Photopolymerization Devolatilization Apparatus for High Viscosity Polymers
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Solution Overview
Problem
The commercial production of high molecular weight polymers in neat melt form faces challenges in reducing cycle time and removing residual volatiles due to high viscosity, making conventional polymerization and devolatilization processes inefficient and quality-maintaining.
Innovation Solution
An apparatus comprising a reaction vessel with a circulation loop and light emitters for polymerization, along with optional devices like heat exchangers and analyzers, that assists in mixing and temperature control, and the use of entraining agents for volatile removal, enhancing the efficiency of the polymerization and devolatilization processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional polymerization methods are used to produce high molecular weight polymers in neat melt form, then the molecular weight and polymer quality are improved, but the cycle time increases significantly and productivity decreases
Solution Approach 1:
The reaction system is segmented into multiple zones with different agitator types (high-shear and low-shear zones) and multiple light emitter arrays positioned at different locations. This segmentation allows simultaneous polymerization in different regions with optimized local conditions, reducing overall cycle time while maintaining polymer quality
Solution Approach 2:
The system employs periodic alternation between polymerization phases and devolatilization phases. During polymerization, light emitters activate monomer conversion; during devolatilization, the system removes volatiles. This periodic action optimizes both reaction efficiency and cycle time reduction
2Manufacturing precision
If high molecular weight polymer is produced in neat melt form, then polymer quality is improved, but mixing becomes difficult due to high viscosity
Solution Approach 1:
The agitation system is segmented into high-shear agitators for initial mixing and low-shear agitators for later stages. This segmentation allows effective mixing at different viscosity stages without compromising polymer quality or requiring excessive energy
Solution Approach 2:
The system replaces conventional prolonged mechanical mixing with photopolymerization-driven reaction and controlled devolatilization. Light-emitting arrays enable polymerization without extensive mechanical mixing, reducing the time polymer spends in high-viscosity mixed state
3Manufacturing precision
If high molecular weight polymer is produced in neat melt form, then polymer quality is improved, but removal of residual volatiles becomes problematic
Solution Approach 1:
The system employs periodic alternation between polymerization phases and devolatilization phases. During devolatilization, the circulation loop transports melt to a devolatilization zone where volatiles are removed under reduced pressure, then returns polymer to the reaction zone. This periodic action efficiently removes volatiles while maintaining polymer quality
Solution Approach 2:
The circulation loop uses pump-driven fluid transport to move high-viscosity polymer melt through the devolatilization zone and back to the reaction zone. This hydraulic circulation enables effective volatile removal without relying on mechanical mixing or extended processing time
4Productivity
If conventional means are used to reduce cycle time, then productivity is improved, but product quality deteriorates
Solution Approach 1:
The reaction system is segmented into multiple zones with different agitator types (high-shear and low-shear zones) and multiple light emitter arrays positioned at different locations. This segmentation allows simultaneous polymerization in different regions with optimized local conditions, reducing overall cycle time while maintaining polymer quality
Solution Approach 2:
The system uses feedback control to monitor reaction progress and adjust processing parameters in real-time. This ensures that cycle time reductions through intensified processing do not compromise polymer quality, as the system automatically compensates to maintain optimal conditions
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 apparatus significantly reduces cycle time while maintaining product quality by effectively polymerizing and devolatilizing high melt viscosity compositions, improving throughput and residual volatile removal.
Implementation Method 1
an emitter for emitting light that polymerizes, crosslinks, or polymerizes and crosslinks the composition
Implementation Method 2
circulating the polymerizable composition or the polymerized composition outside of the reaction vessel and returning the circulated composition to the reaction vessel
Implementation Method 3
maintaining a temperature of the composition flowing through the circulation loop
Data Source
AI summary
Apparatuses for polymerizing or devolatilizing a composition, especially one of high melt viscosity, are disclosed. Methods of polymerizing and devolatilizing a composition, especially one of high melt viscosity, are also disclosed.