Thin film micro-suspension drying forming process
By optimizing the structure of the spray equipment and drying chamber, combining efficient stirring equipment and temperature adjustment, the problems of uneven thickness and unstable anti-fog performance in the film micro-suspended drying molding process are solved, and uniformity and anti-fog effect are improved.
Patent Information
- Application Number
- CN202510727253.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-03
- Publication Date
- 2025-07-25
AI Technical Summary
In the existing film micro-suspended drying molding process, the anti-fog performance instability caused by uneven film thickness, uneven droplet size distribution, uneven air flow field and inconsistent drying temperature.
The optimized spray equipment and drying chamber structure are adopted to ensure uniform particle size of the droplets, uniform distribution of the airflow through the airflow circulation system, and a temperature sensor is installed to adjust the temperature of the drying area in real time. At the same time, efficient stirring equipment and mixing processes are used in the raw material mixing stage to ensure uniform dispersion of anti-fog agents, optimize drying process parameters, and reduce volatility and decomposition of anti-fog agents.
The film thickness uniformity and anti-fog performance stability are achieved, the film transparency and anti-fog effect are improved, the mechanical properties are enhanced, and the temperature and airflow uniformity are ensured.
Smart Images
Figure CN120363493A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of thin film production, specifically to a micro-suspension drying and forming process for thin films. Background Art
[0002] At present, there are various types of thin films, including anti-fog highly transparent environmental protection films. Anti-fog films are usually used in occasions where the surface needs to remain transparent and prevent fogging, such as automobile windshields, spectacle lenses, greenhouse greenhouses, etc. High transparency means that the thin film has a high light transmittance, and environmental protection may refer to the material being recyclable, non-toxic or degradable. The micro-suspension drying and forming process may refer to a method for producing such thin films, involving the treatment of suspended particles or micro-nano levels, as well as the optimization of the drying process.
[0003] The existing micro-suspension drying and forming process for thin films still has the following problems: the thickness of the thin film is uneven. During the micro-suspension drying process, factors such as uneven droplet size distribution, uneven air flow field, or inconsistent drying temperature may all cause differences in the thickness of the thin film. In addition, its anti-fog performance is unstable. Uneven distribution of the anti-fog agent in the thin film, loss of the anti-fog agent during the drying process, or adverse reactions with other components may all affect the anti-fog performance of the thin film.
[0004] Therefore, we have developed a new micro-suspension drying and forming process for thin films. Summary of the Invention
[0005] (I) Technical Problems to be Solved In view of the deficiencies of the prior art, the present invention provides a micro-suspension drying and forming process for thin films, which solves the above problems.
[0006] (II) Technical Solutions To achieve the above objectives, the present invention is realized through the following technical solutions: a micro-suspension drying and forming process for thin films, including a micro-suspension drying and forming process, the micro-suspension drying and forming process produces an anti-fog highly transparent environmental protection thin film, and the micro-suspension drying and forming process includes the following specific steps: S01. Raw material preparation: Select a suitable bio-based material as the base resin, add functional additives according to the performance requirements of the desired thin film, and mix these raw materials evenly in a certain proportion to obtain the raw material system of the thin film; S02. Solution or suspension preparation: Add the mixed raw materials to an appropriate solvent, stir to dissolve or disperse, and form a solution or suspension with a certain concentration and viscosity; S03. Micro-suspension formation: Convert the solution or suspension into tiny droplets or particles by means of spraying or jetting, etc., so that it forms a micro-suspension state in the air; S04. Drying and forming, the heating method usually uses hot air as the drying medium. The air is heated to an appropriate temperature by a heating device. The hot air can form a uniform air flow field in the drying area through a circulating fan, enabling the micro-suspended droplets or particles to fully contact the hot air and achieve rapid drying; S05. Film collection: During the drying process, the micro-suspended droplets or particles gradually lose the solvent and form a solid film. When the film reaches a certain degree of dryness, it is collected by a collection device and transferred from the drying area to the subsequent processing procedures.
[0007] Preferably, the anti-fog high-transparency environmental protection film uses biodegradable materials such as polylactic acid and polyhydroxyalkanoates as the base material.
[0008] Preferably, the anti-fog functional layer of the anti-fog high-transparency environmental protection film is designed with a hydrophilic coating, an internal addition type anti-fog agent, and nano-structure regulation is adopted.
[0009] Preferably, the optical performance optimization of the anti-fog high-transparency environmental protection film includes low haze design and wide-band light transmission.
[0010] Preferably, in the hybrid extrusion process of the anti-fog high-transparency environmental protection film, molecular design is optimized. A two-component anti-fog agent is used. The hydrophilic component provides rapid anti-fogging, and the lipophilic component maintains the performance for a long time. The anti-fog agent is encapsulated in mesoporous silica or graphene quantum dots, and the migration rate is slowed down through the confinement effect. Finally, a cross-linked network is fixed, and dynamic covalent bonds are introduced into the coating, so that the anti-fog agent is anchored on the surface of the base material through reversible cross-linking while maintaining the anti-fogging activity.
[0011] Preferably, in the extrusion molding process of the anti-fog high-transparency environmental protection film, nano-enhancement technology is adopted. Cellulose nanocrystals or graphene nanosheets are added. The tensile strength is increased to 19.54 MPa, and PLA and polyhydroxyalkanoates are blended and modified. The interfacial compatibility is enhanced through an interfacial compatibilizer, and the elongation at break is increased to 1600%. Finally, supramolecular self-healing is carried out, and a dynamic hydrogen bond network is introduced. The material can self-heal within 3 seconds after fracture, and the mechanical property recovery rate reaches 98%.
[0012] Preferably, in the micro-suspension formation process, the spraying equipment is optimized to ensure uniform droplet size. By designing a reasonable drying chamber structure and air flow circulation system, the air flow is evenly distributed. Multiple temperature sensors are installed to monitor and adjust the temperature in the drying area in real time to ensure temperature uniformity.
[0013] Preferably, in the micro-suspension formation process, in the raw material mixing stage, more efficient stirring equipment and mixing processes are adopted to ensure that the anti-fog agent is evenly dispersed in the raw materials, the drying process parameters are optimized to reduce the volatilization and decomposition of the anti-fog agent during drying, and the raw materials are pretreated to remove impurities that may react with the anti-fog agent.
[0014] (III) Beneficial Effects The present invention provides a film micro-suspension drying and forming process, which has the following beneficial effects: 1. In this film micro-suspension drying and forming process, by optimizing the spraying equipment, the droplet size is ensured to be uniform. By designing a reasonable drying chamber structure and air flow circulation system, the air flow is evenly distributed. Multiple temperature sensors are installed to monitor and adjust the temperature in the drying area in real time to ensure temperature uniformity.
[0015] 2. In this film micro-suspension drying and forming process, in the raw material mixing stage, more efficient stirring equipment and mixing processes are adopted to ensure that the anti-fog agent is evenly dispersed in the raw materials, the drying process parameters are optimized to reduce the volatilization and decomposition of the anti-fog agent during drying, and the raw materials are pretreated to remove impurities that may react with the anti-fog agent. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figure 1 It is a process flow chart of the film micro-suspension drying and forming process of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention. Embodiment:
[0018] As Figure 1 shown, the embodiment of the present invention provides a film micro-suspension drying and forming process, including a micro-suspension drying and forming process. The micro-suspension drying and forming process produces an anti-fog highly transparent environmental protection film. The micro-suspension drying and forming process includes the following specific steps: S01. Raw material preparation: Select a suitable bio-based material such as polylactic acid (PLA) as the base resin, and add appropriate amounts of functional additives such as anti-fog agent, plasticizer, antioxidant, etc. according to the performance requirements of the film. Mix these raw materials evenly in a certain proportion to obtain the raw material system of the film; S02. Solution or suspension preparation: Add the mixed raw materials into an appropriate solvent, stir to dissolve or disperse them to form a solution or suspension with a certain concentration and viscosity. For example, organic solvents such as dichloromethane and acetone can be used as solvents. The specific solvent selection and concentration control need to be optimized according to the characteristics of the raw materials and the requirements of subsequent processes; S03. Micro-suspension formation: Convert the solution or suspension into tiny droplets or particles by means of spraying or jetting, etc., to form a micro-suspension state in the air. This can be achieved by using equipment such as spray nozzles and ultrasonic atomizers. Parameters such as the aperture of the nozzle, spraying pressure, and solution flow rate will affect the size and distribution of the micro-droplets. Generally, the optimal parameter combination needs to be determined through experiments to obtain a micro-suspension with uniform particle size and reasonable distribution; S04. Drying and forming: The heating method usually uses hot air as the drying medium. Heat the air to an appropriate temperature through a heating device. The hot air can form a uniform air flow field in the drying area through a circulation fan, enabling the micro-suspended droplets or particles to fully contact the hot air and achieve rapid drying. In addition, auxiliary heating methods such as infrared heating and microwave heating can also be considered to improve the drying efficiency and uniformity. When controlling the drying parameters, the drying temperature, time, and air flow rate are key parameters affecting the film forming quality. Generally speaking, the drying temperature should be determined according to the characteristics of the raw materials and the boiling point of the solvent, ensuring both rapid evaporation of the solvent and avoiding decomposition of the raw materials or deterioration of the film properties due to excessive temperature. The drying time is related to factors such as the size of the droplets or particles, the initial water content, and the drying temperature, and needs to be optimized through experiments. The air flow rate should be moderate. Excessive air flow may cause the micro-droplets to be scattered or the film surface to be uneven, while too slow air flow will affect the drying efficiency and uniformity; S05. Film collection: During the drying process, the micro-suspended droplets or particles gradually lose the solvent and form a solid film. When the film reaches a certain degree of dryness, collect it through a collection device. The collection device can be a rotating drum, a flat conveyor belt, etc., and transfer the film from the drying area to subsequent processing procedures, such as cooling, cutting, packaging, etc.
[0019] Among them, the anti-fog high-transparency environmental protection film uses biodegradable materials such as polylactic acid (PLA) and polyhydroxyalkanoates (PHA) as the base material. For example, the BOPLA film of Zhonglun New Materials improves the mechanical properties through biaxial stretching technology while maintaining a light transmittance of more than 90%. Such materials can be completely degraded within 6 months under industrial composting conditions, and the carbon footprint is reduced by 68% compared with traditional plastics.
[0020] Among them, the anti-fog functional layer of the anti-fog high-transparency environmental protection film is designed with a hydrophilic coating, an internal addition type anti-fog agent, and nano-structure regulation.
[0021] Among them, the hydrophilic coating technology, such as the bionic film developed by the University of Science and Technology of China, forms a superhydrophilic interface on the surface through the "brick - fiber" structure of bacterial cellulose and nano - clay, enabling the fog to spread into a uniform water film with a light transmittance of over 73%.
[0022] Among them, the internal - addition type anti - fog agent uses a bio - based surfactant (such as Einar 611 from Palsgaard). The hydrophilic groups in its molecular chain can adsorb water vapor to prevent droplet condensation. This anti - fog agent is derived from palm oil and meets food contact standards, with an anti - fog effect superior to traditional fossil - based products.
[0023] Among them, nanostructure regulation constructs a nano - scale porous structure on the film surface through sol - gel method or magnetron sputtering technology (such as the tension gradient self - assembly technology of Tsinghua University), and enhances the hydrophilic performance by using surface roughness.
[0024] Among them, the optical performance optimization of the anti - fog high - transparency environmental - protection film includes low - haze design and broadband light transmittance.
[0025] Among them, for the low - haze design, the BOPLA film can control the haze below 5% by optimizing the crystallinity and stretching process, approaching the level of traditional BOPP films.
[0026] Among them, for broadband light transmittance, the ultra - thin diamond nanomembrane developed by the Shenzhen Institute of Advanced Technology, Chinese Academy of Sciences, has a light transmittance of 85% - 98% in the ultraviolet - infrared band, and at the same time has anti - fog and self - cleaning functions.
[0027] Among them, in the mixing and extrusion process of the anti - fog high - transparency environmental - protection film, molecular design is optimized. A two - component anti - fog agent is used, where the hydrophilic component quickly prevents fogging, and the lipophilic component maintains the performance for a long time. The anti - fog agent is encapsulated in mesoporous silica or graphene quantum dots, and the migration rate is slowed down through the confinement effect. Finally, a cross - linked network is fixed, and dynamic covalent bonds (such as disulfide bonds) are introduced into the coating, enabling the anti - fog agent to be anchored on the substrate surface through reversible cross - linking while maintaining anti - fog activity.
[0028] Among them, in the extrusion molding process of the anti - fog high - transparency environmental - protection film, nano - enhancement technology is adopted. Cellulose nanocrystals (CNCs) or graphene nanosheets are added (such as the CNCs - IAME / IESO composite material of Qingdao University of Science and Technology), and the tensile strength is increased to 19.54 MPa. PLA is blended with polyhydroxyalkanoates (PHA), and the interfacial combination is enhanced through an interfacial compatibilizer (such as maleic anhydride grafted product), and the elongation at break is increased to 1600%. Finally, supramolecular self - repair is introduced, and a dynamic hydrogen - bond network (such as rubber - seed - oil - based polyurethane from Anhui Agricultural University) is introduced. The material can self - heal within 3 seconds after fracture, and the mechanical property recovery rate reaches 98%.
[0029] Among them, in the micro-suspension formation process, the spraying equipment is optimized to ensure uniform droplet size. By designing a reasonable drying chamber structure and air circulation system, the air flow is evenly distributed. Multiple temperature sensors are installed to monitor and adjust the temperature in the drying area in real time to ensure temperature uniformity.
[0030] Among them, in the micro-suspension formation process, in the raw material mixing stage, more efficient stirring equipment and mixing processes are adopted to ensure that the anti-fog agent is evenly dispersed in the raw materials. The drying process parameters are optimized to reduce the volatilization and decomposition of the anti-fog agent during drying. The raw materials are pretreated to remove impurities that may react with the anti-fog agent.
[0031] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principle and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.
Claims
1. The thin-film micro-suspension drying and forming process, including the micro-suspension drying and forming process, the micro-suspension drying and forming process produces an anti-fog highly transparent environmental protection film, and is characterized in that: The micro-suspension drying and forming process includes the following specific steps: S01. Raw material preparation: Select a suitable bio-based material as the base resin, add functional additives according to the performance requirements of the film, and mix these raw materials evenly in a certain proportion to obtain the raw material system of the film; S02. Solution or suspension preparation: Add the mixed raw materials into an appropriate solvent, stir to dissolve or disperse, and form a solution or suspension with a certain concentration and viscosity; S03. Micro-suspension formation: Convert the solution or suspension into tiny droplets or particles by means of spraying or jetting, etc., so that it forms a micro-suspension state in the air; S04. Drying and forming, the heating method usually uses hot air as the drying medium, heats the air to a suitable temperature through a heating device, and the hot air can form a uniform air flow field in the drying area through a circulating fan, so that the micro-suspended droplets or particles can fully contact the hot air and achieve rapid drying; S05. Film collection: During the drying process, the micro-suspended droplets or particles gradually lose the solvent and form a solid film. When the film reaches a certain degree of dryness, it is collected by a collection device and the film is transferred from the drying area to the subsequent processing process.
2. The thin-film micro-suspension drying and forming process according to claim 1, characterized in that: The anti-fog high-transparency environmental protection film uses bio-degradable materials such as polylactic acid and polyhydroxyalkanoates as the base material.
3. The thin-film micro-suspension drying and forming process according to claim 1, characterized in that: The anti-fog functional layer of the anti-fog high-transparency environmental protection film is designed with a hydrophilic coating, an internal addition type anti-fog agent, and nano-structure regulation is adopted.
4. The thin-film micro-suspension drying and forming process according to claim 1, wherein: The optical performance optimization of the anti-fog high-transparency environmental protection film includes low haze design and wide-band light transmission.
5. The thin film micro-suspension drying and forming process according to claim 1, characterized in that: In the mixing and extrusion process of the anti-fog high-transparency environmental protection film, molecular design is optimized, a two-component anti-fog agent is used, the hydrophilic component has rapid anti-fogging, the lipophilic component maintains the performance for a long time, and the anti-fog agent is encapsulated in mesoporous silica or graphene quantum dots, and the migration rate is slowed down through the confinement effect. Finally, the cross-linked network is fixed, dynamic covalent bonds are introduced into the coating, so that the anti-fog agent is anchored on the surface of the base material through reversible cross-linking while maintaining the anti-fog activity.
6. The thin-film micro-suspension drying and forming process according to claim 1, characterized in that: In the extrusion molding process of the anti-fog high-transparency environmental protection film, nano-enhancement technology is adopted, cellulose nanocrystals or graphene nanosheets are added, the tensile strength is increased to 19.54 MPa, and PLA and polyhydroxyalkanoate are blended and modified. The interfacial compatibilizer enhances the interfacial combination, and the elongation at break is increased to 1600%. Finally, supramolecular self-repair is carried out, and a dynamic hydrogen bond network is introduced.
7. The thin film micro-suspension drying and forming process according to claim 1, wherein: In the micro-suspension formation process, the spraying equipment is optimized, a reasonable drying chamber structure and air flow circulation system are designed, and multiple temperature sensors are installed to monitor and adjust the temperature of the drying area in real time.
8. The thin-film micro-suspension drying and forming process according to claim 1, characterized in that: In the micro-suspension formation process, in the raw material mixing stage, more efficient stirring equipment and mixing process are adopted to ensure that the anti-fog agent is evenly dispersed in the raw materials, the drying process parameters are optimized, and the raw materials are pretreated.