Thermoplastic Polymer Particles Cold Crystallization
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Solution Overview
Problem
Conventional methods for manufacturing thermoplastic polymer particles face challenges in achieving uniformity, purity, and suitable physical properties, often resulting in the incorporation of impurities and deformation of particle shapes, which affects their application in products.
Innovation Solution
The method involves extruding thermoplastic polymer resin, granulating it with air, and cooling it to produce particles with a specific aspect ratio and roundness, forming a continuous matrix phase, and having a peak of cold crystallization temperature between the glass transition and melting points, using polymers like PLA, TPU, PE, PP, PES, PMMA, and EVOH, with controlled particle diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the crushing method is used to manufacture thermoplastic polymer particles, then particles can be obtained, but it is difficult to secure uniformity of the manufactured particles and high cost is incurred due to liquid nitrogen usage
Solution Approach 1:
The patent replaces the mechanical crushing method with a chemical precipitation method. Instead of mechanically crushing polymer resin with liquid nitrogen, the invention dissolves the polymer in a solvent and precipitates it by adding a non-solvent, thereby eliminating the need for mechanical crushing equipment and liquid nitrogen while achieving uniform particle morphology through controlled precipitation kinetics
Solution Approach 2:
The patent changes the physical state parameters of the polymer during processing. By controlling the temperature, solvent concentration, and addition rate of non-solvent, the polymer transitions from dissolved state to precipitated particles with controlled size and uniformity, replacing the low-temperature mechanical crushing process
2Quantity of substance
If the solvent dissolution-precipitation method is used, then thermoplastic resin particles can be obtained, but other components such as solvent are detected as impurities and particle purity is compromised
Solution Approach 1:
The patent extracts and removes the solvent and other volatile components from the precipitated particles through drying processes. The precipitated particles are dried to remove residual solvent, ensuring high particle purity while maintaining the quantitative yield achieved through the precipitation method
Solution Approach 2:
The patent discards the solvent and volatile impurities from the precipitation process through drying and filtration, recovering only the pure polymer particles. The solvent is separated and discarded while the purified particles are collected, achieving both high yield and high purity
3Productivity
If the melt kneading method is used, then thermoplastic resin particles can be obtained, but other components such as solvent are detected as impurities and particle shape control is difficult
Solution Approach 1:
The patent changes the processing parameters from high-temperature melt kneading to controlled-temperature precipitation. By controlling the temperature, solvent composition, and addition rate during precipitation, the particles achieve uniform spherical shapes with controlled size distribution while maintaining continuous production capability
Solution Approach 2:
The patent replaces the mechanical kneading and extrusion process with a chemical precipitation process. Instead of using mechanical force to form particles through extrusion, the invention uses controlled precipitation from solution to naturally form uniform spherical particles, eliminating shape defects caused by mechanical processing
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
This approach results in thermoplastic polymer particles with improved handling and processing characteristics, high purity, and the ability to generate thermal energy during processing, enhancing the quality and utility of products made from these particles.
Implementation Method 1
supplying a thermoplastic polymer resin to an extruder and extruding it
Implementation Method 2
bringing the extruded thermoplastic polymer resin into contact with air to granulate the thermoplastic polymer resin
Implementation Method 3
granulating it with air
Implementation Method 4
having a peak of cold crystallization temperature between the glass transition and melting points
Implementation Method 5
cooling it to manufacture thermoplastic polymer particles
Data Source
AI summary
Provided are thermoplastic polymer particles having an aspect ratio of 1.00 or more and less than 1.05, and a roundness of 0.95 to 1.00. The thermoplastic polymer particles are formed from a thermoplastic polymer resin in a continuous matrix phase. The thermoplastic polymer particles show a peak cold crystallization temperature (Tcc) at a temperature between a glass transition temperature (Tg) and the melting point (Tm) in a differential scanning calorimetry (DSC) curve which is derived from temperature rise analysis at 10° C./min by differential scanning calorimetry.