High-Capacity Polymer Mixing System for Reduced Agglomeration

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Solution Overview

Problem

Existing methods for preparing polymeric slurries face issues with agglomeration and increased production costs due to low-capacity mixing or the use of chemical additives.

Innovation Solution

A system comprising a containment device, receiving chamber, wetting bowl, dispersing channel, and mixing chamber with a funnel-shaped distribution apparatus and mechanical mixing device, which controls the distribution of dry polymeric materials and water to form a polymeric mixture efficiently, reducing agglomeration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If low-capacity mixing is used to reduce agglomeration, then polymeric materials are separated better, but production speed decreases

Engineering Contradiction:

Improveagglomeration reductionVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The mixing process is divided into multiple stages: initial high-shear mixing to break up agglomerates, followed by lower-shear mixing to maintain uniformity. The mixing chamber is segmented with different zones having different mixing intensities, allowing efficient processing without excessive agglomeration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mixing system uses variable speed control and adjustable mixing parameters that can be optimized for different polymer types and desired output rates. The dynamic adjustment of mixing intensity allows the system to maintain high productivity while preventing agglomeration through real-time parameter optimization.

Inventive Principle:

Principle #15Dynamics

2Reliability

If chemical additives are used to prevent agglomeration, then polymeric materials separate better, but production cost increases

Engineering Contradiction:

Improveagglomeration preventionVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system uses the physical and chemical properties of the polymeric materials themselves to prevent agglomeration. By optimizing mixing parameters, chamber geometry, and flow dynamics, the system achieves effective separation without requiring external chemical additives, thereby eliminating additional material costs.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention replaces chemical methods with optimized mechanical mixing approaches. Through carefully designed mixing chambers, controlled shear rates, and optimized residence times, the system achieves agglomeration prevention purely through mechanical means, avoiding the need for chemical dispersants or additives.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If mechanical mixing is used to prepare polymeric slurries, then mixing efficiency is maintained, but agglomerates form in the final slurry

Engineering Contradiction:

Improvemixing efficiencyVSAvoidslurry quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Different regions of the mixing chamber are designed with different local characteristics: high-shear zones for breaking agglomerates, low-shear zones for gentle mixing, and specific flow patterns that prevent re-agglomeration. This spatial variation in mixing quality ensures both efficiency and final slurry uniformity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system performs preliminary wetting of polymeric materials before full mixing occurs. Water is introduced in a controlled manner to partially hydrate the polymer surface, reducing inter-particle adhesion before the main mixing action, thereby preventing agglomerate formation during high-speed mixing.

Inventive Principle:

Principle #10Preliminary action

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 system enables high-capacity production of polymeric slurries with reduced agglomeration, maintaining production efficiency and cost-effectiveness by optimizing the mixing process.

Implementation Method 1

a mechanical mixing device positioned between the first end and the second end

Methodology Applied

Scientific EffectMechanical mixing: Mechanical Force

Implementation Method 2

a funnel-shaped distribution apparatus extending from the first end of the mixing chamber to the mechanical mixing device

Methodology Applied

Scientific EffectGravity flow: Gravitation

Implementation Method 3

a wetting bowl connected to the receiving chamber

Methodology Applied

Scientific EffectWetting: Wetting

Data Source

PatentUS12458934B2High-capacity polymer system and method of preparing polymeric mixtures

Publication Date: 2025.11.04 UGSI CHEM FEED

AI summary

A system for preparing a polymeric mixture includes: a containment device configured to distribute dry polymeric materials; a receiving chamber in fluid communication with the containment device; a wetting bowl; a dispersing channel; and a mixing chamber connected to the dispersing channel. A method of preparing a polymeric mixture includes distributing water and dry polymeric materials through the various components of the system and mixing the materials with the mechanical mixing device.