Polymer Pellet Liquid Component Distribution via Fluidization
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Solution Overview
Problem
Existing methods for distributing further components onto polymer pellets often result in mechanical dust generation, non-homogeneous distribution, and require additional steps to remove dust, which can affect the performance of final articles like electric cables.
Innovation Solution
A process and equipment utilizing a first mixing section with vibration, oscillation, or fluidization to introduce further components in a liquid medium onto polymer pellets, ensuring homogeneous distribution and minimizing dust formation, with optional static mixing and drying sections for enhanced absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical mixing of pellets is used during the distribution step, then the further components are distributed onto the pellets, but polymer dust is generated which absorbs the liquid and causes non-homogeneous performance
Solution Approach 1:
The patent replaces mechanical mixing with fluidization technology. A fluidizing gas is introduced to suspend and fluidize the pellets, enabling liquid component distribution without mechanical contact that would generate dust. The gas flow accomplishes both pellet suspension and liquid distribution, eliminating the dust generation problem inherent in mechanical mixing systems.
Solution Approach 2:
The invention uses a fluidizing gas (pneumatic medium) to achieve pellet suspension and liquid distribution. The gas flow serves dual purposes: fluidizing the pellet bed to enable uniform liquid distribution and simultaneously preventing dust generation by keeping pellets in a controlled suspended state rather than allowing mechanical abrasion.
2Manufacturing precision
If further components are added after pellet formation by depositing onto preformed pellets, then the component distribution can be controlled, but additional processing steps and time are required
Solution Approach 1:
The patent combines the pellet formation process with the component distribution process. By introducing the liquid further components during the extrusion process itself (rather than in a separate post-processing step), the invention merges two operations into one, achieving component distribution without adding extra processing time while maintaining control over distribution uniformity.
Solution Approach 2:
The invention performs component distribution preliminarily during the extrusion process itself, before the pellets are fully formed and cooled. By adding the liquid components to the molten polymer during extrusion, the distribution occurs in advance of what would otherwise be a separate post-processing step, reducing total processing time while ensuring uniform distribution.
3Stability of the object's composition
If liquid components are allowed to impregnate into pellets at temperature below melting point, then the pellet structure is preserved, but the distribution homogeneity is reduced
Solution Approach 1:
The patent utilizes the phase transition of the polymer from solid to molten state during extrusion. By introducing liquid components during the molten phase, the polymer matrix becomes sufficiently fluid to allow complete and uniform impregnation of the liquid components throughout the pellet structure. Upon cooling, the pellets solidify with the components uniformly distributed, achieving both structure integrity and distribution homogeneity.
Solution Approach 2:
The invention changes the temperature parameter during the distribution process. By heating the polymer to its molten state (changing from solid to liquid phase), the viscosity decreases dramatically, enabling complete penetration and uniform distribution of liquid components. After distribution, the temperature is reduced to solidify the pellets, preserving both the uniform distribution and structural integrity.
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 efficient, homogeneous distribution of components within and between pellets, reducing dust generation and enhancing the physical integrity and performance of polymer pellets, particularly in high-demand applications like electric cable manufacturing.
Implementation Method 1
said first mixing section (A) is provided with mixing means (2) for moving and mixing said fed pellet stream along said section (A)... wherein said mixing means (2) is selected from one or more of a vibration means (2a), oscillation means (2b) or fluidisation means (2c)
Implementation Method 2
said mixing means (2) is selected from one or more of a vibration means (2a), oscillation means (2b) or fluidisation means (2c)
Implementation Method 3
said mixing means (2) is selected from one or more of a vibration means (2a), oscillation means (2b) or fluidisation means (2c)
Implementation Method 4
one or more of said further components may be added after pellet formation by depositing the component(s) onto preformed pellet and allowing the component(s) to be absorbed inside the pellet matrix
Implementation Method 5
During said distribution step said further component(s) present in the liquid are typically allowed to impregnate into the pellets at a temperature below the melting point of the major polymer component of the polymer material of said pellet and then are subjected to a drying step
Data Source
AI summary
The present invention relates to an equipment and method for producing polymer pellets which comprise one or more polymer components and one or more further components, wherein in said process at least one of said one or more further components is incorporated into pellets by applying a liquid, which comprises said at least one component, onto said pellets.