Jet Vibrator for Homogeneous Polymer Sphere Synthesis
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Solution Overview
Problem
Existing methods for synthesizing homogeneous polymer spheres, such as suspension polymerization, face challenges with wide particle size distribution, low yield, and inefficient polymerization of uniform droplets, leading to high material waste and limited industrial scalability.
Innovation Solution
A device and method utilizing a jet vibrator with a multichannel micropore plate and a spiral prepolymerization channel, combined with a water phase circulating system, to generate and stabilize uniform oil droplets for effective polymerization, ensuring high yield and continuous production of homogeneous white spheres with controlled particle size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If suspension polymerization is used to prepare resin white spheres, then the synthesis process is simple, but the particle size distribution is wide and uniformity is poor
Solution Approach 1:
The invention divides the oil phase into multiple channels (e.g., 5 channels) with each channel containing micropores that generate individual droplet streams. This segmentation allows each channel to produce uniform droplets independently, and the combined output achieves narrow particle size distribution while maintaining manufacturing simplicity
Solution Approach 2:
The invention performs preliminary droplet formation in the jet vibrator before polymerization. Uniform droplets are generated and stabilized in the water phase, then pre-polymerized in a spiral channel before entering the main reactor. This preliminary action ensures particle size uniformity is established before the main synthesis process
2Manufacturing precision
If jet vibration is used to produce uniform oil droplets, then droplet uniformity is improved, but droplet stability and polymerization efficiency are compromised
Solution Approach 1:
The invention introduces a water phase as an intermediary medium. Uniform droplets generated by jet vibration are immediately stabilized in the water phase, which acts as a protective environment preventing droplet coalescence. The water phase circulates through the spiral pre-polymerization channel, maintaining droplet stability throughout the process
Solution Approach 2:
Droplets are stabilized in the water phase immediately after generation, before entering the polymerization process. This preliminary stabilization prevents droplet breakage and coalescence during subsequent handling and polymerization, ensuring both uniformity and stability
3Productivity
If multiple pumps or multichannel pump are used to improve yield, then production capacity increases, but cost and floor space increase greatly
Solution Approach 1:
The invention merges multiple droplet generation channels (e.g., 5 channels) into a single integrated jet vibrator unit. This allows high yield to be achieved through multi-channel simultaneous operation without requiring multiple separate pumps, thus increasing productivity while controlling device complexity and floor space requirements
Solution Approach 2:
The invention transitions from single-channel sequential processing to multi-channel parallel processing within the same device footprint. By adding spatial dimensions (multiple channels operating simultaneously), the system achieves higher yield without proportionally increasing floor space or device complexity
4Device complexity
If single channel is used for droplet generation, then device complexity is reduced, but yield is limited
Solution Approach 1:
The jet vibrator is divided into multiple independent channels (e.g., 5 channels), each capable of generating uniform droplets. This segmentation allows the device to maintain relative simplicity while achieving high yield through parallel operation of multiple channels within a single integrated unit
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 solution achieves a high yield of uniform polymer spheres with a narrow particle size distribution, improving the efficiency and scalability of the synthesis process while ensuring droplet stability and timely polymerization, resulting in resin products with a coefficient of uniformity below 1.2 and particle sizes ranging from 100 μm to 2000 μm.
Implementation Method 1
a jet vibrator including a jet oil phase tank, a jet micropore plate and a vibration exciter for outputting vibration
Implementation Method 2
a spiral prepolymerization channel... ensuring that the droplets will not be broken and coalesced before polymerization
Data Source
AI summary
A homogeneous polymer sphere synthesis device based on channel prepolymerization comprises a jet vibrator, a spiral prepolymerization channel, a reactor and a water phase circulating system; two ends of the water phase circulating system are connected to the reactor and the spiral prepolymerization channel through pipes, respectively; the jet vibrator comprises a jet oil phase tank, a jet micropore plate and a vibration exciter for outputting vibration; the jet micropore plate is arranged in the jet oil phase tank; an outlet end of the spiral prepolymerization channel is connected to the reactor, while an inlet end thereof is connected to the jet oil phase tank.