Cryogenic Grinding Micronized Rubber Powder Purity
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Solution Overview
Problem
Traditional processes for producing micronized powders, such as cryogenic grinding of vulcanized rubber, are expensive and inefficient, limiting the types of materials that can be recycled and resulting in impurities like fibrous materials that are difficult to remove.
Innovation Solution
A method involving pre-grinding processing, cryogenic freezing, grinding, warming with recirculation to optimize efficiency, and using a vibrating screener to remove fibrous materials, along with screening and storage, to produce micronized powders with predictable particle sizes and compositions, allowing for the use of any vulcanized rubber regardless of supplementary materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cryogenic grinding processes are used to produce micronized powders, then the particles can be reduced to small sizes, but the process becomes expensive and inefficient with impurities difficult to remove
Solution Approach 1:
The patent applies preliminary action by implementing pre-grinding processing before the main cryogenic grinding step. This preliminary size reduction prepares the material for more efficient micronization, reducing the energy and time required in subsequent processing stages while maintaining particle size control
Solution Approach 2:
The patent segments the grinding process into distinct stages: pre-grinding, cryogenic freezing, and micronized grinding. This segmentation allows each stage to be optimized independently, with pre-grinding handling bulk size reduction and cryogenic grinding achieving precise particle size control, thereby improving overall production efficiency
2Reliability
If traditional processes are used to remove fibrous materials from micronized rubber powder, then some purification is achieved, but the process remains inefficient and costly
Solution Approach 1:
The patent applies parameter changes by utilizing the temperature difference between the cryogenically cold micronized powder and the ambient environment. The warming phase creates thermal expansion and moisture condensation that facilitates the separation and removal of fibrous impurities through screening, making the purification process more efficient
Solution Approach 2:
The patent employs mechanical vibration through vibrating screeners to remove fibrous materials from the micronized powder. The vibration enhances the screening efficiency by preventing particle bridging and ensuring thorough separation of impurities based on size and density differences
3Use of energy by moving object
If the warming apparatus operates below threshold efficiency, then energy is wasted, but if recirculation is implemented to improve efficiency, then additional processing steps are required
Solution Approach 1:
The patent implements feedback control by monitoring the operating efficiency of the warming apparatus and automatically recirculating micronized powder when efficiency falls below a predetermined threshold. This closed-loop control optimizes energy usage by maintaining the warmer at peak efficiency while preventing unnecessary energy waste
Solution Approach 2:
The patent ensures continuity of useful action by implementing recirculation of micronized powder through the warming apparatus when needed. This continuous circulation maintains thermal efficiency and ensures complete warming of all material passing through the system, eliminating cold spots and energy waste
4Device complexity
If grinding and screening are coupled in traditional processes, then the process flow is simpler, but both operations must run at compromised rates reducing overall productivity
Solution Approach 1:
The patent segments the coupled grinding and screening operations into independent processes. By decoupling these operations, each can be optimized and operated at its maximum efficient rate without being constrained by the other, thereby improving overall productivity despite increased process complexity
Solution Approach 2:
The patent introduces an intermediary buffer storage system between the grinding and screening operations. This buffer acts as a mediator that allows independent operation of grinding and screening at optimal rates, decoupling their operational constraints while maintaining continuous material flow
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 increases the purity and homogeneity of micronized rubber powder, enhances the efficiency of the production process, and decouples grinding and screening to maintain optimal rates, enabling the use of any vulcanized rubber as infeed material.
Implementation Method 1
cryogenic freezing
Implementation Method 2
warming the micronized powder
Implementation Method 3
vibrating screener
Data Source
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AI summary
A method (100) of cryogenically grinding particles exemplary comprising pre-grinding processing (102), cryogenic freezing (104), grinding (106) and warming (108) of infeed material, ferrous metal and fiber removal (110), accumulation (112), screening (114), and storage (116) of micronized powder. Generally, the warming may involve recirculation of micronized powder through the warming apparatus. Further, the accumulation may permit the grinding and screening to occur at their respectively optimal rates, and the fiber removal, via use of a vibrating screener, may increase the purity of the micronized powder. In one embodiment, the micronized powder comprises micronized rubber powder ("MRP").