Polymer Processing Device for Gel Dispersion and Pressure Drop Reduction
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Solution Overview
Problem
Existing polymer processing technologies face challenges in reducing the size and dispersion of gels in polyolefin resins, leading to undesirable characteristics in final products like films, which can result in lower product value and marketability due to pressure drop limitations and inefficiencies in conventional screen technologies.
Innovation Solution
A device with a hollow elongated body and multiple holes is designed to process polymers, allowing for reduced gel size and improved dispersion with minimal pressure drop, featuring a geometric design that accelerates secondary components through specific openings, breaking them down into smaller particles and dispersing them within the polymer matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional screen mesh filters are used to filter or break up undesired species from the polymer stream, then gel removal is improved, but pressure drop increases excessively
Solution Approach 1:
The invention changes the physical state parameter of the polymer from solid granules to molten state, allowing gels to be dispersed and broken up through viscous flow and shear forces rather than mechanical filtration, thereby avoiding excessive pressure drop while achieving gel removal
Solution Approach 2:
The invention replaces the mechanical filtration system (screen mesh filters) with a melt processing system that uses viscous flow and shear forces to disperse and break up gels, substituting mechanical filtration with rheological-based gel removal
2Manufacturing precision
If screens with extremely small openings are used to filter very small species (typically 400 microns or less), then gel filtration is improved, but pressure drop becomes excessive
Solution Approach 1:
The invention changes the size parameter of gel species through in-situ dispersion and break-up in the molten state, converting small filterable species into larger dispersed gel structures that can be removed without requiring extremely small screen openings
3Device complexity
If thin profile screens are used for gel filtration, then device complexity is reduced, but gels can elongate, stretch, or deform to penetrate the screen device
Solution Approach 1:
The invention changes the physical state parameter of gels to molten state where they can be effectively dispersed and broken up before solidification, preventing gel deformation and penetration issues that occur with thin screens in solid state filtration
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 effectively reduces the average gel size by at least 30% and improves dispersion, enhancing the quality of polymer compositions and articles produced, such as films, while minimizing pressure drop and maintaining operational efficiency.
Implementation Method 1
The geometric design of the device accelerates secondary component through specific openings to a degree such that the secondary component is broken up into smaller particles
Data Source
AI summary
Embodiments of an invention disclosed herein relate to devices, processes, and systems for processing one or more polymers.