Corrugated Roll Mill for Narrow SAP Particle Size Distribution
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Solution Overview
Problem
Existing methods for reducing super absorbent polymer particle size result in broad particle size distribution and increased generation of fine particles, leading to process inefficiencies and productivity issues.
Innovation Solution
A roll mill with controlled specifications of roll gap and roll corrugations, featuring increased numbers of corrugations on rollers, is used to grind super absorbent polymer particles, achieving narrow particle size distribution without increasing fine particle generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the roll gap is reduced to decrease particle size, then the particle diameter is reduced, but the particle size distribution becomes broad and fine particle generation increases
Solution Approach 1:
The invention changes the parameters of the roll mill system by increasing the number of corrugations on the roller surface and optimizing the roll gap distance. This parameter modification allows achieving reduced particle size with narrow particle size distribution, resolving the contradiction between particle size reduction and distribution control.
Solution Approach 2:
The invention uses corrugated roller surfaces with specific curvature characteristics instead of flat surfaces. The corrugations create localized stress zones that enable controlled particle size reduction while maintaining narrow size distribution, addressing the contradiction between reducing particle diameter and controlling particle size distribution.
2Length of moving object
If the roll gap is reduced to decrease particle size, then the particle diameter is reduced, but the amount of fine particles increases leading to process load increase
Solution Approach 1:
By changing the roll mill parameters (increasing corrugation number and optimizing roll gap), the invention achieves particle size reduction without generating excessive fine particles, thereby maintaining productivity and reducing process load.
Solution Approach 2:
The invention converts the potential harm of fine particle generation into a benefit by optimizing the corrugation pattern and roll gap, transforming the grinding process to produce desired particle sizes while minimizing fine particle byproducts that would increase process load.
3Manufacturing precision
If the number of corrugations is increased to reduce particle size, then the particle size distribution becomes narrow, but the device complexity increases
Solution Approach 1:
The invention optimizes specific parameters of the corrugations (number, height, pitch) to achieve narrow particle size distribution. By carefully selecting these parameters within specific ranges, the invention achieves precise particle size control without excessive device complexity.
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 method effectively reduces particle size and achieves uniform particle distribution, enhancing productivity and facilitating surface treatment while minimizing fine particle generation.
Implementation Method 1
a method of increasing shear during chopping
Implementation Method 2
The roll mill comprises one pair of rollers that have plural corrugations formed on each outer perimeter surface, and are arranged parallel to each other while being spaced by a roll gap
Data Source
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AI summary
Disclosed is a roll mill for super absorbent polymer. The roll mill for super absorbent polymer grinds introduced super absorbent polymer particles and discharges them. The roll mill for super absorbent polymer comprises one pair of rollers that have plural corrugations formed on each outer perimeter surface, and are arranged parallel to each other while being spaced by a roll gap, wherein plural corrugations are formed on the outer perimeter surface of the roller, and the number of corrugations per unit circumference of the roller may be 0.89/mm - 1.15/mm. Also disclosed is a method for preparing super absorbent polymer using the roll mill.