Particulate Fillers With Low Coarse Particle Content
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Solution Overview
Problem
The presence of coarse particles in particulate fillers can be detrimental to applications such as polymer compositions, leading to issues like increased pressure during extrusion and undesirable properties in final products, highlighting the need for fillers with very low coarse material content.
Innovation Solution
Development of particulate fillers with less than 3 ppm of particles greater than or equal to 40 μm, achieved through methods like dry sieving, mill classification, and air classification, which reduce coarse particle content and improve processing and performance in polymer-based products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional filler processing methods are used, then manufacturing simplicity is maintained, but coarse particle content increases causing increased pressure during extrusion and undesirable product properties
Solution Approach 1:
The patent applies preliminary action by implementing classification steps (dry sieving, mill classification, or air classification) during the filler processing stage to remove coarse particles before the filler is used in polymer compositions. This preliminary removal of coarse particles (reducing them to less than 3 ppm) prevents pressure increases and product defects during subsequent extrusion and processing operations.
2Strength
If filler is used in polymer compositions, then enhancement of mechanical properties is achieved, but presence of coarse particles causes increased pressure during extrusion
Solution Approach 1:
The patent applies the extraction principle by removing coarse particles from the filler material through classification processes (dry sieving, mill classification, or air classification) before incorporating the filler into polymer compositions. This extraction of harmful coarse particles (reducing them to less than 3 ppm) maintains the mechanical property enhancements while eliminating the cause of increased extrusion pressure.
3Reliability
If coarse particles are present in filler, then production cost is reduced, but film defects increase and mechanical performance deteriorates
Solution Approach 1:
The patent converts the potentially harmful presence of coarse particles into a beneficial outcome by implementing classification processes that selectively remove these particles. The harm of coarse particles causing film defects and mechanical performance deterioration is transformed into a benefit by systematically eliminating them, resulting in filler with less than 3 ppm coarse material that produces high-quality films with improved mechanical properties.
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 use of particulate fillers with low coarse particle content enhances processability, reduces film defects, and improves mechanical performance, including impact strength and tear strength, while maintaining high recovery rates and throughput.
Implementation Method 1
dry sieving (e.g. sifting) the particulate material to produce a particulate filler comprising less than about 3ppm of particles having a particle size greater than or equal to about 40μm
Implementation Method 2
mill classifying the particulate material to produce a particulate filler comprising less than about 3ppm of particles having a particle size greater than or equal to about 40μm
Implementation Method 3
air classifying the particulate material to produce a particulate filler comprising less than about 3ppm of particles having a particle size greater than or equal to about 40μm
Data Source
AI summary
The present invention relates to particulate fillers which possess no, or very low, amounts of coarse material, compositions comprising said fillers and uses thereof. The present invention also relates to methods of producing said particulate fillers and compositions.