Auxiliary Inline Mixer for Foam Cell Refinement
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Solution Overview
Problem
In industrial continuous production of foams from water borne resin, using surfactants with molecular weights higher than ammonium stearate results in foamed layers with cracks and coarse cells, making it difficult to achieve stable and homogeneous foams, as existing solutions like upgrading mixing devices or reformulating resins are economically and technically challenging.
Innovation Solution
Implementing an auxiliary in-line mixer with a suitable mixing head line speed of 5-30 m/s to further process the foam generated in a conventional foaming machine, which uses surfactants with higher molecular weights, to achieve finer and more stable foam cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surfactants with molecular weight higher than ammonium stearate are used in continuous foam production, then foam stability is improved, but cell fineness deteriorates and cracks appear in the foamed layer
Solution Approach 1:
The patent changes the mixing parameters by introducing a second mixing stage with specific line speed (5-30 m/s) to optimize foam cell fineness while maintaining stability. This parameter adjustment resolves the contradiction between foam stability and cell fineness without changing the surfactant formulation.
Solution Approach 2:
The foaming process is segmented into two distinct mixing stages: the first stage uses conventional mixing to generate foam, while the second stage uses an auxiliary inline mixer with controlled line speed to refine the cell structure. This segmentation allows each stage to optimize for different objectives.
2Manufacturing precision
If the mixing device is upgraded to increase line speed, then cell fineness is improved, but equipment cost and complexity increase significantly
Solution Approach 1:
An auxiliary inline mixer is introduced as an intermediary device between the foam generation and coating stages. This intermediate mixing stage with controlled line speed (5-30 m/s) refines the foam cells without requiring a complete upgrade of the main mixing device, thus improving cell fineness while controlling equipment complexity and cost.
3Manufacturing precision
If resin formulation is changed to optimize foam quality, then cell fineness is improved, but formulation development time and cost increase
Solution Approach 1:
Instead of changing the chemical formulation, the patent uses a mechanical solution by introducing an auxiliary inline mixer with controlled line speed (5-30 m/s) to refine the foam cells. This mechanical approach achieves cell fineness improvement without the time-consuming resin formulation redevelopment.
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 approach significantly reduces cell size and improves foam stability, providing a cost-effective and efficient solution for industrial-scale production without requiring significant changes to existing equipment or resin formulations, resulting in finer, more homogeneous, and stable foams.
Implementation Method 1
mixing the foam obtained from the foaming machine in an auxiliary inline mixer connected to the foaming machine, at a mixing head line speed of 5 ̃30 m/s
Data Source
AI summary
A method can be used to improve the quality of a foam, produced in a process for continuous production of foams using a surfactant with higher molecular weight as an additive in an aqueous polymer dispersion. The process involves foaming a mixture of the aqueous polymer dispersion and the surfactant, and the mixture is mixed in a foaming machine with a mixing head line speed of less than 4 m/s. The process additionally involves mixing the foam obtained from the foaming machine in an auxiliary inline mixer connected to the foaming machine, at a mixing head line speed of 5˜50 m/s. A process for continuous production of foams and a continuous production line are also provided.