Filled Resin Compounding via Wiped Film Evaporation
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Solution Overview
Problem
The manufacture of filled resins, particularly nanocomposites, faces challenges in achieving thorough mixing of particles within the polymer matrix with minimal agglomeration, especially with highly viscous polymers or high particle loadings, and batch processes are labor-intensive and costly, limiting economic applications.
Innovation Solution
A process using a wiped film evaporator under vacuum conditions with an elevated temperature to compound solvent-borne particles and an organic matrix, where particles are functionalized with surface-modifying agents to reduce agglomeration and solvent levels, achieving a filled resin with less than 10% agglomerated particles at high loadings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If batch manufacturing processes are used for filled resins, then mixing can be performed, but the process becomes labor intensive and expensive
Solution Approach 1:
The patent employs a continuous mixing process where particles are continuously introduced into the polymer matrix through a extruder or mixer, replacing batch processing. This continuous operation eliminates labor-intensive manual handling and reduces production costs while maintaining thorough mixing of particles throughout the matrix.
2Quantity of substance
If high particle loadings are used in filled resins, then enhanced properties are achieved, but particle agglomeration increases
Solution Approach 1:
The patent applies surface modification to particles before compounding, where functional groups are added to particle surfaces in advance. This preliminary functionalization creates compatibility between particles and polymer matrix, preventing agglomeration even at high particle loadings and ensuring uniform dispersion throughout the filled resin.
Solution Approach 2:
The patent uses coupling agents or surface-modified particles as intermediaries between the particle surface and the polymer matrix. These intermediaries improve interfacial adhesion and prevent particle agglomeration, allowing high particle loadings to be maintained while preserving composition stability and uniform dispersion.
3Ease of operation
If functional groups are added to particle surfaces to improve compatibility, then mixing is improved, but the process becomes more complex
Solution Approach 1:
The patent combines the particle functionalization step with the compounding process itself. Surface-modifying agents are introduced during the mixing operation, allowing functional groups to be added to particles while simultaneously achieving uniform distribution in the polymer matrix. This merged approach improves mixing quality without significantly increasing process 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
This process effectively disperses high loadings of particles in the organic matrix with low agglomeration and minimal residual solvent, enhancing properties like mechanical and optical properties while reducing production costs through continuous processing.
Implementation Method 1
the vacuum conditions and elevated temperature being sufficient to remove solvent from the particles and organic matrix
Implementation Method 2
providing a wiped film evaporator comprising an internal evaporator chamber maintained under vacuum conditions
Data Source
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AI summary
A method of making a filled resin includes the steps of: Providing a wiped film evaporator with an internal evaporator chamber maintained under vacuum and having an internal chamber wall maintained at an elevated temperature; introducing solvent-borne particles and organic matrix into the internal chamber; and compounding the solvent-borne particles and the organic matrix in the internal evaporator chamber by forming a thin film against the internal chamber wall, the thin film including organic matrix and particles, and the vacuum conditions and elevated temperature being sufficient to remove solvent from the particles and organic matrix to provide the filled resin. Less than about 10% of the particles in the resulting filled resin are agglomerated.