Dripping Device for Low-Viscosity Plastic Melt Granules
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Solution Overview
Problem
Existing methods for producing granules from low-viscosity plastic melts face challenges such as deformation, sticking, and foaming, which affect the spherical shape and processing of granules, particularly due to the low viscosity of the materials.
Innovation Solution
A droplet-forming device with a pressure vessel maintaining overpressure above ambient, a drop section for forming spherical granules, and a cooling section with a circulating fluid to prevent clumping, combined with adjustable elements for optimal granule formation and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If low-viscosity plastic melt is dripped through a casting nozzle, then granule production is achieved, but deformation and sticking of granules occurs due to low viscosity
Solution Approach 1:
The patent changes the physical parameters of the granule formation process by introducing a cooling fluid that rapidly cools the molten plastic upon contact. This rapid cooling solidifies the granules quickly, preventing deformation and sticking that would otherwise occur due to the low viscosity of the plastic melt. The cooling fluid transforms the thermal state of the melt, enabling precise spherical granule formation.
Solution Approach 2:
The cooling fluid acts as an intermediary substance between the molten plastic and the final granule. Instead of the plastic cooling on its own, the cooling fluid mediates the cooling process, providing controlled thermal contact that solidifies the granules in a manner that preserves their spherical shape and prevents sticking, while maintaining high productivity.
2Productivity
If granules are formed from low-viscosity plastic melt, then production efficiency is improved, but foaming of granules occurs due to volatile substances
Solution Approach 1:
The patent applies preliminary anti-action by introducing the cooling fluid before the volatile substances can cause foaming. The rapid cooling that occurs upon contact with the cooling fluid solidifies the granule structure quickly, preventing the expansion and foaming that would otherwise occur as volatile substances escape from the low-viscosity melt during the cooling process.
Solution Approach 2:
The cooling fluid dramatically changes the temperature parameter of the plastic melt upon contact. This rapid temperature reduction solidifies the granule structure before volatile substances can expand and cause foaming, thereby eliminating the harmful effect while maintaining the high productivity enabled by the low-viscosity material.
3Manufacturing precision
If complex liquid distribution devices are used to prevent deformation, then granule shape is improved, but device complexity increases
Solution Approach 1:
The patent extracts the complex liquid distribution device from the system and replaces it with a simple cooling fluid bath. Instead of using complex mushroom-shaped convex liquid distribution devices to prevent deformation, the invention uses a straightforward cooling fluid that contacts the granules after they are formed, achieving the same protective effect with minimal structural complexity.
Solution Approach 2:
The patent replaces expensive, complex liquid distribution devices with a simple, easily replaceable cooling fluid system. The cooling fluid can be simply circulated through a bath, eliminating the need for intricate mechanical liquid distribution structures while maintaining granule shape integrity.
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 solution ensures reliable production of spherical granules that are easy to process, avoiding deformation and sticking, while maintaining structural simplicity and flexibility in handling low-viscosity plastic melts.
Implementation Method 1
a pressure vessel (1) in which there is an overpressure above the ambient pressure, for the further treatment of the granulate grains
Implementation Method 2
a cooling section (k) with a cooling fluid, into which the granulate droplets are immersed
Implementation Method 3
the circulating device being designed in such a way that so that turbulence can be generated in the cooling fluid
Data Source
Figure 1
Figure 2~3
Figure 4~5b
AI summary
The invention relates to a dripping device for producing granules (9) from a low-viscosity plastic melt, comprising a molding nozzle (3) with boreholes, in which the plastic melt can be supplied with harmonious pressure vibration such that the plastic melt exiting there from the boreholes forms granule drops (8), a pressurized container (1) in which excess pressure prevails over ambient pressure, with a drop section (f) in a gas space (4) and a cooling section (k) comprising a coolant (5), into which the granule drops are immersed, an output device (10), and a separator (11), wherein the excess pressure in the pressurized container can be set at least as high as the steam pressure of the volatile substances present in the plastic melt, the length of the drop section (f) in the gas space can be set, a collecting device (6) is provided after the drop section (f), and at least one circulation device (7) is provided for the coolant, wherein turbulence in the coolant can be generated by the circulation device. The invention also relates to a corresponding dripping method.