Superabsorbent Polymer Pulverizer Design for Particle Size Control
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Solution Overview
Problem
Conventional methods for producing superabsorbent polymers fail to achieve the required particle sizes and absorption rates needed for modern absorbent products, as existing gel pulverizers are too large for industrial processes and result in dimensions that do not meet the increasing demands for higher absorption rates.
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 polymers with improved absorption rates and liquid conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional gel pulverizer is used to reduce particle size, then the particle dimensions can be reduced, but the equipment size becomes too large for industrial processes
Solution Approach 1:
The perforated plate is divided into multiple sections with different hole diameters (first diameter and second diameter), allowing segmented processing of the gel at different size stages. This segmentation enables the use of a compact pulverizer while achieving the desired particle size reduction without requiring an excessively large equipment.
2Productivity
If the gel particles are made smaller to increase absorption rate, then the absorption rate improves, but the existing pulverizer dimensions cannot satisfy the requirement
Solution Approach 1:
Different regions of the perforated plate have different hole diameters (first diameter larger than second diameter), creating local variations in particle size output. This allows precise control over the final particle size distribution to optimize absorption rate while maintaining manufacturability with the available equipment.
3Length of moving object
If the hole diameters are made smaller to reduce particle size, then the particle dimensions are reduced, but the equipment becomes less efficient for industrial processing
Solution Approach 1:
The perforated plate is designed with dynamic hole diameter variations (first diameter larger than second diameter), allowing the system to adaptively process gel at different size stages. This dynamic design enables efficient industrial processing while achieving the required particle size reduction, balancing equipment efficiency with product requirements.
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 and surface roughness of the colloid gel, resulting in enhanced bulk density, absorption rate, and liquid conductivity of the superabsorbent polymers, meeting the requirements for modern absorbent products.
Implementation Method 1
shearing the colloid gel by using a pulverizer to obtain plural superabsorbent polymer particles
Implementation Method 2
performing a surface crosslinking reaction to the superabsorbent polymer particles, a surface crosslinking agent and a reaction polymer
Implementation Method 3
performing a free radical polymerization reaction to a superabsorbent polymer composition, so as to obtain a colloid gel
Data Source
AI summary
A superabsorbent polymer and a method of fabricating the same are 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.