Soft Sensor for Polymer Morphology Control
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Solution Overview
Problem
Current methods for controlling the morphology of multiphase latex polymer particles in emulsion polymerization lack effectiveness in monitoring and optimizing production processes, leading to inconsistent product quality and increased production times due to reliance on complex simulations and difficulty in scaling reaction conditions.
Innovation Solution
A soft sensor system that uses time series data from reference polymerization processes to provide a reference trajectory for monitoring and controlling the morphology of multiphase latex polymer particles, allowing for real-time adjustment of production processes to maintain desired morphology independent of plant design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex simulations are used to control polymer particle morphology, then manufacturing precision is improved, but device complexity and loss of time increase
Solution Approach 1:
The patent extracts the essential morphological trajectory information from complex simulations and represents it as a simplified soft sensor model. The soft sensor captures the critical evolution path of polymer cluster mobility and morphology without requiring full simulation complexity, enabling real-time monitoring with reduced computational burden.
Solution Approach 2:
The patent creates a simplified copy of the complex simulation results in the form of a soft sensor model. This model reproduces the essential morphological trajectory characteristics using simplified mathematical representations and measurable process variables, avoiding the need for complex simulations while maintaining predictive accuracy.
2Manufacturing precision
If complex simulations are used to control polymer particle morphology, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The patent extracts the essential morphological trajectory information from complex simulations and represents it as a simplified soft sensor model. The soft sensor captures the critical evolution path of polymer cluster mobility and morphology without requiring full simulation complexity, enabling real-time monitoring with reduced computational burden.
Solution Approach 2:
The patent replaces computationally intensive simulation mechanisms with a soft sensor system that uses mathematical models and measurable process variables. This substitution eliminates the time-consuming simulation calculations while maintaining the ability to predict and control morphology through real-time data processing.
3Manufacturing precision
If reliance on complex simulations is used, then manufacturing precision is improved, but ease of operation deteriorates
Solution Approach 1:
The patent extracts the essential morphological trajectory information from complex simulations and represents it as a simplified soft sensor model. The soft sensor captures the critical evolution path of polymer cluster mobility and morphology without requiring full simulation complexity, enabling real-time monitoring with reduced computational burden.
Solution Approach 2:
The patent introduces a soft sensor as an intermediary between the complex polymerization process and the control system. This intermediary translates complex simulation results into simplified, real-time predictions that can be easily processed and acted upon, removing the barrier between process monitoring and control decision-making.
4Manufacturing precision
If difficulty in scaling reaction conditions is present, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent develops a universal soft sensor model that can predict morphology trajectories across different production scales and conditions. The model uses dimensionless numbers and normalized process variables that maintain their predictive capability regardless of reactor size or specific operating conditions, enabling direct scaling from lab to production.
Solution Approach 2:
The patent transforms the control approach by using dimensionless parameters and normalized variables that scale invariantly. This allows the same soft sensor model to accurately predict morphology trajectories across different production scales without requiring re-calibration or complex scaling relationships, directly enabling productivity improvement.
Data Source
AI summary
A method of producing a soft sensor for a reference morphology of multiphase latex polymer particles synthesized in a production process is provided. The method is used in monitoring and/or controlling the production process. The method may also be used for optimizing production capacities of the production process.