Spinnable Silica Sol Viscosity Control via Online Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for producing spinnable silica sol materials face challenges in accurately predicting viscosity, leading to inefficiencies and losses due to the need for offline measurement of the loss factor and adaptation of spinning plant parameters, resulting in reduced space-time yield and increased personnel costs.
Innovation Solution
A process that measures viscosity during solvent removal and uses dynamic viscosity as a termination criterion, allowing for precise prediction of the spinnable silica sol material's viscosity and eliminating the need for loss factor measurement during ripening, thereby improving reproducibility and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If offline measurement of loss factor is performed to determine spinnability, then measurement precision is improved, but loss of time and productivity deteriorate due to extended process cycles and personnel requirements
Solution Approach 1:
The patent replaces offline loss factor measurement with online viscosity measurement using a measuring probe inserted into the reaction mass. This substitution of measurement method enables continuous monitoring during the process, eliminating the need for time-consuming offline tests and allowing real-time process control, thereby maintaining measurement precision while significantly improving productivity
Solution Approach 2:
The system uses automatic viscosity measurement and control without requiring manual intervention for sample extraction and testing. The measuring probe continuously monitors the reaction mass viscosity, and the process control system automatically adjusts parameters based on the measured values, eliminating the need for personnel to perform offline measurements and thereby increasing productivity
2Manufacturing precision
If spinning plant parameters are adapted for each new sol to achieve optimal spinning, then manufacturing precision is improved, but device complexity and loss of time increase due to repeated parameter optimization
Solution Approach 1:
The patent implements feedback control by continuously measuring the viscosity of the spinnable sol material during production and using this information to automatically adjust spinning plant parameters. This ensures optimal spinning conditions are maintained for each batch without requiring manual parameter optimization, thereby maintaining manufacturing precision while reducing operational complexity
Solution Approach 2:
The system automatically adjusts spinning parameters based on the measured viscosity values of the sol material. By dynamically changing operational parameters according to actual material properties, the system maintains optimal spinning quality across different batches without requiring complex manual optimization procedures
3Manufacturing precision
If extended ripening time is used to achieve desired viscosity, then manufacturing precision is improved, but loss of time and productivity deteriorate
Solution Approach 1:
The patent employs continuous online viscosity measurement during the ripening process, allowing the system to monitor viscosity development in real-time and terminate the process as soon as the target viscosity range is reached. This continuous monitoring eliminates the need for extended fixed-duration ripening cycles, maintaining viscosity control precision while significantly reducing process cycle time
Solution Approach 2:
The system replaces traditional offline viscosity measurement methods with continuous online measurement using a measuring probe. This enables real-time detection of viscosity changes during ripening, allowing the process to be stopped immediately when the desired viscosity is achieved, thereby reducing unnecessary extended processing time while maintaining precision
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 process enables reproducible production of spinnable silica sol materials with a predicted viscosity within ±10 Pa·s, enhancing space-time yield and reducing operational delays and losses, while maintaining biodegradability and resorbability.
Implementation Method 1
Hydrolysis-condensation of a hydrolysable silicon compound
Implementation Method 2
the removal of the solvent is terminated immediately upon reaching a desired viscosity
Data Source
AI summary
In a process for producing a spinnable silica sol material, a viscosity value VS is stipulated which the spinnable silica sol material should have after ripening. A viscosity value VR corresponding to VS which the silica sol material has before ripening is ascertained. An aqueous acid solution and a hydrolysable silicon compound are combined. The combined mixture is evaporated to give a single-phase solution while measuring the viscosity of the mixture and the evaporation process is terminated upon reaching the viscosity value VR. The single-phase solution thus obtained is then ripened to give a silica sol material with the viscosity value VS. The process exhibits reduced waste and more exact reproducibility of the spinning sol properties during the synthesis and an increased space-time yield in the production of biologically degradable and/or resorbable fibers and nonwoven fabrics.