Polymer Blend Homogenization via Colloid Mill and Vacuum Degassing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for preparing liquid polymer blends for polyurethane systems result in insufficient homogenization and undefined gas charges, leading to gas inclusions in the final product, which can alter its appearance and necessitate post-processing measures or product rejection.
Innovation Solution
A device and method utilizing a colloid mill for homogenization, a vacuum ventilator for degassing, and a gas mass flow meter for controlled gassing, ensuring a defined and evenly distributed gas charge in the polymer blend, using a device comprising a toothed colloid mill, vacuum ventilator, and electronic control for precise gas addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gas charge is added by stirring and transporting in process containers, then the polyol compound is processed, but the gas charge remains unconsidered and undefined, leading to insufficient homogenization and gas inclusions in the end product
Solution Approach 1:
The patent applies preliminary action by performing degassing of the polyol compound before the gas charge is added. This removes undefined gas inclusions beforehand, ensuring that only the intended gas charge remains. The sequence is: degassing → gas charge addition → homogenization. This preliminary removal of unwanted gas ensures precise control over the final gas content and eliminates gas inclusions that would otherwise compromise product quality consistency.
Solution Approach 2:
The patent extracts unwanted gas inclusions from the polyol compound through degassing in a vacuum chamber before adding the defined gas charge. By removing the undefined gas content beforehand, the process ensures that only the intended gas charge contributes to the final foam structure, eliminating gas inclusions and ensuring consistent end product quality.
2Manufacturing precision
If a vacuum ventilator and colloid mill are used for degassing and homogenization, then high-quality homogenization and defined gas distribution are achieved, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated processing units. The vacuum ventilator serves both degassing and vacuum creation functions. The colloid mill integrates homogenization and gas charge distribution in a single device with rotor-stator geometry. The mixing chamber combines storage and mixing functions. This merging of functions achieves high homogenization quality while minimizing the number of separate processing steps and equipment.
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 solution achieves high-quality homogenization and defined gas distribution in the polymer blend, ensuring consistent product quality and eliminating gas inclusions, allowing for immediate and effective use in polyurethane systems.
Implementation Method 1
the homogenization unit homogenizes the polymer blend according to a friction process
Implementation Method 2
The polymer blend is centrifuged against an inner wall of the container due to centrifugal forces
Implementation Method 3
Gases released in this manner are in turn suctioned by a vacuum pump
Data Source
AI summary
A device for preparing a liquid polymer blend is proposed having a storage container for the liquid polymer blend; a degassing device, which is arranged downstream of the storage container, for the liquid polymer; a gassing device, which is arranged downstream of the degassing device, for adding an additive gas to the liquid polymer blend; a homogenization unit, which is arranged downstream of the gassing device, for the polymer blend to which the additive gas was added; and an output line, which is connected to the homogenization unit, for the homogenized polymer blend.