Flame Black Comminution for Viscosity Control
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Solution Overview
Problem
Flame blacks produced by conventional methods have high structures leading to high viscosities in solvent-based and aqueous systems, limiting their filling levels and functionality in applications such as paints, plastics, and rubbers.
Innovation Solution
Mechanical comminution of flame black in a rotor ball mill with controlled energy input and conditions to reduce DBP values, aggregate size, and volatile content, resulting in a product with specific physical and chemical properties suitable for improved dispersion and performance in various materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flame black is produced by conventional production methods, then it achieves high structure and good color strength, but it results in high viscosity in solvent-based and aqueous systems and limits filling levels
Solution Approach 1:
The flame black aggregates are segmented into smaller units through mechanical comminution in a rotor ball mill, reducing the average aggregate size and structure. This segmentation breaks down the large aggregates into smaller particles while maintaining color strength, thereby reducing viscosity in applications.
Solution Approach 2:
The patent changes the physical parameters of flame black by controlling the comminution process to achieve specific DBP values (less than 100 ml/100g) and aggregate size distributions. By adjusting energy input, comminution time, and mill operating conditions, the structure and aggregate size are optimized to balance color strength and viscosity.
2Strength
If flame black has high structure, then it provides good color strength, but it allows only low levels of filling in systems
Solution Approach 1:
Mechanical comminution segments the high-structure flame black into smaller aggregates with reduced DBP values, enabling higher filling levels in paint, plastic, and rubber systems while preserving sufficient color strength for practical applications.
3Manufacturing precision
If mechanical comminution energy input is increased, then aggregate size is reduced and DBP values decrease, but energy consumption increases
Solution Approach 1:
The rotor ball mill operates continuously with optimized energy input to achieve the desired aggregate size reduction and DBP values without excessive energy consumption. The continuous comminution process maintains efficient energy transfer to the material being ground.
Solution Approach 2:
By optimizing comminution parameters such as energy input, time, and mill operating conditions, the process achieves effective aggregate size reduction and DBP value control while minimizing energy consumption. The patent identifies specific parameter ranges that balance processing effectiveness with energy efficiency.
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 modified flame black exhibits reduced DBP values, increased tamped density, and volatile content, enhancing color strength in paints, reducing viscosity and increasing tensile strength in rubbers, while maintaining color stability and performance across different applications.
Implementation Method 1
flame black is mechanically comminuted in a rotor ball mill
Implementation Method 2
The energy input can occur almost exclusively through collision and less through friction and shear
Implementation Method 3
the energy is mainly transferred via shear and friction
Implementation Method 4
As a result of the heat radiation from the extractor hood, the raw material evaporates and is partially burned
Implementation Method 5
the raw material evaporates and is partially burned
Implementation Method 6
the raw material evaporates and is partially burned
Data Source
AI summary
The invention relates to lamp blacks having a DBP value of less than 100 ml/100g. The invention also relates to a method for producing said lamp black, wherein lamp black is mechanically size-reduced in a rotary ball mill. The lamp blacks according to the invention can be used in carbon black dispersions, paint systems, printing inks, plastic mixtures and rubber mixtures.