Closed Flocculation Tank for Uniform Polymer Latex Particle Size
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Solution Overview
Problem
The existing methods for producing polymer latex resin powder result in the generation of fine and coarse particles, which cause issues in dehydration, drying, transport, and compatibility with other polymer resins, and lack uniform shear force application.
Innovation Solution
An apparatus and method involving a closed system flocculation tank with a stirring part and a discharge line connected tangentially and inclined at a predetermined angle, ensuring uniform shear force application and reducing particle size by maintaining the tank and discharge line filled with polymer slurry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an open system flocculation tank is used with a stirring part, then the stirring operation can be performed, but coarse particles are generated by formation of vortexes around the stirring part
Solution Approach 1:
The patent applies the principle of creating a closed system environment by filling the flocculation tank and discharge line with polymer slurry, eliminating the air layer present in open systems. This prevents air entrainment and vortex formation that cause coarse particles, while still allowing stirring operation to proceed. The closed system maintains an inert environment free from air interference during the flocculation process.
2Manufacturing precision
If slow coagulation method is used to control particle size, then particle size can be controlled, but fine particles are generated that deteriorate dehydrator and dryer performance
Solution Approach 1:
The patent modifies the physical parameters of the flocculation system by transitioning from an open to a closed system and optimizing the discharge line configuration (tangential connection at predetermined angle). These parameter changes alter the flow dynamics and shear force distribution, enabling controlled coagulation that produces uniform particles without generating excessive fine particles that would harm downstream equipment.
Solution Approach 2:
The patent introduces a new dimensional aspect by connecting the discharge line tangentially at a predetermined angle rather than using conventional vertical or horizontal connections. This angular dimensionality change optimizes the flow pattern and shear force distribution throughout the tank, improving particle uniformity while preventing fine particle generation that would deteriorate dehydrator and dryer performance.
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 closed system approach reduces fine and coarse particles, ensuring uniform shear force application, thereby improving the production process of polymer latex resin powder.
Implementation Method 1
capable of applying uniform shear force
Implementation Method 2
coarse particles are generated by formation of vortexes (V) around the stirring part (20)
Implementation Method 3
an aqueous solution of a flocculant such as an inorganic salt and an acid is divided in small amounts and added to break stability of an emulsifier, whereby the polymer in the latex is agglomerated
Implementation Method 4
a discharge line (130), respectively and the first flocculation tank (110) is provided so as to operate in a closed system upon operating the stirring part (120)
Data Source
AI summary
The present invention relates to an apparatus and a method for producing a polymer latex resin powder, and according to one aspect of the present invention, there is provided an apparatus for producing a polymer latex resin powder comprising a first flocculation tank to which a polymer latex and a flocculant are each supplied, wherein the first flocculation tank is provided with a stirring part including a rotation axis and one or more impellers mounted on the rotation axis, and a discharge line, and the first flocculation tank is configured to operate as a closed system upon operation of the stirring part.