Centrifugal Atomizer Resin Build-Up Prevention
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Solution Overview
Problem
Centrifugal atomizers used for spraying water-insoluble resins in the manufacture of lignocellulosic-based composite materials, such as oriented strand boards, face issues with resin build-up, which leads to decreased performance, potential clogging, and safety hazards due to the lack of effective solvents for non-water-soluble resins.
Innovation Solution
A process involving a centrifugal atomizer with a housing and rotary disc that uses an emulsion of water-insoluble resin combined with a mist of air and aqueous liquid to prevent build-up, where the aqueous liquid is not a solvent for the resin, effectively flushing the atomizer and preventing resin accumulation without affecting the composite material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a centrifugal atomizer is used to spray water-insoluble resin, then resin distribution efficiency is improved, but resin build-up occurs in the atomizer causing performance degradation and safety hazards
Solution Approach 1:
The patent introduces an intermediary substance (solvent or compressed air) that mediates between the resin and the atomizer surfaces. The solvent acts as a intermediary that prevents resin from adhering to the atomizer surfaces, while compressed air serves as a gaseous intermediary that sweeps resin particles away from critical areas, thus preventing build-up without interfering with the primary resin spraying function
Solution Approach 2:
The system performs self-cleaning during operation by continuously introducing solvent or compressed air that automatically removes resin build-up as it occurs. This self-service mechanism eliminates the need for periodic shutdowns for manual cleaning, maintaining continuous productivity while preventing performance degradation
2Ease of repair
If solvent is introduced to prevent resin build-up, then atomizer cleaning is improved, but flammability risk increases due to use of organic solvents
Solution Approach 1:
The patent changes the chemical parameter of the cleaning agent from organic solvents (high flammability) to water-based solutions or uses compressed air (zero flammability). This parameter change maintains the cleaning function while eliminating the harmful flammability effect, allowing the system to operate in safer conditions
Solution Approach 2:
The patent creates an inert environment by using compressed air or water-based solutions instead of flammable organic solvents. This inert approach prevents combustion reactions that could occur with organic solvents, effectively eliminating the flammability hazard while maintaining the resin removal capability
3Reliability
If the atomizer is stopped periodically for cleaning, then resin build-up is removed, but production downtime increases
Solution Approach 1:
The patent implements continuous cleaning action during atomizer operation by continuously introducing solvent or compressed air. This continuous useful action prevents resin build-up accumulation throughout the production cycle, eliminating the need for periodic interruptions and maintaining uninterrupted productivity
Solution Approach 2:
The system performs preliminary cleaning action by continuously removing resin deposits before they can accumulate to problematic levels. This preliminary prevention approach avoids the need for corrective shutdowns, maintaining continuous production while preventing performance degradation
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
This solution effectively prevents resin build-up in the atomizer, ensuring consistent resin distribution, reducing downtime, improving safety, and enhancing the curing process of the composite material while minimizing MDI emissions.
Implementation Method 1
the rotary disc spins at high speeds. Liquid resin is supplied, via at least one resin feed channel, to the chamber of the rotary disc. The resin is propelled by the rotary motion of the disc through the apertures formed around the circumference of the front face of the disc, onto the inside surfaces of the cone, and sprayed as an atomized fog
Implementation Method 2
one or several air lines are also provided, that issue in a space formed behind the cone of the disc, i.e. between the rotary disc and the housing of the centrifugal atomizer. The air lines are operative to create an air flow and to maintain a desired pressure in the atomizer, to helps atomization and resin projection
Implementation Method 3
the solvent is introduced during the resin spraying process with the aim of sweeping away, thanks to the solvation effect of the solvent, the accumulated material in the atomizer, on the rotary disc and on the housing
Data Source
AI summary
The invention relates to a process for spraying an emulsion of water insoluble composition, such as an emulsified resin, with a centrifugal atomizer. The centrifugal atomizer comprises a housing, a rotary disc provided in a recess of the housing. An emulsion of a water insoluble composition is supplied to a chamber or formed in the atomizer, the chamber being formed between a front face and a cone of the rotary disc. A mist of air and an aqueous liquid is sprayed in the recess of the housing. The mist flushes the atomizer and limits or avoid water insoluble composition build-up. The invention also relates a centrifugal atomizer system adapted to perform such process.