Rotating Horizontal Reactor for Vacuum Solid-State Polymerization
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Solution Overview
Problem
Continuous solid-state polymerization processes face challenges in preventing the formation of prepolymer stagnation zones and require the use of inert gases, leading to energy inefficiency and increased costs due to the need for gas purification and heating/cooling cycles.
Innovation Solution
A continuous solid-state polymerization apparatus featuring a rotatable transverse reactor with a stirring device and a release coating film on its inner wall, operating under vacuum conditions without the use of inert gases, which includes a feeder, a chamber, and a vacuum pump to maintain a sealed system and prevent polymer stagnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If inert gas is used to prevent discoloration and remove by-products during solid-state polymerization, then product quality is maintained, but energy consumption increases due to gas heating, cooling, and purification requirements
Solution Approach 1:
The patent removes the inert gas circulation system entirely from the solid-state polymerization process. Instead of using inert gas to prevent discoloration and remove by-products, the invention operates the polymerization under vacuum conditions, extracting the harmful dependency on energy-intensive gas handling while maintaining product quality through alternative means (controlled atmosphere and by-product removal systems).
Solution Approach 2:
The patent replaces the active inert gas circulation with a passive vacuum environment. By maintaining negative pressure in the reaction chamber, the system prevents oxidation and discoloration without requiring large volumes of heated inert gas, thereby eliminating the energy consumption associated with gas heating, cooling, and purification cycles.
2Productivity
If inert gas circulation is implemented to discharge reaction by-products, then polymerization efficiency is maintained, but operational costs increase due to by-product removal from circulated gas
Solution Approach 1:
The patent extracts the by-product removal function from the inert gas circulation system. Instead of circulating inert gas and removing by-products from it, the invention uses a vacuum system that directly抽吸s by-products from the reaction chamber, eliminating the need for gas purification infrastructure and associated operational costs.
Solution Approach 2:
The patent introduces a vacuum pump as an intermediary device between the reaction chamber and the external environment. This vacuum system serves as a more efficient mediator for by-product removal compared to inert gas circulation, as it directly evacuates by-products without requiring large volumes of carrier gas and subsequent purification.
3Reliability
If melting process is used to increase intrinsic viscosity and heat resistance, then polymer performance is improved, but product breakdown occurs due to high shear stress during processing
Solution Approach 1:
The patent changes the fundamental processing parameter from melting temperature to solid-state polymerization temperature. By conducting polymerization below the melting point of the polymer (typically 10-50°C below), the process achieves increased intrinsic viscosity and heat resistance while avoiding the high shear stresses and thermal degradation associated with melt processing.
Solution Approach 2:
The patent utilizes the phase transition boundary between solid and melt states. By operating in the solid state (below melting point) and controlling moisture and temperature parameters, the process achieves polymerization without complete melting, thereby maintaining product integrity while still achieving the desired increase in intrinsic viscosity and heat resistance properties.
4Productivity
If high temperature heating is applied during melting process to achieve desired intrinsic viscosity, then polymerization efficiency increases, but carbonization and discoloration occur due to prolonged exposure
Solution Approach 1:
The patent changes the temperature parameter from high-temperature melt processing (above melting point) to moderate-temperature solid-state polymerization (10-50°C below melting point). Although the absolute temperature is lower, the process achieves comparable or superior polymerization efficiency by extending the reaction time and maintaining optimal moisture content, thereby avoiding carbonization and discoloration.
Solution Approach 2:
The patent implements continuous solid-state polymerization where prepolymers are continuously fed into the reaction chamber, processed at controlled temperatures below the melting point, and discharged as finished polymer. This continuous operation at moderate temperatures eliminates the need for repeated heating and cooling cycles, maintaining steady-state conditions that prevent carbonization while achieving high polymerization efficiency.
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 allows for continuous solid-state polymerization under vacuum conditions, reducing energy consumption and costs by eliminating the need for inert gas recycling and maintaining product quality through the prevention of stagnation zones and polymer adhesion.
Implementation Method 1
the reactor is maintained in a vacuum environment, thereby eliminating the need for an inert gas
Implementation Method 2
the reactor has a release coating film formed on an inner wall
Implementation Method 3
a stirring device including a stirring shaft rotating in a direction opposite a rotational axis of the transverse reactor within the transverse reactor and a stirring vane vertically attached to the stirring shaft
Implementation Method 4
heated for several to tens of hours while supplying an inert gas into the reactor
Data Source
AI summary
The continuous solid-state polymerization device of the present invention comprises: a feeder for continuously introducing a prepolymer; a horizontal reactor which is connected via a first connecting part to the feeder and receives the prepolymer from the feeder so as to subject same to solid-state polymerization, wherein the reactor itself is rotated; a stirring device which comprises a stirring shaft rotating inside the horizontal reactor, in the direction opposite to that of the rotational axis of the horizontal reactor, and comprises stirring blades joined vertically to the stirring shaft; and a chamber which is connected via a second connecting part to the horizontal reactor and, once the solid-state polymerization has been completed, receives the resulting polymer discharged from the horizontal reactor, and, here, the feeder, the horizontal reactor and the chamber are in a vacuum state. The continuous solid-state polymerization device prevents the formation of prepolymer stagnation zones, and allows solid-state polymerization to take place continuously in the vacuum state without any inert gas.