Encapsulated Cleaning Agent for Plastic Processing Equipment
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Solution Overview
Problem
Current cleaning agents for plastic processing and production devices, such as extruders and injection molding machines, are ineffective in thoroughly cleaning hard-to-reach areas and suffer from reduced cleaning power due to acid neutralization by mineral particles during storage, leading to contamination issues and increased production downtime.
Innovation Solution
A cleaning agent comprising encapsulated mineral particles and crystalline free acid, where the acid and mineral particles are separated to prevent neutralization, allowing for reliable cleaning of plastic processing devices by releasing the encapsulated components under pressure and temperature, effectively removing plastic residues and preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If cleaning agents containing acid and mineral particles are stored, then cleaning agent is available for use, but the acid neutralizes with mineral particles causing loss of cleaning power
Solution Approach 1:
The cleaning agent is segmented into separate functional components: encapsulated acid particles and mineral particles are kept physically separated during storage. The encapsulation creates distinct segments that only interact when needed, preventing premature neutralization while maintaining both cleaning mechanisms available for action during the cleaning process.
Solution Approach 2:
The acid is pre-encapsulated in a protective coating before use, which preserves its cleaning power during storage. This preliminary protective action prevents the acid from contacting mineral particles until the cleaning process begins, ensuring the acid remains effective when actually needed for cleaning plastic residues.
2Ease of operation
If cleaning materials are conveyed through devices to loosen plastic residues, then cleaning is performed, but difficult-to-access areas like the non-conveying side of the screw web are not adequately cleaned
Solution Approach 1:
The cleaning agent exhibits local quality by having different components act in different locations within the device. The encapsulated acid particles can reach and act on hard-to-access areas like the non-conveying side of the screw web, while mineral particles provide abrasive cleaning in more accessible areas. This localized effectiveness ensures comprehensive cleaning coverage throughout the entire device.
Solution Approach 2:
The encapsulated acid acts as an intermediary that can penetrate into difficult-to-reach areas where conventional cleaning materials cannot effectively reach. The encapsulation allows the acid to be transported to these isolated locations and then released to perform cleaning action, serving as a mediator that bridges the gap between accessible and inaccessible areas.
3Reliability
If mechanical dismantling and cleaning of devices is performed, then thorough cleaning is achieved, but the process is labor-intensive and time-consuming causing production loss
Solution Approach 1:
The cleaning agent enables self-service cleaning where the device cleans itself by conveying the cleaning material through its own structure. The encapsulated acid and mineral particles are transported through the device during normal operation or dedicated cleaning cycles, allowing the device to clean its own internal surfaces including hard-to-reach areas without external disassembly or manual intervention.
Solution Approach 2:
The invention replaces manual mechanical cleaning operations with a chemical-mechanical cleaning system. Instead of labor-intensive dismantling and manual scrubbing, the encapsulated acid provides chemical cleaning action while mineral particles provide mechanical abrasion, both delivered through the device's existing conveyance mechanism, substituting human labor with an automated cleaning material delivery system.
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 encapsulated cleaning agent maintains its cleaning power over time, ensures thorough cleaning of difficult-to-access areas, and prevents contamination, reducing the number of cleaning cycles required and extending storage stability without compromising device safety.
Implementation Method 1
releasing the encapsulated components under pressure and temperature
Implementation Method 2
releasing the encapsulated components under pressure and temperature
Implementation Method 3
preventing corrosion
Implementation Method 4
The organic polymer in the cleaning agent according to the invention has an 'eraser'-like effect and also removes plastic deposits in the device to be cleaned
Data Source
AI summary
The invention relates to a cleaning agent comprising mineral particles, crystalline free acid, and an organic polymer, wherein the mineral particles and/or the crystalline free acid are at least partially encapsulated. The invention further relates to the use of the cleaning agent for cleaning equipment for plastics manufacturing or processing, and to a method for cleaning such equipment. The invention also relates to a method for producing the cleaning agent.