Mixed Reactor Reflux Condensation for Stable Precursor Solution
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Solution Overview
Problem
The existing preparation process of electrothermal film precursor solution faces issues with evaporation leading to concentration changes, poor quality control, and inadequate ultrasonic dispersion due to fixed ultrasonic transducer positions in conventional heated reaction kettles.
Innovation Solution
A mixed reactor equipped with a reflux condensation mechanism and multifunctional stirring mechanism, featuring a rotating condensing coil and movable ultrasonic transducer, enhances condensation efficiency and ultrasonic dispersion, reducing mechanical wear and improving product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional heated reaction kettle is used for preparing electrothermal film precursor solution, then heating and stirring can be performed, but evaporation of liquid raw materials occurs leading to concentration changes and poor quality control
Solution Approach 1:
The patent converts the harmful evaporation of liquid raw materials into a beneficial reflux condensation process. The condensation system captures evaporated materials and returns them to the reaction kettle, transforming material loss into a controlled condensation-reflux cycle that maintains solution concentration and improves quality control.
Solution Approach 2:
The patent utilizes phase transitions by implementing a condensation system that converts evaporated liquid materials back into liquid form through condensation. This phase change process (from liquid to vapor and back to liquid) ensures that evaporated materials are recovered and returned to the reaction system, preventing concentration changes and improving manufacturing precision.
2Adaptability or versatility
If ultrasonic transducer is directly installed on reaction kettle body, then ultrasonic dispersion function is provided, but the fixed position results in poor ultrasonic dispersion effect
Solution Approach 1:
The patent transforms the static, fixed-position ultrasonic transducer into a dynamic, movable system. The ultrasonic transducer is mounted on a movable mechanism that allows it to change position within the reaction kettle, enabling it to adapt to different processing needs and improve dispersion effectiveness throughout the material.
Solution Approach 2:
The patent enhances the ultrasonic transducer system's versatility by making it multi-functional through its movable capability. The same ultrasonic transducer can serve different positions and functions depending on its location, allowing it to effectively disperse materials throughout the entire reaction volume rather than being limited to a fixed zone.
3Manufacturing precision
If fixed ultrasonic transducer position is used, then device structure is simple, but ultrasonic dispersion effect on mixed materials is poor
Solution Approach 1:
The patent implements a dynamic movable ultrasonic transducer system that can change its position within the reaction kettle. This dynamic capability allows the transducer to optimize its location for different dispersion needs, significantly improving the quality of material dispersion while the movement mechanism is designed to be operationally simple.
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 reactor effectively condenses evaporated materials back into the reaction kettle, enhances ultrasonic dispersion, and ensures consistent product quality, resulting in high-performance electrothermal films with improved sheet resistance and infrared radiation.
Implementation Method 1
a corresponding condensing coil is wound around inside of the condensate tank... the cover is provided with an intake pipe for sending evaporated gas into the condensate tank
Implementation Method 2
a corresponding condensing coil is wound around inside of the condensate tank... for refluxing the condensed liquid into the reaction kettle body
Implementation Method 3
an ultrasonic transducer arranged apart from the blind hole is movably arranged in the blind hole... the ultrasonic transducer is connected to a piston rod end of a driving cylinder
Implementation Method 4
an ultrasonic transducer arranged apart from the blind hole is movably arranged in the blind hole... When the materials are dispersed, the external ultrasonic generator is started
Data Source
AI summary
Disclosed is a mixed reactor and a method for preparing electrothermal film precursor solution based on the mixed reactor. The mixed reactor includes a reaction kettle body, a reflux condensation mechanism, and a multifunctional stirring mechanism. The reflux condensation mechanism includes a condensate tank, a condensing coil is wound around inside of the condensate tank, two ends of the condensing coil are horizontally arranged, and hermetically and rotatably installed on both sides of the condensate tank, the condensing coil is driven by a coil driving motor; the multifunctional stirring mechanism includes a stirring shaft and a plurality of stirring blades driven by the stirring shaft. The bottom of the stirring shaft is fixedly sleeved with an isolation sleeve. Buffer rubber gaskets are hermetically connected between the mounting parts and the installation holes. It can effectively improve the quality of products and the quality controllability during the product preparation process.