Non-Circular Nozzle Cross-Sections for Polymer Devolatilization
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Solution Overview
Problem
Current devolatilizer nozzles in polymer processing do not efficiently distribute molten polymer to maximize surface area for devolatilization, leading to suboptimal removal of unreacted monomer and solvent, which affects polymer quality and processing efficiency.
Innovation Solution
A devolatilizer vessel design featuring a vessel header with alternating penetrations and lateral flow tubes having non-circular cross-sections, such as circular or elliptical sectors, and irregular quadrilaterals, which increase the number of flow tubes and usable surface area, allowing for more efficient polymer distribution and devolatilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional circular nozzles are used in devolatilizer vessels, then the structure is simple and easy to manufacture, but the surface area for polymer distribution is limited, reducing devolatilization efficiency
Solution Approach 1:
The patent applies asymmetry by transitioning from traditional circular nozzle cross-sections to non-circular cross-sections (such as rectangular or oval shapes). This asymmetric change increases the surface area of the nozzles, allowing for greater polymer distribution and enhanced devolatilization efficiency while maintaining manufacturability through standard fabrication processes
2Productivity
If the number of flow tubes is increased to improve polymer distribution, then devolatilization efficiency improves, but the vessel header complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies merging by integrating multiple flow tubes into a unified vessel header structure with a optimized cross-sectional design. This consolidation approach allows for increased polymer distribution capacity while reducing overall structural complexity compared to having multiple separate flow management systems
Solution Approach 2:
The patent applies dimensionality change by transitioning from circular to non-circular nozzle cross-sections, utilizing the additional geometric dimensions more effectively. This dimensional optimization increases surface area and flow distribution capacity without proportionally increasing the number of separate components or overall structural complexity
3Area of stationary object
If non-circular cross-section nozzles are used, then the surface area for devolatilization is increased, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies asymmetry by using non-circular cross-sections to maximize surface area while working within the constraints of manufacturing precision. The specific geometric shapes chosen balance the need for increased surface area with the practical limitations of fabrication accuracy
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 design enhances the throughput capacity and devolatilization efficiency by increasing the surface area for polymer strands to exit, resulting in reduced volatile content in the polymer, such as styrene monomer, and improved polymer quality.
Implementation Method 1
volatiles may be removed by vacuum distillation, flash devolatization, stripping, increasing polymer surface area
Implementation Method 2
volatiles may be removed by vacuum distillation, flash devolatization, stripping
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
A vessel header includes lateral flow tubes arranged in a parallel configuration. The lateral flow tubes enter the vessel header through alternating vessel header penetrations with a single vessel header penetration per lateral flow tube. Each lateral flow tube has a perforated section within the vessel header having a non-circular cross-section having the shape of a circular sector, an elliptical sector, or an irregular quadrilateral. A method includes passing a molten polymer through the lateral flow tubes of the vessel header. The molten polymer exits the lateral flow tubes as strands through perforations in the lateral flow tubes within the vessel header. The method includes obtaining devolatilized polymer.