High-Pressure Liquid Jet Milling Elastomer
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Solution Overview
Problem
Existing methods for producing milled elastomer, such as high-pressure liquid jet milling, face inefficiencies due to high energy consumption, heat generation, and the challenge of producing homogeneous, fine-grained rubber granulates, leading to economic and energy wastage issues.
Innovation Solution
The method involves optimizing the first phase of the milling process by reducing the velocity of the liquid jet and increasing the nozzle diameter, along with adjusting the forward-feed rates between phases to minimize heat generation and enhance energy efficiency, using a controlled high-pressure liquid jet milling apparatus capable of handling multiple tyres simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If high-pressure liquid jet milling is used to produce rubber granulates, then the rubber material can be recycled, but the specific energy consumption is high and heat generation occurs
Solution Approach 1:
The patent changes the parameters of the liquid jet milling process by optimizing jet pressure, nozzle diameter, and feed rate to reduce specific energy consumption and minimize heat generation during rubber granulate production
Solution Approach 2:
The patent replaces conventional mechanical milling systems with a liquid jet-based system, substituting mechanical contact and friction with fluid dynamics-based material removal, thereby reducing heat generation and energy consumption
2Productivity
If the velocity of the liquid jet is increased to improve milling efficiency, then productivity increases, but heat generation and energy consumption increase
Solution Approach 1:
The patent optimizes the velocity parameter of the liquid jet by conducting systematic investigations to determine the optimal velocity range that achieves high milling efficiency while minimizing energy consumption and heat generation
Solution Approach 2:
The patent introduces dynamic control of the liquid jet velocity and feed rate, allowing real-time adjustment of parameters to maintain optimal milling conditions without excessive energy input or heat generation
3Manufacturing precision
If conventional mechanical milling is used, then the process is simple, but the rubber granulates contain contaminants and have mixed material composition
Solution Approach 1:
The patent replaces conventional mechanical milling with liquid jet milling technology, which uses high-pressure fluid streams to erode and remove rubber material without mechanical contact, thereby preventing contamination from metal components and achieving cleaner granulates
Solution Approach 2:
The patent introduces a liquid medium (water or other suitable fluid) as an intermediary between the energy source and the rubber material, allowing material removal without direct mechanical contact and preventing contamination from milling tools
4Manufacturing precision
If high-pressure liquid jet milling is applied, then rubber crumbs can be produced, but size inhomogeneity occurs in the crumbs
Solution Approach 1:
The patent systematically investigates and optimizes multiple parameters including jet pressure, nozzle diameter, feed rate, and jet-to-surface distance to achieve consistent particle size distribution while maintaining high milling productivity
Solution Approach 2:
The patent employs dynamic adjustment of milling parameters during the process to maintain optimal conditions for producing uniformly sized crumbs, preventing size inhomogeneity that would otherwise occur with static parameter settings
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
This approach reduces specific energy consumption, achieves more uniform particle size distribution, and enhances the economic production of milled elastomer by minimizing energy wastage and improving milling efficiency.
Implementation Method 1
Exploiting the tearing effect of the liquid jet, milled elastomer is separated from the surface of the elastomeric material
Implementation Method 2
a liquid jet having a pressure in the range of 650-1350 bar is directed on an elastomeric material moving in an at least partially transversal direction with respect to the discharge direction of the liquid jet
Data Source
AI summary
The invention is a method for producing milled elastomer, comprising the steps of directing a liquid jet from at least one nozzle on an elastomeric material moving in an at least partially transversal direction with respect to the discharge direction of the at least one nozzle. In the method according to the invention the liquid jet directed on the elastomeric material has a pressure of 650-1350 bar, and the elastomeric material is moved with respect to the at least one nozzle such that, in a first phase adapted for disintegrating a surface of the elastomeric material, the elastomeric material has a first forward-feed rate of 10 to 20 mm/s at a point of impact of the liquid jet in a direction transverse to the discharge direction, and, in a second phase after disintegrating the surface, the elastomeric material has a second forward-feed rate being decreased with 35-65% compared to the first forward-feed rate. The invention is, furthermore, an apparatus for producing milled elastomer.