Bimodal Precipitated Silica Carrier for Caking and Flowability
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Solution Overview
Problem
Conventional precipitated silicas used as carrier materials for converting liquid active ingredients into solid, free-flowing forms often result in caking issues during production, leading to reduced yield and product quality due to inadequate mechanical stability and high dust formation, despite improved flowability.
Innovation Solution
Development of novel precipitated silicas with enhanced hardness and porosity, achieved through a specific preparation process involving basic substance treatment and drying, which reduces fine particle formation and maintains high absorptivity, ensuring better mechanical stability and flowability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If microgranular precipitated silicas with spherical form and mean particle size >150 μm are used to improve flowability, then flowability is improved, but mechanical stability deteriorates leading to caking during production
Solution Approach 1:
The patent applies parameter changes by modifying the particle size distribution parameters of the precipitated silica. Specifically, it uses a bimodal distribution with a first peak at 2-10 μm and a second peak at 15-30 μm, which changes the physical parameters to achieve both good flowability and mechanical stability, preventing caking during production.
Solution Approach 2:
The patent applies local quality by creating different particle size regions within the overall distribution. The bimodal distribution creates two distinct particle size populations that perform different functions: smaller particles fill voids and improve stability, while larger particles maintain flowability, thus addressing both requirements locally within the material structure.
2Quantity of substance
If conventional precipitated silicas are used as carrier materials, then absorptivity is achieved, but dust formation increases and yield decreases due to caking
Solution Approach 1:
The patent changes the particle size distribution parameters from conventional single-mode distributions to a bimodal distribution with specific peak positions (2-10 μm and 15-30 μm). This parameter change reduces dust formation and caking during production, thereby reducing substance loss and improving yield while maintaining absorptivity.
Solution Approach 2:
The patent creates a composite particle size structure by combining two distinct particle size populations. This composite approach allows the material to exhibit both good flow properties and reduced dust formation, preventing caking and improving production yield while maintaining the absorptivity function.
3Quantity of substance
If precipitated silicas with high absorptivity are used, then loading capacity is improved, but processibility deteriorates due to caking in mixers and delivery systems
Solution Approach 1:
The patent modifies the particle size distribution parameters to a bimodal pattern with peaks at 2-10 μm and 15-30 μm. This parameter change improves processibility by reducing caking in mixers and delivery systems while maintaining high loading capacity through the preserved absorptivity of the precipitated silica.
Solution Approach 2:
The patent applies local quality by having different particle size regions serve different functions during processing. The smaller particles (2-10 μm) reduce caking and improve flow during manufacturing, while the larger particles (15-30 μm) maintain absorptivity and loading capacity, thus resolving the processibility contradiction.
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 novel precipitated silicas exhibit improved mechanical stability, reduced caking, and enhanced flowability, allowing for high-loading absorbates with minimal carrier material usage while maintaining storage stability and absorption capacity.
Implementation Method 1
carrier materials which have good processibility and allow absorbates with high loading and good flowability to be produced
Implementation Method 2
the carrier materials serve primarily as a filler, whereas they absorb the liquid in the case of liquid or low-melting substances
Data Source
AI summary
The present invention relates to novel precipitated silicic acids for use as support materials, manufacture thereof and use thereof.