Near-Infrared Resin Flowability Estimation for Recycled Molding
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Solution Overview
Problem
Existing methods struggle to accurately measure the physical properties of low-viscosity thermoplastic resins with high melt mass flow rates, making it difficult to control the quality of recycled resins made from various waste plastics.
Innovation Solution
A resin molding method that estimates resin flowability using electromagnetic wave intensity, particularly near-infrared rays, to adjust molding conditions and improve the quality of recycled resin products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electromagnetic wave intensity measurement method is used to estimate resin flowability, then measurement accuracy for low-viscosity thermoplastic resins is improved, but the complexity of the measurement system increases
Solution Approach 1:
The patent replaces traditional mechanical MFR measurement systems with an electromagnetic wave-based measurement system. By irradiating the resin with near-infrared electromagnetic waves and measuring the reflected wave intensity, the system estimates flowability without requiring complex mechanical testing apparatus, thereby reducing device complexity while maintaining or improving measurement accuracy.
Solution Approach 2:
The patent changes the measurement parameter from mechanical flow rate to electromagnetic wave intensity. By measuring the intensity of reflected near-infrared electromagnetic waves and correlating it with resin flowability, the system provides an accurate non-contact measurement method that avoids the complexity of traditional mechanical measurement systems.
2Ease of manufacture
If traditional MFR measurement method is used, then the measurement process is simple, but it cannot accurately measure low-viscosity thermoplastic resins with high MFR
Solution Approach 1:
The patent substitutes mechanical MFR measurement with electromagnetic wave intensity measurement. This replacement maintains process simplicity by using non-contact optical measurement while dramatically improving the ability to accurately measure low-viscosity resins that have high flow rates and are difficult to measure with traditional mechanical methods.
Solution Approach 2:
The patent introduces electromagnetic waves as an intermediary to measure resin properties. By using near-infrared electromagnetic waves that interact with the resin molecules, the system obtains flowability information without direct mechanical contact, enabling accurate measurement of high-flow resins while keeping the measurement process simple and non-invasive.
3Quantity of substance
If waste plastics from various sources are used to ensure quality and quantity of recycled resins, then the supply of recycled resin materials is improved, but the variation in physical properties of raw materials increases
Solution Approach 1:
The patent implements a feedback mechanism by measuring the electromagnetic wave intensity of each batch of waste plastic and using this information to adjust molding conditions. This feedback loop allows the system to accommodate variations in raw material physical properties while maintaining consistent product quality, enabling the use of diverse waste plastic sources.
Solution Approach 2:
The patent introduces dynamic adjustment of molding conditions based on real-time electromagnetic wave measurements. By continuously monitoring resin flowability through electromagnetic wave intensity and adjusting molding parameters accordingly, the system adapts to variations in waste plastic physical properties, ensuring stable production from diverse material sources.
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
Enables accurate estimation of resin flowability, allowing for consistent and high-quality molding of recycled resins by adjusting molding conditions based on electromagnetic wave intensity information.
Implementation Method 1
When a resin is irradiated with electromagnetic waves, heat is conducted from the resin surface to the inside of the resin.
Implementation Method 2
The electromagnetic wave intensity information refers to information including the intensity of electromagnetic waves reflected by the resin surface when the resin is irradiated with the electromagnetic waves.
Data Source
AI summary
A resin molding method includes a physical property estimation step and a molding step. In The physical property estimation step, a resin is irradiated with electromagnetic waves including near-infrared rays; electromagnetic wave intensity of electromagnetic waves reflected by a surface of the resin is estimated; and flowability of the resin is estimated, based on electromagnetic wave intensity information that includes the electromagnetic wave intensity. In the molding step, a molding condition is adjusted, based on the estimated flowability of the resin; and the resin is molded under the adjusted molding condition.