color, gloss, transparency, refractive index, electrical conductivity, resistance, resistivity, dielectric constant, dielectric loss, thermal conductivity, specific heat capacity, coefficient of thermal expansion, and shrinkage rate.

[0073] By measuring the flow rate, temperature, pressure, viscosity, and other processing properties at a certain point in the system, the flow rate is preferably the weight flow rate or volume flow rate. The temperature can be the temperature at the heater or the temperature of the material. High pressure can damage the equipment and may cause instability in continuous operation. High viscosity can also damage the equipment, making it difficult to process and flow. This allows for easy monitoring of continuous production status and feedback signals, enabling the overall process to be automatically adjusted and stabilized.

[0074] By measuring parameters such as melt flow index (flow rate of material at a specific temperature, pressure, and pipe diameter), PVT coefficient (the relationship between pressure, volume, and temperature of material), density (mass per unit volume of material), hardness (the ability of material to resist penetration), elastic modulus (the ratio of material to dimensional change under a certain tensile force), shrinkage rate (the ratio of dimensional shrinkage during cooling and hardening of material), and Poisson's ratio (the ratio of dimensional change due to longitudinal stretching to dimensional shrinkage due to transverse shrinkage of material) in the material measurement system, subsequent processing parameters of the material can be obtained, which facilitates obtaining the performance that needs to be tested later in the production process, improves testing efficiency and timeliness, and enhances product quality control capabilities.

[0075] By measuring the composition ratio (the proportion between the components of the material), dispersibility (the uniformity between the components of the material), moisture content (the water content in the material), filling amount (the proportion of the unmelted part of the material during measurement), foaming rate (the volume ratio of the material containing air bubbles during measurement), and porosity (the volume ratio of the material containing voids during measurement), the quality performance of the material produced can be ensured by measuring the material composition ratio in a steady-state process. When the filling material flow is slow, it will gradually accumulate and block at a certain point, and the produced material will not meet the specifications. It can also obtain controlled addition of gas to form foam and uncontrolled cracking, which facilitates monitoring of the quality of material processing and timely adjustment of the process to ensure quality.

[0076] By measuring the color, gloss, transparency, refractive index, and other appearance parameters of the materials produced in the system, online measurement and feedback can be used to dynamically control the material's appearance quality and facilitate color matching. Measuring the electrical conductivity, resistance, resistivity, dielectric constant (a parameter for radio wave isolation), and dielectric loss (a parameter for radio wave penetration energy loss) of the materials produced in the system facilitates monitoring the product's electrical performance. Measuring the thermal conductivity, specific heat capacity, and coefficient of thermal expansion of the materials produced in the system facilitates monitoring the product's thermal performance.

[0077] Traditional batch production processes use different processing equipment for each step. Since the mixing container can hold a maximum of 7 kg of material at a time, and the weighing equipment can weigh a maximum of 5 kg at a time, and each finished product weighs only 0.8 kg, producing 20 products requires 16 kg of material, involving 4 batching processes, 3 mixing processes, and 20 shaping processes. Furthermore, if there is even a single possibility of a defective product, it necessitates increased material input and carries the risk of waste, which in turn exacerbates the amount and likelihood of waste. Simultaneously, batch-to-batch quality variations are unavoidable. Therefore, this invention proposes a novel continuous production process to replace the traditional batch processing process and solve the above problems.

[0078] The continuous production method for refined products of the present invention requires high-level continuous production equipment, as well as a high level of informatization and automatic control capabilities. At the same time, it provides a brand-new manufacturing mode for refined products. Continuous production can eliminate batch-to-batch fluctuations, reduce waste caused by mismatch between cycle and capacity, reduce the risk of cost increases caused by quality abnormalities, and also help to centralize scattered processes for overall control, facilitating intelligent transformation and intelligent management.

[0079] The continuous production method for refined products of this invention is novel in design yet highly flexible in terms of process. In addition to a single-screw extruder, other supporting equipment can be flexibly configured. Not only can the type of equipment be replaced, but the number of equipment can also be changed. This not only increases the length of the entire continuous production process, but also allows for the flexible division and combination of individual continuous production stages.

[0080] The continuous production method for refined products of the present invention also has strong processing capabilities, capable of handling a wide range of raw materials and mixtures with viscosity, from emulsions to high-viscosity polymers. It can also realize chemical reactions between materials during processing, playing a role in modifying materials, thereby making it possible to complete continuous production from raw materials to final products.

[0081] This continuous production system and method for refined chemical products can be fully automatic or semi-automatic. Sensors and data feedback systems can be installed at all or some process nodes. The material state of the refined chemical products in this continuous production system can be either continuously combined or continuously dispersed. It can continuously realize various processing steps for refined chemical products, including but not limited to weighing, feeding, mixing, kneading, shearing, chemical reaction, extrusion, molding, packaging, and transportation.

[0082] Example 3:

[0083] The application of a continuous production system for refined chemical products, specifically its application in the preparation of cosmetics and daily necessities, yields cosmetics and daily necessities.

[0084] Cosmetics include, but are not limited to, solid or liquid products such as lipstick, eyebrow pencil, lotion, and cream; daily necessities include, but are not limited to, solid or liquid products such as toothpaste and soap.

[0085] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A continuous production system for refined products, characterized in that, It includes at least one continuous tubular processor (2) and one or more of the following: automatic feeding equipment (1), extrusion equipment (3), continuous forming extrusion tooling (4), automatic slitting equipment (5), automatic packaging equipment (6), and discharge conveying device (7); The continuous tubular processor (2) includes one or more of a mixing section, a kneading section, and a shearing section. The mixing section, kneading section, and shearing section are located after the automatic feeding device (1) and are used to mix and process materials. The continuous tubular processor (2) and the extrusion device (3) include a screw extruder and / or a reciprocating screw extruder. The automatic feeding device (1) includes a liquid feeding device (11) and / or a solid feeding device (12); The liquid feeding device (11) and the solid feeding device (12) include a feeding conveyor and an automatic metering feeder. The automatic metering feeder includes a feeding unit (13) and a feeding control unit (14). The feed conveyor of the liquid feeding device (11) includes a pipe; the feeding control unit (14) of the liquid feeding device (11) includes a valve, which is used to control the flow rate and velocity of the liquid material; The feeding control unit (14) of the solid feeding device (12) includes a loss-in-weight scale, which is equipped with a high-precision stable feeding control system and a loss-in-weight scale sensor. The mixing section includes a mixing chamber and a mixing screw. The mixing screw has through holes or notches along its spiral direction. The inner wall of the mixing chamber is provided with mixing columns and / or protrusions that obstruct the flow of materials. The kneading section includes a kneading cavity, a kneading screw, and a kneading limiting port. The distance between the kneading screw and the kneading limiting port is adjustable. Furthermore, the shearing section can be designed separately from or integrated with the mixing section and kneading section, and the thread density and the gap between the thread and the pillar and / or protrusion in the mixing section, kneading section and shearing section are adjustable; The continuous production system for refined products also includes several monitoring sensors (8), which are installed in each piece of equipment in the continuous production system for refined products and are used to collect parameter signals of materials in each piece of equipment. The parameter signals include one or more of the following: flow rate, temperature, pressure, viscosity, melt flow index, PVT coefficient, density, hardness, elastic modulus, Poisson's ratio, composition ratio, dispersibility, water content, filler content, foaming rate, porosity, color, gloss, transparency, refractive index, electrical conductivity, resistance, resistivity, dielectric constant, dielectric loss, thermal conductivity, specific heat capacity, coefficient of thermal expansion, and shrinkage rate. The system also includes a central control device (9), which is electrically or wirelessly connected to a monitoring sensor (8), an automatic feeding device (1), a continuous tubular processor (2), an extrusion device (3), a continuous forming extrusion fixture (4), an automatic slitting device (5), an automatic packaging device (6), and a discharge conveying device (7).

2. The continuous production system for refined products according to claim 1, characterized in that, The feed conveyor of the solid feeding device (12) includes a conveyor belt; The feeding section (13) of the solid feeding device (12) includes a hopper and a feeding screw located in the middle of the hopper.

3. A method for continuous production of refined products using a continuous production system for refined products as described in claim 1 or 2, characterized in that, Includes the following steps: A. The raw materials of refined products are transported to the feeding position of the continuous production system of refined products by the automatic feeding equipment (1). Different feeding positions are set with different conveying volumes or conveying frequencies according to the demand. B. Different raw materials enter the continuous tubular processor (2) through their respective automatic feeding equipment (1). The feeding control unit (14) in the automatic feeding equipment (1) is used to ensure that the rate at which the raw materials enter the production equipment remains stable. C. Different raw materials undergo one or more continuous processes of mixing, kneading, shearing, and chemical reaction in a continuous tubular processor (2), while the resulting mixture is pressurized and propelled. D. The mixture passes through the extrusion equipment (3) and enters the continuous forming extrusion fixture (4) to obtain semi-finished or finished products in a continuous forming manner.

4. An application of a continuous production system for refined products, characterized in that, The cosmetics and daily necessities are prepared by applying the continuous production system for refined products as described in claim 1 or 2 in the field of cosmetics and daily necessities preparation.

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