Liquid Polymer Additive Concentrates for Uniform Dispersion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional polymer additives in powder or granule form are difficult to handle and can pose health, fire, and explosion risks, and when added to solution or suspension polymerization processes, they often form slurries with large particles that settle, foul equipment, and cause defects in the finished product.
Innovation Solution
Preparing liquid polymer additive concentrates by extruding or compacting the additives to create finely dispersed pellets that dissolve completely in the polymerization media, reducing particle size and improving dispersability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional powder or granule polymer additives are added to solution or suspension polymerization processes, then the additives can be easily handled and fed, but they form slurries with large particles that settle, foul equipment, and cause defects in the finished product
Solution Approach 1:
The invention changes the physical state parameter of the additive from solid powder/granule to liquid concentrate form. This parameter change allows the additive to be easily pumped and mixed while preventing slurry formation and particle settling, thus resolving the contradiction between ease of operation and manufacturing precision
Solution Approach 2:
The invention utilizes phase transition by converting the additive from solid phase to liquid phase through the use of a carrier liquid. This phase transition enables the additive to remain in solution without forming settleable particles, maintaining both ease of handling and uniform dispersion in the polymerization process
2Ease of manufacture
If conventional powder polymer additives are used, then no additional processing is required, but they pose health, fire, and explosion risks and are difficult to handle and feed
Solution Approach 1:
The invention introduces a carrier liquid as an intermediary substance that dissolves or suspends the polymer additive. This intermediary form eliminates the hazards of handling free powder (fire, explosion, health risks) while maintaining the additive's functionality, thus resolving the contradiction between manufacturing simplicity and safety
Solution Approach 2:
The invention transitions from solid powder handling to liquid hydraulic handling. The liquid concentrate can be pumped and delivered through standard fluid handling equipment, eliminating the dust explosion and inhalation hazards associated with powder while requiring only minimal additional processing infrastructure
3Adaptability or versatility
If multiple additive components are required, then the polymer performance can be enhanced, but the additives must be pre-blended or require more than one feeder
Solution Approach 1:
The invention merges multiple additive components into a single liquid concentrate formulation. Multiple additives are dissolved or suspended together in a carrier liquid, allowing them to be delivered through a single feeding system, thus resolving the contradiction between adaptability and device complexity
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 resulting liquid additive concentrates exhibit high dispersability and fine particle dispersion, minimizing settling and equipment fouling, and significantly reducing the percentage of particles retained on a 100 mesh screen, thereby enhancing the uniformity and quality of the polymerization process.
Implementation Method 1
The additive blend is fed through an extruder and forced through a die to produce pellets
Implementation Method 2
The remaining un-melted particles are subjected to shear and/or heat and are finely dispersed
Implementation Method 3
During extrusion at least one of the additives is melted or softened
Implementation Method 4
The remaining un-melted particles are subjected to shear and/or heat and are finely dispersed
Implementation Method 5
The pellets so formed are dispersed in the same liquid solvent used in solution or slurry polymerization to form a liquid additive concentrate
Implementation Method 6
The polymer additive blend is fed through a compaction mill and forced through a die to produce pellets
Implementation Method 7
during compaction the polymer additives are subjected to shear and pressure forces which cause attrition of the individual particles
Data Source
AI summary
A method is described for preparing liquid concentrates of additives for incorporation in polymers, particularly polymers prepared in solution or slurry phase polymerization media. Additive concentrates according to the invention are characterized by a finer dispersion than would result from the direct addition of particulate or granular additives to the same liquid solvent.