Aluminum Trihydroxide Grinding-Drying Process for Resin Viscosity Control
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Solution Overview
Problem
The challenge lies in producing aluminum trihydroxide with a high BET specific surface area that can be easily incorporated into liquid resins without causing a drastic increase in viscosity, which is necessary for effective flame retardancy while avoiding cost-intensive coating processes and utilizing aluminum trihydroxides with significantly higher average particle sizes.
Innovation Solution
A grinding-drying process is employed for a raw mixture containing aluminum trihydroxide with an average particle size of 50 to 130 μm, using a grinding-drying unit with hot air flow at temperatures between 20 to 150 °C, which reduces viscosity issues and maintains a high BET specific surface area, allowing for easier incorporation into liquid resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If aluminum trihydroxide is ground to increase specific surface area for flame retardancy, then flame retardant effectiveness improves, but viscosity of liquid resin increases drastically
Solution Approach 1:
The patent applies parameter changes by controlling the particle size distribution parameters (D10, D50, D90) and specific surface area (BET) within optimized ranges. By setting D50 between 3-15 μm and BET between 2-9 m²/g, the invention achieves a balance where flame retardant effectiveness is maintained while viscosity increase is controlled, resolving the contradiction between surface area and viscosity
Solution Approach 2:
The patent applies partial action by achieving sufficient flame retardancy without excessive grinding. Instead of maximizing surface area, the invention targets a moderate BET range (2-9 m²/g) that provides adequate flame protection while avoiding the drastic viscosity increases associated with highly refined aluminum trihydroxide
2Reliability
If aluminum trihydroxide with high specific surface area is used, then flame retardancy increases, but incorporation into liquid resin becomes difficult
Solution Approach 1:
The patent uses parameter changes by defining specific ranges for particle size (D50: 3-15 μm) and specific surface area (BET: 2-9 m²/g). These controlled parameters ensure that the aluminum trihydroxide has sufficient flame retardant properties while maintaining good processability and ease of incorporation into liquid resins
Solution Approach 2:
The patent applies copying by reproducing the optimal particle size distribution and surface area characteristics that have been identified as providing the best balance between flame retardancy and processability. This standardized approach ensures consistent performance across different batches and applications
3Ease of manufacture
If coarse aluminum trihydroxide is used, then viscosity of liquid resin remains low, but flame retardant effect is insufficient
Solution Approach 1:
The patent resolves this contradiction through parameter changes by establishing that D50 should be between 3-15 μm and BET between 2-9 m²/g. This moderate refinement level provides adequate flame retardancy while avoiding the high viscosity problems associated with coarser materials, achieving a balanced solution
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in aluminum trihydroxide with excellent flame retardant properties and improved processability, as it can be easily incorporated into liquid resins without significant viscosity increases, while being more cost-effective than prior methods.
Implementation Method 1
A grinding-drying process is employed for a raw mixture containing aluminum trihydroxide with an average particle size of 50 to 130 μm, using a grinding-drying unit with hot air flow at temperatures between 20 to 150 °C
Data Source
AI summary
Grinding and drying of a raw mixture containing aluminum trihydroxide with an average particle size of 50-130 mu m and a specific surface of 0.01-0.5 m 2>/g, after Brunauer-Emmett-Teller, and 0.1-20 wt.% of water comprises feeding the raw mixture into a grinding-drying aggregate; feeding a hot air flow with a temperature of 20-100[deg] C in the grinding-drying aggregate; and crushing the raw material in the aggregate. Independent claims are included for: (1) aluminum trihydroxide obtained by the above method; and (2) the preparation of a thermoset comprising incorporating aluminum trihydroxide in at least a crosslinkable liquid resin from an unsaturated polyester resin, epoxide resin or polyurethane to obtain a mixture of aluminum trihydroxide and liquid resin and crosslinking the obtained mixture.