Polymerisation station for grafting a bioactive coating
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Solution Overview
Problem
Current methods for grafting bioactive polymers onto articles, such as PolyNaSS, are not scalable for industrial use, lacking repeatability and efficiency in large quantities and rapid processing.
Innovation Solution
A polymerization station with two reactors is used, where the first reactor performs ozonation and radical polymerization consecutively in different solutions, and the second reactor prepares and heats the monomer solution, allowing for sequential processing and reducing total treatment time by optimizing the monomer solution's readiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If oxidation and grafting are carried out in the same reactor sequentially, then productivity is improved by reducing treatment time, but device complexity increases due to the need for multiple inlets and drainage systems
Solution Approach 1:
The first reactor is designed to perform multiple functions: oxidation treatment, grafting polymerization, and serving as a transfer point for monomer solution. By making the reactor multi-functional with appropriate inlets, outlets, and heating systems, the patent eliminates the need for separate reactors for each step, thereby reducing overall system complexity while improving productivity
Solution Approach 2:
The monomer solution is prepared in advance in the second reactor and then transferred to the first reactor for the grafting step. This preliminary preparation of the monomer solution allows the oxidation and grafting steps to be seamlessly connected without intermediate preparation time, reducing total treatment time while maintaining a manageable reactor configuration
2Manufacturing precision
If monomer solution is prepared in a separate second reactor, then manufacturing precision is improved by optimizing monomer solution conditions, but device complexity increases due to additional reactor components
Solution Approach 1:
The second reactor is dedicated to preparing the monomer solution under optimal conditions (heating, mixing) before transferring it to the first reactor for grafting. This preliminary action ensures the monomer solution is ready for immediate use, improving the precision and consistency of the grafting process while keeping the system configuration reasonable
Solution Approach 2:
The second reactor acts as an intermediary device that prepares the monomer solution in advance and transfers it to the first reactor. This intermediary step allows for optimized monomer solution preparation without requiring the first reactor to perform both oxidation and grafting simultaneously, thereby improving manufacturing precision while maintaining device complexity at an acceptable level
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 enables efficient and controlled oxidation and grafting of articles on an industrial scale, reducing treatment duration while maintaining optimal conditions for the monomer solution, facilitating high-volume, repeatable, and rapid processing.
Implementation Method 1
an ozone inlet for bubbling ozone into the first vessel with the aim of oxidizing the surface of the articles immersed in the water
Implementation Method 2
the first tank comprises a first double wall in a manner such as to define a peripheral circuit for circulating a heat transfer fluid, such as oil, with the aim of heating the contents of the first tank to a predetermined temperature
Implementation Method 3
a step for grafting by radical polymerization in a polymerization station
Data Source
AI summary
An oxidation and grafting method for grafting a bioactive polymer, such as polyNaSS, onto an article, in particular a polymer or ceramic article. The method comprises a step of oxidation by ozonation and a step of grafting by radical polymerisation in a polymerisation station having a first reactor. The two steps of oxidation and grafting are carried out consecutively in different solutions in the reactor of the polymerisation station.