Hydrogel Micronizing Rotor-Stator to Reduce Particle Pressure Damage
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Solution Overview
Problem
Conventional grinding methods for hydrogel of super absorbent polymer apply excessive pressure to the cutting part, leading to increased extractable contents (E/C) and vortex decrease due to particle aggregation.
Innovation Solution
A micronizing apparatus using centrifugal force to transfer hydrogel, featuring a rotor and stator with alternating blades and recesses, reduces pressure on the cutting part and minimizes particle damage by increasing the width of stator recesses radially outward.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a screw continuously pushes hydrogel to a cutting part until the hydrogel passes through the through holes, then the hydrogel is cut into smaller pieces, but strong pressure is applied to the cutting part causing damage to hydrogel particles and increase in extractable contents
Solution Approach 1:
The invention divides the cutting process into two distinct stages: a chopping stage with a chopper that performs initial coarse cutting, and a grinding stage with a mill that performs fine grinding. This segmentation allows each stage to operate under optimized pressure conditions, preventing excessive pressure damage while achieving the desired particle size reduction.
Solution Approach 2:
The invention introduces an intermediary classification mechanism (classifier) between the chopping and grinding stages. This classifier separates particles based on size, directing only those that require further size reduction to the grinding stage, while allowing adequately sized particles to proceed directly to drying. This intermediary step prevents unnecessary pressure application on particles that have already reached acceptable size.
2Stress or pressure
If the thickness of the hole plate is decreased to reduce pressure on the cutting part, then pressure is reduced, but the hole plate may be broken by applied pressure limiting thickness decrease
Solution Approach 1:
The invention replaces the single thick hole plate with a segmented structure consisting of multiple thin plates with through holes, positioned at different stages (chopping stage and grinding stage). This segmentation distributes the pressure load across multiple thinner components rather than concentrating it on a single thick plate, reducing the risk of breakage while maintaining adequate pressure control.
3Manufacturing precision
If grinding is continued until hydrogel completely passes through the through holes, then particle size is reduced, but vortex becomes slow due to aggregation of particles
Solution Approach 1:
The invention implements a feedback mechanism through the classifier that continuously monitors particle size and redirects particles for further processing only when necessary. Particles that have achieved the desired size are immediately diverted to the drying stage, preventing over-grinding and subsequent aggregation. This feedback control maintains particle size precision while minimizing aggregation-related vortex degradation.
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
Prevents excessive pressure on the cutting part, reduces vortex decrease, and minimizes extractable contents (E/C) by using centrifugal force to grind hydrogel effectively.
Implementation Method 1
the hydrogel transferred to the rotor by the screw is transferred radial outwardly by centrifugal force
Implementation Method 2
cut/ground by the gap between the rotor and the stator
Data Source
AI summary
The micronizing apparatus includes: a body having a transfer space where hydrogel is transferred, and a discharge space where ground hydrogel is discharged; a rotation shaft disposed in the transfer space, wherein at least one screw is formed on an outer perimeter surface of the first rotation shaft, to transfer the hydrogel along a longitudinal direction of the body; a rotor installed on the rotation shaft so as to rotate together with the rotation shaft, wherein a plurality of rotor blades and a plurality of rotor recesses are alternately formed along a circumferential direction on an outer perimeter part of the rotor; and a stator surrounding the rotor with an air gap between the rotor and the stator, which is a predetermined distance between an outside diameter of the rotor and an inside diameter of the stator, and is fixed to the body.