Granulation Device Roller Cutters Sphericity
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Solution Overview
Problem
Existing methods for manufacturing cleaning granules fail to produce uniform, spherical granules with a diameter of at least 5 mm, leading to exposure of functional materials to air or moisture, resulting in degradation and breakage during storage and transportation.
Innovation Solution
A method involving a granulation device with a first and second roller cutter, featuring parallel blades and grooves, is used to cut and polish a solid mixture into spherical granules with a sphericity of at least 0.90, ensuring the granules maintain their shape and encapsulate functional materials effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional centrifugal spheronizer is used to manufacture cleaning granules, then the granulation process can be completed, but the resulting granules have particle size less than 5 mm and sphericity less than 0.8, which causes functional materials to be exposed to air or moisture and leads to degradation
Solution Approach 1:
The patent changes the operating parameters of the granulation device, specifically using a rotation speed of 5-20 rpm (lower than traditional centrifugal spheronizers) and controlling the granule diameter to be 5-10 mm (larger than traditional 0.05-5 mm). These parameter changes result in granules with sphericity of 0.85-0.95 and particle size of 5-10 mm, which effectively enclose functional materials and prevent their exposure to air or moisture during storage and transportation.
2Ease of manufacture
If smaller particle size granules are produced, then the granulation process is easier, but functional materials cannot be effectively enclosed and are likely to lose strength or escape during storage
Solution Approach 1:
The patent specifies a particle size range of 5-10 mm, which is larger than traditional granule sizes. This parameter change ensures that functional materials are effectively enclosed within the granules, preventing them from losing strength or escaping during storage, while still maintaining ease of manufacture through the optimized granulation process.
3Device complexity
If granules with low sphericity are produced, then the manufacturing process is simpler, but the granules are prone to breakage during transportation or packaging, exposing functional materials to air or moisture
Solution Approach 1:
The patent employs a granulation device with a spherical cavity that rotates to form granules with high sphericity (0.85-0.95). This spheroidality principle ensures that the granules have a smooth, rounded shape without edges or corners, making them resistant to breakage during transportation or packaging and preventing functional materials from being exposed to air or moisture.
4Reliability
If larger particle size granules are produced, then functional materials can be better enclosed, but the granulation process becomes more difficult
Solution Approach 1:
The patent optimizes the granulation parameters including rotation speed (5-20 rpm) and granule diameter (5-10 mm) to achieve the desired balance. These parameter changes enable the production of larger granules that effectively enclose functional materials while maintaining manufacturing precision and processability through the optimized granulation device and process conditions.
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 produces granules with enhanced sphericity, firmness, and stability, preventing functional material degradation and breakage, while maintaining cleaning effectiveness and fragrance persistence during storage and use.
Implementation Method 1
cutting the solid mixture into a rough granule by cooperating the first blades with the second blades
Implementation Method 2
polishing the rough granule into the solid granule by friction rubbing between the first grooves and the second grooves
Data Source
AI summary
A method of manufacturing a solid granule for use as or in a cleaning agent includes providing an anionic surfactant component having at least one anionic sulfonate surfactant and at least one anionic fatty alcohol-based sulfate surfactant; providing a granule-forming agent; mixing the anionic surfactant component and the granule-forming agent into a solid mixture; receiving the solid mixture in a granulation device, the granulation device having a first roller cutter and a second roller cutter, the first roller cutter includes a plurality of first blades and a plurality of first grooves, the second roller cutter having a plurality of second blades and a plurality of second grooves; cutting the solid mixture into a rough granule by cooperating the first blades with the second blades; and polishing the rough granule into the solid granule by friction rubbing between the first grooves and the second grooves.