Compacted Powder Surface Treatment for Single Screw Extrusion
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Solution Overview
Problem
The thermoplastic processing industry faces challenges in dispersing primary powder additives within thermoplastic polymers without the need for intermediate compounding steps, as conventional single screw extruders struggle to achieve uniform dispersion without forming agglomerates.
Innovation Solution
A process involving the use of high-speed mixers and surface treatment polymers to coat primary powder particles, creating a compacted material that can be well dispersed in thermoplastic polymers, eliminating the requirement for intermediate compounding steps and allowing for the use of conventional single screw extrusion equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional single screw extruders are used to disperse primary powder additives, then the equipment is simple and widely available, but the powder forms agglomerates and does not disperse uniformly
Solution Approach 1:
The patent applies preliminary action by coating primary powder particles with surface treatment polymers and compacting them into agglomerates with controlled porosity before extrusion. This pre-treatment enables the powder to disperse uniformly in conventional single screw extruders without forming harmful agglomerates during processing
Solution Approach 2:
The patent changes physical parameters of the powder by treating surfaces with polymers and compacting at controlled porosity (5-50%). These parameter changes transform the powder into a form that disperses uniformly in conventional extruders, resolving the contradiction between equipment simplicity and dispersion quality
2Manufacturing precision
If intermediate compounding steps are used to prepare masterbatches, then uniform dispersion is achieved, but the process complexity and manufacturing time increase
Solution Approach 1:
The patent eliminates intermediate compounding steps by performing preliminary surface treatment and compaction of powder particles before extrusion. The compacted material with controlled porosity and surface coating disperses uniformly directly in the final extrusion step, removing the need for separate masterbatch preparation
Solution Approach 2:
The patent merges surface treatment, compaction, and extrusion into an integrated process. The compacted material serves as a pre-prepared additive that combines the functions of surface treatment and dosage, eliminating the need for separate masterbatch preparation and simplifying the overall manufacturing process
3Ease of manufacture
If primary powder is used directly without surface treatment, then the material is simple and cost-effective, but it dusts and does not flow well
Solution Approach 1:
The patent changes surface parameters of powder particles by coating with polymers and compacting at controlled porosity. This transforms the surface properties to eliminate dusting and improve flowability while maintaining material simplicity and cost-effectiveness
Solution Approach 2:
The patent applies local quality changes by treating only the surface of powder particles with polymers rather than changing the bulk material properties. This surface treatment improves flowability and eliminates dusting while keeping the core material simple and cost-effective
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 process results in a well-dispersed, non-dusting compacted material with improved flowability and bulk density, enabling the uniform incorporation of additives into thermoplastic polymers at various concentrations without the need for masterbatches or concentrates, thus reducing costs and simplifying manufacturing.
Implementation Method 1
mixing the at least one primary powder material and the at least one molten surface treatment polymer in the high speed mixer
Implementation Method 2
transferring the mixed material obtained from step d) to a cooling unit
Implementation Method 3
surface treatment polymers which are able to form thin layers around the singularised particles of the primary powder which totally cover the particles surfaces
Data Source
AI summary
The present invention relates to the field of processing thermoplastic polymers, particularly the present invention relates to a process for manufacturing compacted material suitable for the use in thermoplastic polymers without a compounding step, comprising the steps of a) providing at least one primary powder material; b) providing at least one molten surface treatment polymer; c) simultaneously or subsequently feeding the at least one primary powder material and the at least one molten surface treatment polymer into the high speed mixer unit of a cylindrical treatment chamber; d) mixing the at least one primary powder material and the at least one molten surface treatment polymer in the high speed mixer, e) transferring the mixed material obtained from step d) to a cooling unit, as well as the compacted material obtained by this process and its use in thermoplastic polymers.