Polymer Particle Mixer with Counter-Flow Impulse
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Solution Overview
Problem
Existing methods for mixing water-absorbing polymer particles with liquids often result in agglomeration, requiring high peripheral speeds and specific mixing tool angles to achieve effective mixing, which can be inefficient and costly.
Innovation Solution
A method involving a mixer with mixing tools attached to a rotating shaft, where polymer particles move due to gravity and receive an impulse counter to the product flow direction, utilizing a cylindrical wall with a diameter of 90 to 500 mm and a mixing tool with a peripheral speed of 3 to 20 m/s, and an angle of attack greater than 0 to 30°, minimizing agglomeration by reversing the usual transport direction of mixing tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If mixing tools transport polymer particles in the product flow direction, then mixing is simplified, but agglomeration increases and mixing efficiency decreases
Solution Approach 1:
The mixing tools are designed with an angle of attack greater than 0 to 30°, causing them to transport polymer particles counter to the product flow direction. This inverted approach prevents agglomeration by ensuring particles are not pushed together by the mixing tool motion, while still achieving effective mixing through the interaction between counter-transported particles and the liquid phase.
2Reliability
If high peripheral speeds are used to prevent agglomeration, then mixing effectiveness improves, but energy consumption and device complexity increase
Solution Approach 1:
The patent specifies a moderate peripheral speed range of 3 to 20 m/s for the mixing tool outer tip, which is lower than conventional high-speed mixers. This parameter change is sufficient to prevent agglomeration when combined with the counter-flow transport mechanism created by the positive angle of attack, thereby reducing energy consumption while maintaining mixing effectiveness.
3Reliability
If mixing tools are designed with specific angles and high speeds, then agglomeration is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The patent defines a specific angle of attack range (greater than 0 to 30°) and moderate peripheral speed range (3 to 20 m/s) that achieve agglomeration prevention without requiring complex high-speed mechanisms. These parameter specifications simplify manufacturing compared to conventional high-speed mixers, as they allow for standard motor speeds and simpler tool geometries.
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 achieves a residence time distribution at moderate peripheral speeds, reducing the tendency for agglomeration and improving mixing efficiency, allowing for the effective post-crosslinking of water-absorbing polymer particles with aqueous solutions.
Implementation Method 1
the polymer particles are accelerated in the product flow direction by gravity due to their own weight
Implementation Method 2
at least a part of the material to be mixed receives an impulse against the product flow direction due to the rotational movement of at least one mixing tool attached to a rotating shaft
Data Source
Figure 1
AI summary
The invention relates to a method for the continuous mixing of water-absorbing polymer particles with liquids or other particles. According to said method, the polymer particles flow in the direction of the product stream as a result of their own weight and at least part of the mixed product is propelled against the direction of the product stream by the rotational displacement of at least one mixing tool that is fixed to a rotating shaft.