Polymer Emulsion Binder for Press Polymer-Bonded Explosives
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Solution Overview
Problem
The existing water-slurry process for manufacturing press polymer-bonded explosives requires high-temperature distillation to remove organic solvents, posing safety hazards and environmental risks, and limits the use of energy metals due to hydration reactions at high temperatures.
Innovation Solution
The process is improved by using a polymer emulsion instead of organic solvents, which eliminates the need for high-temperature distillation, allowing for safer and more environmentally friendly production, and enabling the incorporation of metals like aluminum, magnesium, and boron to enhance explosion energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If organic solvent is used in the water-slurry process, then coating and agglomeration of explosive particles can be achieved, but high-temperature distillation is required which poses safety hazards and environmental risks
Solution Approach 1:
The patent changes the fundamental parameter of the binder system from organic solvent-based to water-based polymer emulsion. This parameter change eliminates the need for high-temperature distillation (100°C or more) while maintaining the coating and agglomeration functions, thereby improving safety and environmental compatibility without sacrificing manufacturability
Solution Approach 2:
The patent replaces the thermal field (distillation process) with a chemical field approach (water-based polymer emulsion). Instead of using heat to remove organic solvent, the invention uses water-soluble polymer emulsion that naturally forms the binder matrix, substituting a thermal processing system with a chemical composition system that achieves the same functional result without safety hazards
2Productivity
If high-temperature distillation is performed to remove organic solvent, then granular powder can be obtained, but manufacturing time is extended and production efficiency is reduced
Solution Approach 1:
By changing from organic solvent to water-based polymer emulsion, the patent eliminates the time-consuming distillation step. The water-based system allows for direct drying at lower temperatures, dramatically reducing the manufacturing cycle time and increasing production efficiency by 1000% per reactor
Solution Approach 2:
The patent extracts and removes the distillation step from the manufacturing process by using water-based polymer emulsion instead of organic solvent. This extraction of the problematic step eliminates the time loss associated with high-temperature solvent removal while maintaining the essential function of obtaining granular powder
3Object-affected harmful factors
If high-temperature distillation is used, then organic solvent can be removed, but environmental harm and handling safety issues arise
Solution Approach 1:
The patent changes the solvent parameter from organic to water-based, fundamentally altering the environmental and safety profile of the process. Water-based polymer emulsion eliminates volatile organic compound emissions and fire hazards associated with organic solvents, improving environmental compatibility while maintaining process simplicity through straightforward drying operations
Solution Approach 2:
The patent converts the potential harm of water (requiring drying) into a benefit by using water-based polymer emulsion. Water serves as a safe, non-flammable, environmentally benign carrier that can be easily removed by low-temperature drying, transforming what could be a disadvantage (moisture content) into an advantage (safety and environmental compatibility)
4Adaptability or versatility
If high-temperature processing is performed, then solvent removal is achieved, but energy metals cannot be incorporated due to hydration reactions
Solution Approach 1:
By changing from high-temperature organic solvent processing to low-temperature water-based polymer emulsion processing, the patent creates conditions suitable for incorporating temperature-sensitive energy metals like aluminum, magnesium, and boron. The lower processing temperature prevents unwanted hydration reactions while maintaining material composition flexibility
Solution Approach 2:
The patent performs preliminary action by incorporating energy metals into the mixture before the binder sets, taking advantage of the low-temperature water-based system to include these metals without triggering hydration reactions. This preliminary incorporation is made possible by the gentler processing conditions of the water-based system
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
This approach reduces manufacturing time and costs, increases production efficiency by 1000% per reactor, and enhances the explosion energy of the final product while ensuring safety and eco-friendliness.
Implementation Method 1
adding a polymer emulsion to a suspension in which explosive particles are dispersed in water, thus agglomerating the explosive particles and the polymer binder
Implementation Method 2
a polymer emulsion is used to maximize the efficiency of a process
Data Source
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AI summary
Disclosed is a method of manufacturing a press polymer-bonded explosive, in which a polymer emulsion is used to maximize the efficiency of a process, and a press polymer-bonded explosive manufactured using the same. The method includes a polymer-emulsion-manufacturing step of mixing a monomer of a polymer binder and an emulsifier with a process water and then adding an initiator to thus manufacture a polymer emulsion using a polymerization reaction, a slurry-manufacturing step of mixing a raw material including an explosive and an emulsion breaker with fresh process water to thus manufacture a slurry, an agglomerated-particle-forming step of adding the manufactured polymer emulsion to the manufactured slurry to thus form agglomerated particles in which a surface of the raw material is coated with the polymer binder, and an agglomerated-particle-obtaining step of collecting the agglomerated particles using filtration and drying the collected agglomerated particles.