Continuous Polymerization Reactor Ultrasonic Bath Control
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Solution Overview
Problem
Current batch or semi-batch processes for producing polymerizable/crosslinkable polymeric materials are hazardous, difficult to control, and result in inconsistent product quality due to the use of toxic chemicals and strict reaction conditions, making them unsafe and inefficient for large-scale production of contact lenses.
Innovation Solution
A continuous-flow process using microreactors and flow-through polymerization reactors, where reactants are mixed and polymerized in a coil form, with the reactor immersed in an ultrasonic bath to minimize high-molecular-weight fractions and ensure uniform product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If batch or semi-batch processes are used for producing polymerizable/crosslinkable polymeric materials, then the process can be performed with relatively simple equipment, but the product quality consistency and reproducibility deteriorate due to difficulty in controlling reaction conditions uniformly
Solution Approach 1:
The patent divides the polymerization process into multiple continuous flow reactors arranged in series, where each reactor performs a specific function (mixing, polymerization, temperature control). This segmentation allows precise control of reaction conditions in each stage while maintaining overall process simplicity through modular design.
Solution Approach 2:
The patent implements continuous flow polymerization where reactants continuously flow through the reactor system, eliminating the start-stop nature of batch processes. This continuity ensures uniform reaction conditions, consistent product quality, and improved reproducibility while using relatively simple continuous flow equipment.
2Ease of operation
If batch or semi-batch processes are used for producing polymerizable/crosslinkable polymeric materials, then the process can be performed with straightforward操作流程, but safety deteriorates due to use of large amounts of highly toxic chemical substances
Solution Approach 1:
The patent segments the reaction process into multiple continuous flow stages, allowing toxic reactants to be present in small amounts only in the first reactor at any given time, rather than large amounts in a single batch reactor. This dramatically reduces safety risks while maintaining ease of operation through automated continuous flow control.
Solution Approach 2:
The continuous flow process ensures that toxic chemicals are constantly moving through the system rather than being stored in large quantities, reducing exposure risks. The automated nature of continuous flow operation simplifies safety management while maintaining operational simplicity.
3Device complexity
If batch or semi-batch processes are used for producing polymerizable/crosslinkable polymeric materials, then the process can be performed with less complex control systems, but productivity deteriorates due to inability to perform fast highly efficient production
Solution Approach 1:
The patent implements continuous flow polymerization that operates without interruption, allowing fast and efficient production of polymeric materials. The continuous process eliminates downtime between batches while using relatively simple control systems that monitor and adjust flow rates and temperatures of the continuous streams.
Solution Approach 2:
The patent uses multiple continuous flow reactors in series, where each reactor is independently controlled but works together in a coordinated continuous process. This segmentation allows optimized reaction conditions in each stage while maintaining overall high productivity through continuous operation.
4Device complexity
If batch or semi-batch processes are used for producing polymerizable/crosslinkable polymeric materials, then the process can be performed with simpler reactor design, but manufacturing precision deteriorates due to difficulty in ensuring uniform local concentration profile of reactants
Solution Approach 1:
The patent uses multiple continuous flow reactors where reactants are mixed and reacted in small, controlled volumes in each reactor. This segmentation ensures uniform local concentration profiles in each reaction zone while keeping individual reactor designs simple. The continuous flow nature maintains consistent mixing and concentration distribution.
Solution Approach 2:
The continuous flow process ensures constant mixing and uniform distribution of reactants throughout the reaction zone, eliminating the concentration gradients that develop in batch processes. This continuity achieves uniform product quality while using relatively simple reactor designs without complex internal mixing mechanisms.
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 process enhances safety, reproducibility, and yield by controlling reaction conditions and eliminating unwanted polymer fractions, resulting in a consistent and high-quality polymeric material suitable for contact lenses.
Implementation Method 1
the flow-through polymerization reactor is immersed in an ultrasonic bath to minimize or substantially eliminate unwanted high-molecular-weight fractions of the polymer
Implementation Method 2
introducing at least two solutions, each comprising one or more reactants, into at least one microreactor to mix the two solutions to form a reacting solution
Implementation Method 3
feeding continuously the reacting solution into a flow-through polymerization reactor in a coil form, wherein the flow-through polymerization reactor is capable of providing a residence time sufficient for (co)polymerizing the reactants to form a polymer with a desired polydispersity
Data Source
AI summary
The invention provides a continuous-flow process for producing a polymeric material. The process of the invention comprises the steps of: introducing at least two solutions, each comprising one or more reactants, into a microreactor to mix the two solutions to form a reacting solution, wherein the one or more reactants are selected from the group consisting of a monomer, an initiator, a coupling agent, a prepolymer, a macromer, and mixtures thereof; feeding continuously the reacting solution into a flow-through polymerization reactor in a coil form, wherein the flow-through polymerization reactor is capable of providing a residence time sufficient for (co)polymerizing the reactants to form a polymer with a desired polydispersity, wherein the flow-through polymerization reactor is immersed in an ultrasonic bath to minimize or substantially eliminate unwanted high-molecular-weight fractions of the polymer.