Solvent Extraction of Carbon Black from Devulcanized Rubber
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Solution Overview
Problem
Current methods for separating carbon black from polymers in devulcanized rubber are inefficient and costly, particularly due to the small size of carbon black particles and the challenges of using centrifuges and filtration, which often result in slow separation rates and material binding issues.
Innovation Solution
A method involving the use of a solvent to dissolve polymers from devulcanized rubber without agitation, allowing carbon black particles to remain unsuspended, and then removing the polymer-solvent solution while keeping the carbon black particles undisturbed, using a system of reaction trays to facilitate continuous separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If centrifuge technology is used to separate carbon black particles from polymer-solvent solution, then separation can be achieved, but the small size of carbon black particles makes the process costly and inefficient
Solution Approach 1:
The patent extracts the carbon black particles from the polymer-solvent solution by allowing the polymer to dissolve in the solvent, leaving the carbon black particles behind as a separate solid residue. This extraction method avoids the need for complex centrifugal separation of fine particles.
Solution Approach 2:
The patent segments the devulcanized rubber into two distinct components: soluble polymer that dissolves in the solvent and insoluble carbon black particles that remain as a separate phase. This segmentation enables simple gravity-based separation without requiring sophisticated centrifuge technology.
2Manufacturing precision
If filtration is used to remove carbon black particles, then separation can be achieved, but the process becomes slow and carbon black particles may be pushed through the filter
Solution Approach 1:
The patent extracts carbon black particles from the solution by dissolving the polymer in a solvent, which leaves the carbon black as an insoluble residue that can be easily separated by gravity drainage, avoiding the need for filtration entirely.
Solution Approach 2:
The patent replaces the mechanical filtration system with a simpler gravity-based separation system. By using solvent extraction to leave carbon black as a solid residue, the process eliminates the need for filter media and associated mechanical complexity.
3Manufacturing precision
If pre-coating the filter is used to improve filtration efficiency, then the filter surface is prepared, but the cake formed on the filter rapidly leads to binding of polymer-solvent solution and carbon black
Solution Approach 1:
The patent extracts carbon black particles from the polymer-solvent solution through solvent dissolution, leaving the carbon black as a separate insoluble residue. This eliminates the need for filtration and pre-coating operations that would otherwise be required to remove fine particles.
4Adaptability or versatility
If emulsification techniques are used to separate carbon black particles, then a slurry mixture is created, but the separation into separate phases is ineffective
Solution Approach 1:
The patent extracts the polymer from the devulcanized rubber into the solvent phase, leaving the carbon black particles as an insoluble residue. This extraction approach creates a clear separation between the dissolved polymer and undissolved carbon black, achieving effective separation without requiring emulsification.
Solution Approach 2:
The patent changes the physical-chemical parameters of the system by introducing a solvent that selectively dissolves the polymer but not the carbon black. This parameter change (adding solvent) creates a phase separation based on solubility differences, achieving effective separation.
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 effectively separates carbon black from polymers with minimal suspension of carbon black particles, enabling efficient and cost-effective recycling of devulcanized rubber components, as demonstrated by the extraction of high-quality carbon black and polymer fractions.
Implementation Method 1
bringing the devulcanized rubber into contact with a solvent without agitating the solvent, allowing the solvent to dissolve polymer from the devulcanized rubber
Implementation Method 2
allowing carbon black particles to remain un-suspended in the polymer-solvent solution
Data Source
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AI summary
A method for separating a polymer from carbon black in devulcanized rubber, the method comprising steps of inserting devulcanized rubber into a bath of a solvent, dissolving a polymer out of the devulcanized rubber and into a solution of the solvent and the polymer, removing the solution from the bath without disturbing an un-dissolved residue comprising carbon black, and recovering the un-dissolved residue.