Superabsorbent Polymer Pulverization for Compact Particle Sizing
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Solution Overview
Problem
Conventional methods for producing superabsorbent polymers result in gel particles that are too large, failing to meet the increased absorption rate requirements, and existing pulverizers are too large for industrial processes.
Innovation Solution
A method using a pulverizer with a perforated plate having changeable hole diameters to shear colloid gels, followed by a surface crosslinking reaction, to produce superabsorbent polymer particles with improved absorption properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional gel pulverizers are used to reduce particle size, then particle dimensions can be reduced, but the equipment size becomes too large for industrial application
Solution Approach 1:
The pulverizer is segmented into multiple functional zones with progressively smaller hole diameters in the perforated plate, allowing stepwise particle size reduction. This segmentation enables effective pulverization of gel particles while maintaining a compact overall equipment size suitable for industrial application.
Solution Approach 2:
The invention transitions from conventional three-dimensional bulk pulverization to a two-dimensional planar pulverization process using a perforated plate. The gel particles are crushed and sized by passing through holes in the plate, effectively reducing particle dimensions while concentrating the processing action in a flat, space-efficient configuration.
2Productivity
If gel particles are made smaller to increase absorption rate, then absorption performance improves, but the existing processing equipment cannot achieve the required particle size
Solution Approach 1:
The invention changes the critical parameter of hole diameter in the perforated plate to control particle size. By adjusting the hole diameter parameter, the system can produce gel particles of specific sizes (0.5-2.0 mm) that optimize absorption rate while maintaining manufacturability with the available equipment.
3Manufacturing precision
If a perforated plate with changeable hole diameters is used to shear colloid gels, then particle size and surface roughness are improved, but device complexity increases
Solution Approach 1:
The perforated plate serves multiple functions simultaneously: it acts as a structural support, a particle size control element, and a surface roughening tool. The changeable hole diameters allow the same component to handle different gel viscosities and target particle sizes, reducing the need for multiple specialized components.
Solution Approach 2:
The perforated plate with changeable hole diameters allows dynamic adjustment of particle size output. The hole diameters can be modified to adapt to different gel formulations and desired particle sizes, providing flexibility without requiring complete equipment redesign.
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 increases the compactness, surface roughness, bulk density, and liquid conductivity of the superabsorbent polymer, enhancing its absorption rate and permeability.
Implementation Method 1
shearing the colloid gel by using a pulverizer to obtain plural superabsorbent polymer particles
Implementation Method 2
performing a free radical polymerization reaction to a superabsorbent polymer composition, so as to obtain a colloid gel
Implementation Method 3
performing a surface crosslinking reaction to the superabsorbent polymer particles, a surface crosslinking agent and a reaction polymer
Data Source
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AI summary
A method of fabricating a superabsorbent polymer is provided. The method includes performing a free radical polymerization reaction to a superabsorbent polymer component, so as to obtain a colloid gel. The colloid gel is cut by using a pulverizer to obtain superabsorbent polymer particles. The pulverizer has a perforated plate with changeable hole diameters, which has a first diameter of an inlet hole greater than a second diameter of an outlet hole. The method further includes performing a surface cross-linking reaction to the superabsorbent polymer particles, so as to obtain the superabsorbent polymer. Therefore, a bulk density, an absorption rate and a liquid permeability of the obtained superabsorbent polymer can be increased.