Silanized Filler Mixture Viscosity Reduction
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Solution Overview
Problem
Existing filler mixtures face challenges in achieving reduced viscosity and improved flowability, leading to segregation issues when mixed with pigments or binders, which complicates the production of molded parts like kitchen sinks and bathtubs.
Innovation Solution
A method involving the silanization of filler fractions with specific particle size ranges, where a first fraction of fillers (0.1-0.8 mm) is pre-silanized, followed by the silanization of a second fraction (0.08-0.5 mm) and optionally silanized pigments, ensuring optimal hydrophobicity and preventing segregation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different fillers are mixed one after the other with the casting resin, then the filler mixture can be produced with different grain diameters, but the viscosity increases and flowability deteriorates
Solution Approach 1:
The patent applies parameter changes by systematically varying the particle size distribution of filler fractions and the dosage and type of silane coupling agents. By optimizing these parameters, the invention achieves a filler mixture with reduced viscosity and improved flowability while maintaining heterogeneous composition for different application requirements.
2Adaptability or versatility
If fillers with different grain diameters are mixed, then the filler mixture can accommodate various size requirements, but segregation and sedimentation occur
Solution Approach 1:
The patent applies preliminary action by pre-coating each filler fraction with silane coupling agents before mixing them together. This pre-treatment ensures that all filler surfaces are adequately covered with hydrophobic silane layers, which prevents segregation and sedimentation during subsequent mixing and processing, maintaining homogeneous distribution of different grain sizes.
Solution Approach 2:
The invention uses parameter changes by optimizing the particle size distribution ranges of different filler fractions and controlling the silane coating process parameters. This systematic optimization prevents segregation while maintaining the beneficial effects of heterogeneous grain size distribution.
3Ease of manufacture
If pigments are added to the filler mixture, then coloring can be achieved, but intensive homogenization is required to break down agglomerates
Solution Approach 1:
The patent applies preliminary action by pre-coating pigment particles with silane coupling agents before adding them to the filler mixture. This pre-silanization prevents pigment agglomeration and ensures uniform distribution, significantly reducing the intensity and duration of homogenization required while achieving consistent coloring.
4Reliability
If fillers are coated with silane to improve wetting and mechanical properties, then the coating facilitates binder wetting, but the reactivity of silane is insufficient for fillers with neutral or slightly acidic surfaces
Solution Approach 1:
The patent applies parameter changes by selecting silane coupling agents with appropriate reactivity characteristics for different filler surface properties. For fillers with neutral or slightly acidic surfaces, the invention uses silanes with enhanced reactivity or modifies the silane application parameters (such as adding weak acids or adjusting moisture content) to ensure adequate coating effectiveness.
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 method results in a filler mixture with significantly reduced viscosity (less than 1350 mPas) and enhanced flowability (more than 3 mPa) when mixed with binders, preventing segregation and allowing for efficient processing and reduced pigment usage.
Implementation Method 1
Here the water partially reacts with the alkoxy groups present to form reactive hydroxyl groups
Implementation Method 2
the water partially reacts with the alkoxy groups present to form reactive hydroxyl groups
Data Source
AI summary
The present invention relates to a method for producing a filler mixture comprising silanized fillers in which the viscosity can be minimized and the flowability improved, and to a filler mixture with these properties which can be produced by the method according to the invention.