Dry Polymer Application Method for Papermaking
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Solution Overview
Problem
Low molecular weight polymers used in industrial processes, such as papermaking, are typically transported and applied as solutions, which are costly and prone to damage from high heat and shear, limiting their effectiveness and efficiency.
Innovation Solution
Treating industrial processes with a powder or wetted powder comprising a low molecular weight polymer, allowing it to dissolve within the process, thereby avoiding the need for pre-dissolution and reducing costs associated with transportation and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If low molecular weight polymers are transported and applied as solutions, then they can be effectively added to industrial processes, but transportation and storage costs increase significantly
Solution Approach 1:
The patent changes the physical state parameter of the polymer from liquid solution to solid powder form. This parameter change enables the polymer to be transported and stored in a concentrated dry state, significantly reducing transportation volume and storage requirements while eliminating the need for specialized handling facilities required for liquid solutions
Solution Approach 2:
The powder form of the polymer serves multiple functions: it can be transported cost-effectively as a dry solid, stored without specialized facilities, and then dissolved in-situ at the application site. This multi-functionality resolves the contradiction by making the polymer adaptable to both economical transportation and effective industrial application
2Productivity
If solution-based polymers are added during stock prep, then they can be applied early in the process, but they become irreparably damaged due to high heat and shear
Solution Approach 1:
The patent applies preliminary action by preparing the polymer in a stable powder form that can withstand the harsh stock prep environment. The polymer is dissolved in-situ at the point of application rather than being pre-dissolved and transported, allowing it to remain stable during storage and transport while becoming active when needed in the industrial process
Solution Approach 2:
The patent converts the previously harmful high heat and shear conditions into a beneficial dissolution mechanism. The same high energy conditions that previously damaged pre-dissolved polymers are now used to rapidly dissolve the powder form in-situ, ensuring the polymer remains stable until the moment of application where the harsh conditions facilitate its activation rather than degradation
3Loss of energy
If low molecular weight polymers are processed into powder, then transportation and storage costs decrease, but the wet gel is too soft to cut and process conventionally
Solution Approach 1:
The patent applies parameter changes by modifying the physical state from soft wet gel to free-flowing powder through controlled drying. This parameter change transforms the material into a form that can be easily handled, cut, and processed using conventional powder handling equipment, resolving the manufacturing difficulty while enabling cost-effective transportation
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 enables the use of low molecular weight polymers as effective strength aids in industrial processes, improving paper strength properties and reducing costs by eliminating the need for pre-dissolution and specialized handling systems.
Implementation Method 1
allowing it to dissolve within the process
Data Source
AI summary
A method of incorporating a low molecular weight polymer (e.g., polymer strength aid) into an industrial process (e.g., papermaking process) is provided. The method comprises treating an industrial process (e.g., paper sheet precursor) with a powder or wetted powder, wherein the powder comprises a polymer dry polymer (e.g., polymer strength aid), wherein the polymer dry polymer (e.g., polymer strength aid) has a weight average molecular weight of from about 10 kDa to about 2,000 kDa.