Polymer Gel Reduction via Static Mixer Extensional Flow
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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 introduced, allowing for fluid communication and geometric design that reduces gel size and improves dispersion by applying extensional forces without excessive pressure drop, enabling the production of polymer compositions with reduced gel sizes and improved dispersivity.
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 size is reduced, but pressure drop increases excessively
Solution Approach 1:
The invention changes the physical parameters of the processing system by introducing a static mixing element with specific geometry (helical ribs, baffle plates) that modifies flow characteristics without relying on fine screen filtration. This allows gel disruption through mechanical mixing action while maintaining lower pressure drop compared to conventional screen filters
Solution Approach 2:
The invention replaces the mechanical screening system (screen mesh filters) with a mechanical mixing system (static mixer with helical ribs and baffle plates). Instead of forcing polymer through screens to break gels, the system uses controlled mixing elements to disrupt and disperse gels through shear and extensional flows, achieving gel size reduction without the excessive pressure drop of screen filtration
2Manufacturing precision
If screens with extremely small openings are used to act on very small gel species, then gel dispersivity is improved, but pressure drop becomes excessive
Solution Approach 1:
The invention changes the approach from filtration-based size reduction to mixing-based dispersion. The static mixing elements create controlled shear and extensional flows that effectively disperse very small gel species (400 microns or less) without requiring extremely fine screen openings, thereby avoiding excessive pressure drop while achieving the desired gel dispersivity
3Device complexity
If thin profile screens are used for gel filtration, then device complexity is reduced, but gel species can elongate, stretch, or deform and penetrate the screen device
Solution Approach 1:
The invention replaces the thin screen filtration mechanism with a mechanical mixing and disruption system. The static mixing elements (helical ribs, baffle plates) actively break up and disperse gel species through shear and extensional flows, preventing gel elongation and penetration issues that occur with thin screens while maintaining simple device geometry
Solution Approach 2:
The static mixing elements perform preliminary gel disruption and size reduction before the polymer reaches any screening stage. By breaking up gels early in the process through controlled mixing, the system prevents gel species from elongating or deforming, ensuring more effective subsequent filtration without requiring thick or complex screen structures
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 gel size by at least 30% and improves dispersivity, enhancing the quality of polymer films by minimizing pressure drop and maintaining efficient polymer processing, thus overcoming limitations of conventional screen technologies.
Implementation Method 1
The geometric design of the device applies extensional forces to the polymer melt, effectively reducing gel size and improving dispersion
Data Source
AI summary
Embodiments of an invention disclosed herein relate to devices, processes, and systems for processing one or more polymers.