BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a dispersion apparatus and a dispersion method,
which is used to atomize, agitate, and the like, a range of slurries of, for example, paint,
printing ink, pharmaceuticals, food, and the like, for dispersion processing.
Description of the Related Art
Heretofore, in the fields of paint, printing ink, pharmaceuticals, food, and the like,
a range of slurries, being materials, have undergone dispersion processing such as
agitation, atomization, fine mixing, or the like, to make finished products.
Among them, in the field of printing ink, pigment is dispersed in a vehicle formed
of resin together with varnish, additives and solvent to create base ink with high pigment
concentration, which is then diluted to make the finished ink. For example, in the case of
a base ink with comparatively high viscosity, typically milled base ink in which pigment,
varnish, solvent and the like are mixed, is milled by a bead mill, a roll mill or the like,
additives or the like are added and adjustment then made for production.
When milling the base ink, if the dispersion of the pigment is insufficient, it
detrimentally influences the quality stability, such as density, gloss, transparency, and
printability. As dispersion apparatus used in milling processes, the productivity of roll
mills and ball mills is poor because they are not continuous systems, and in particular, roll
mills also have safety and working environment problems.
On the other hand, a dispersion apparatus such as a media agitating mill or the like
accommodates a lot of granular media in a cylinder, and milled base ink, being rough ink,
is injected, and is agitated together with the granular media by agitating members such as
pins installed on a rotating shaft, discs, or the like, for dispersion mixing. The granular
media agitated and dispersed in the cylinder crush and refine milled base ink, thus
dispersion and milling proceed, so that there is an advantage that the productivity is high.
There are vertical cylinder and horizontal cylinder type media agitating mills. The
vertical cylinder type has a high load in its axis of rotation in a dispersion process of base
ink with comparatively high viscosity when the apparatus is started, and the dispersion
efficiency of milled base ink drops due to congestion of granular media, and a
phenomenon called choking occurs in which granular media accumulates in the vicinity of
the ink discharge side, so that there is a deficiency that stable operation is not possible.
On the other hand, the horizontal cylinder type has become popular in recent years
since it has no deficiency as described above. In a horizontal cylinder type dispersion
apparatus, drive torque is low, and maintenance of the cylinders and rotating shaft is easy,
so there is an advantage that the apparatus is inexpensive.
An example of such a horizontal cylinder type is a media agitating type mill
disclosed in a Japanese Unexamined Patent Application, First Publication No. 9-225279.
This media agitating type mill has a structure as shown in FIG. 9. This mill 1 has
beads 6 loaded in advance as media in a cylinder 2, a rotating shaft 3, and also agitating
discs 4 are fitted along the rotating shaft at a predetermined spacing. In the agitating discs
4, cut slots with a width through which beads can pass, are formed at a predetermined
spacing, and there are open holes through which beads can pass inside the cut slots.
In this media mixing type mill 1, when slurry such as milled base ink or the like is
supplied from an inlet 5, the slurry is crushed and dispersed together with the beads 6 by
the rotation of the rotating shaft 3 and the mixing discs 4. Using this mill 1, especially if
the slurry has a high viscosity, or the compression conveying amount is large, the beads 6
are pushed toward the outlet side of the cylinder 2 by the slurry supply, and the slurry is
discharged through the aperture in the outlet, but the beads 6 accumulate in the vicinity of
the outlet. Afterwards, the beads 6 perform a circulatory motion by being scattered by the
rotating shaft 3 and the mixing discs 4, and being transferred to the inlet side through the
open holes of the mixing discs 4. Consequently, even if the slurry has a high viscosity,
and the compression conveying amount is large, the beads 6 are prevented from being
unevenly distributed on the outlet side, and are circulated, thus enabling the slurry to be
crushed and dispersed.
However, in such a media mixing type mill 1, if the outside diameter of the
rotating shaft 3 is D1, and the inside diameter of the cylinder 2 is D2, the ratio D1/D2 is
set to 0.3 or lower, and the peripheral speed around the outer peripheral surface of the
rotating shaft 3 is comparatively low. Hence there is little movement of the beads 6, and
the capacity of the crushing chamber (milling zone), which is formed by the inside surface
of the cylinder 2, the rotating shaft 3 and the agitating discs 4, is large. Consequently, as
shown in FIG. 10, the distance between the rotating shaft 3 and the cylinder 2 is large, and
the movement of the beads 6 is small, resulting in a significant drop in fluidity, especially
of slurry with high viscoelasticity. Furthermore, in the vicinity of the cylinder inner wall,
since agitating efficiency is poor, agglomerations are formed from the slurry and the beads
6, which adhere easily, so that there is a deficiency that stable operation of the rotating
shaft 3 is not possible due to dispersion failure and load increase.
In particular, with high viscosity slurry whose viscosity is 5000mPa·s or more, the
load is great, so that the fluidity of the beads 6 is inhibited, and a phenomenon called co-rotation
in which an agglomeration of beads 6 and slurry flows together with the rotating
shaft 3 and the agitating discs 4 can occur. Consequently, there is a disadvantage of a high
load on the rotating shaft 3, and that the dispersion process does not continue, so that a
deficiency is possible where processed slurry solution does not come out from the cylinder.
Furthermore, Japanese Unexamined Patent Application, First Publication No. 6-114254
discloses a technique in which a throttle valve is placed on the discharge side of a
cylinder, and the inside of the cylinder is pressurized for dispersion processing by
tightening the valve. The occurrence of a short pass of slurry is suppressed to a certain
degree by the increase in the internal pressure. However, it causes frictional heating and a
rapid increase in the load in the shaft due to overcrowded contact of granular media, so
that there are disadvantages that the physical properties of the slurry are influenced
detrimentally, or stable operation is not possible, and the like. Moreover, it leads to a
deficiency in that uniformity of the dispersion conditions of the slurry is lost.
SUMMARY OF THE INVENTION
The present invention takes such a situation into consideration, with an object of
providing a dispersion apparatus and a dispersion method that enable efficient dispersion
processing of process material, without causing an increase in the driving force.
Another object of the present invention is to perform a dispersion process while
controlling increases in internal heat, and without any detrimental influence to the physical
properties of the process material.
According to the present invention, the above objects are achieved by a dispersion
apparatus as defined in claim 1 and a dispersion method as defined in claim 7, respectively.
The dependent claims define advantageous and preferred embodiments of the invention.
The preset invention is characterized in that there are provided rotors in a cylinder,
and agitating members, which protrude from the rotors radially, are positioned at a
predetermined spacing in the longitudinal direction of the rotors, and when performing
dispersion processing by agitating the process material injected into the cylinder together
with media, a ratio D1/D2 between an outside diameter D1 of the rotors installed in the
cylinder and an inside diameter D2 of the cylinder is set to be in a range of 0.4 to 0.7.
Since the outside diameter D1 of the rotors is large, high kinetic energy is imparted
to the media around the outer peripheral surface of the rotors when rotating, which makes
the beads and the process material accumulating in the vicinity of the internal
circumference of the cylinder collide and disperse, and loss of motion can be reduced, so
that the dispersion process of crushing and agitating the process material in the cylinder
can be performed efficiently even though the capacity of the cylinder is reduced. Thus
both processing quality and productivity can be improved. Furthermore, no increase in
driving force is required for the processing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A dispersion apparatus according to the present invention is a dispersion apparatus
in which there are provided rotors in a cylinder, and a plurality of agitating members
which protrude from the rotors in a radial direction, positioned at a predetermined spacing
in a longitudinal direction of the rotors, and process material injected into the cylinder is
agitated together with media to disperse the process material, wherein the outside diameter
of the rotors is D1, the inside diameter of the cylinder is D2, and a ratio D1/D2 is set in a
range of 0.4 to 0.7.
When the rotors are rotated in the cylinder, since the outside diameter D1 of the
rotors is large, it is possible to disperse the process material by giving the media around
the outer peripheral surface of the rotors a high kinetic energy, and making the media
collide with the beads (media) and the processed material accumulating in the vicinity of
the internal circumference of the cylinder, thus enabling loss of motion to be reduced, and
since the process material is supplied to the cylinder continuously, the dispersion
processing by crushing and agitating the process material in the cylinder can be performed
efficiently even though the capacity of the cylinder is reduced. If the ratio D1/D2 is below
0.4, kinetic energy loss of the granular media accompanying the increase of the distance
between the rotor and the cylinder is high, which leads to short passing of the process
material and poor dispersion. Hence there is a disadvantage of processing efficiency
falling. On the other hand, if the ratio D1/D2 exceeds 0.7, the difference in size between
the outside diameter of the rotors and the agitating members is too low. Hence there are
deficiencies such as being unable to obtain an adequate effect from the agitating members,
and easily inviting overcrowding due to poor flow of the media.
The process material may be a slurry or process liquid such as printing ink, or the
like.
Furthermore, a ratio D1/P between the array pitch P of the agitating members and
the outside diameter D1 of the rotors may be set in a range of 1.4 to 3.0, so that the motion
of media in the cylinder is good, and the process material injected thereinto flows in a
form of laminar flow, so that the processing quality is improved. If it is 1.4 or more, then
the spacing between the agitating members is not too large, which prevents the motion of
media from dropping, thus enabling the process material to be crushed and dispersed
sufficiently. Moreover, if it is 3.0 or less, then the spacing between the agitating members
is not too narrow, and does not cause the media to be unevenly distributed or drift, thus
enabling stable operation.
In addition, the array pitch P of the agitating members does not always need to be a
fixed spacing, and the spacing may be changed depending on the nature of the process
material. For example, if it narrows from the inlet toward the outlet, it is possible to
intensify the dispersion force gradually.
A cooling device may be provided in the rotor, and furthermore a cooling device
may be provided outside the cylinder, which prevents the physical properties of the
process material from changing by temperature increase, and it is especially useful for
process material whose nature changes easily with temperature, such as gravure ink and
the like.
The agitating members may be a plurality of pins installed outside of a rotating
shaft, as shown in FIG. 7, or discs, especially discs provided with a plurality of holes
(through holes) passing through the discs, as shown in FIG. 6, installed on a rotating shaft.
In considering the prevention of a short pass by dispersing the media uniformly in the
processing chamber and circulating it appropriately, a type of disc is preferable that has a
plurality of slot openings in the outer periphery of the disc other than the plurality of
through holes.
Especially, in the case where the viscosity of the process material is high, the
number of notched slots is 3 to 15, and preferably 4 to 12, in order to make the media flow
quickly and increase the circulation force, although it depends on the capacity of the
crushing chamber. Furthermore, the number of through holes is preferably about 3 to 8.
A dispersion method according to the present invention is characterized in that
there are provided rotors and agitating members protruding outside of the rotors in a radial
direction in a cylinder, and an outside diameter of the rotors is D1, an inside diameter of
the cylinder is D2, a ratio D1/D2 is set in a range of 0.4 to 0.7, slurry, being process
material, is injected into the cylinder, and the rotors and agitating members are rotated to
agitate the slurry together with the media for the purpose of dispersion processing.
Whether the viscosity of the process material is high, or the viscosity of the
process material is low, since as the peripheral speed of the rotors increases and the
distance between the rotors and the internal circumference surface of the cylinder becomes
short, the process material and the media collide around the internal circumference surface
of the cylinder in a state that the kinetic energy for scattering the media is high, and the
loss is small, it is possible to perform dispersion processing of the process material
efficiently. Furthermore, it is also possible to suppress local congestion of the media and a
phenomenon of choking, which tend to occur in the case of low viscosity.
In addition, where an array pitch of the agitating members is P, a ratio with the
outside diameter D1 of the rotors, D1/P, may be set in a range of 1.4 to 3.0, and this
enables the dispersion processing of the process material to proceed more reliably.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a dispersion apparatus according to an
embodiment of the present invention.
FIG. 2 is a block diagram of the main part of the dispersion apparatus shown in
FIG. 1.
FIG. 3 is a plan view of an example of an agitating disc mounted in the dispersion
apparatus shown in FIG. 1.
FIG. 4 is a plan view of another example of an agitating disc mounted in the
dispersion apparatus shown in FIG. 1.
FIG. 5 is a plan view of another example of an agitating disc mounted in the
dispersion apparatus shown in FIG. 1.
FIG. 6 is a plan view of another example of an agitating disc mounted in the
dispersion apparatus shown in FIG. 1.
FIG. 7 is a plan view of another example of an agitating member mounted in the
dispersion apparatus shown in FIG. 1.
FIG. 8 is a schematic block diagram of a dispersion apparatus according to a
second embodiment.
FIG. 9 is a schematic block diagram of a conventional dispersion apparatus.
FIG. 10 shows a state in which beads accumulate in the dispersion apparatus
shown in FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 through FIG. 7 show a dispersion apparatus according to a first embodiment.
FIG. 1 is a schematic block diagram of a longitudinal section of the dispersion apparatus,
FIG. 2 is a partial side view of the dispersion apparatus shown in FIG. 1, and FIG. 3 is a
plan view of an agitating member.
A dispersion apparatus 10 in the embodiment as shown in FIG. 1 and FIG. 2 is a
media agitating mill or the like, for example, which has an approximately cylindrically
shaped cylinder 11, an inlet 12 for slurry (process material) such as ink and the like, for
example, formed on one end plate 11a of the cylinder 11, and an outlet 13 for discharging
slurry that has been injected into the cylinder 11, dispersed and milled, formed on the
other end plate 11b opposite the end plate 11a. A separator 14 is fitted over an aperture
13a leading to the cylinder 11 via a gap C, and dispersed and milled slurry is discharged
through the gap C between the separator 14 and the aperture 13a. The gap C does not
allow media loaded in the cylinder 11 to pass through, for example granular shaped beads
22, but it is designed to pass small diameter slurry.
Furthermore, a main shaft 15 is inserted into the cylinder 11 substantially coaxially
with the cylinder 11, passing through the outlet 13 and the separator 14, and disposed such
that it can rotate relative to the internal surface of the cylinder 11. An internal cooling
path 16 is formed in the main shaft 15 as a cooling device for cooling media such as
cooling water or the like to circulate, and this cools the slurry inside the cylinder 11. The
internal cooling path 16 comprises an entry pipe 16a for supplying cooling water, and a
return pipe 16b, for example. An external cooling path 20 is also provided in the outer
periphery of the cylinder 11, which circulates cooling media such as cooling water or the
like to cool the inside of the cylinder 11.
In the cylinder 11, a plurality of agitating discs 18 (agitating members) and a
plurality of rotors 19 are fitted alternately and coaxially, via a ring-shaped spacer 17 from
the separator 14 side, on the main shaft 15.
FIG. 3 shows one example of a case where the agitating members are agitating
discs. In FIG. 3, agitating discs 18 appear approximately disc shaped with a larger outside
diameter than the rotors 19 as shown in this figure. A plurality (4 in the figure) of slots 21
are provided in the agitating disc 18 around its outer periphery at a predetermined spacing
in the circumferential direction. The slots 21 curve inward from the outer peripheral
surface toward the center extending forward in the direction of rotation. The slots 21 are
formed such that the width in the circumferential direction is larger than the outside
diameter of the beads 22, which allows the beads 22 to pass through.
Furthermore, through holes 23 are punched between adjacent slots 21 in the
agitating discs 18 at a predetermined spacing in the circumferential direction, close to the
rotor 19. The beads 22 can also pass through the through holes 23, which enables a large
number of beads 22 gathered on the outlet 13 side of the cylinder 11 to pass through and
move to the inlet 12 side.
The rotors 19 located between adjacent agitating discs 18 are substantially
cylindrically shaped, with a smaller diameter than the agitating discs 18, and the internal
cooling path 16 circulates inside them (not shown in the figure). The agitating discs 18
and the rotors 19 are fitted alternately and coaxially on the main shaft 15, and fixed so as
to rotate together with the main shaft 15.
In FIG. 1, agitating discs 18 are fitted on both ends. However, alternatively, the
construction may be such that rotors 19 are fitted on both ends. In other words, the
agitating discs 18 and the rotors 19 may be arranged alternately, or the agitating discs 18
may be arranged on a rotor 19 formed as a long shaft, at a predetermined spacing. The
space between the internal circumference surface 11c of the cylinder 11, and the agitating
discs 18 and the rotors 19 forms a crushing chamber 24 (milling zone) into which the
beads 22 and slurry are loaded.
FIGS. 4 to 7 show examples of other agitating members which are used in the
present invention. FIG. 4 shows a disc 18 having more slots and through holes 23 than the
agitating disc shown in FIG. 3. Numeral 19 denotes a rotor. FIG. 5 shows a disc 18
having slots 21 and no through holes. In this figure, numeral 19 denotes a rotor. FIG. 6
shows a disc 18 having through holes 23 but no slots. In this figure, numeral 19 denotes a
rotor. FIG. 7 shows an agitating member having pins 18a instead of a disc. In this figure,
numeral 19 denotes a rotor. Numeral 11c indicates the inside of the cylinder.
A large number of granular beads 22 is held in the cylinder, and the beads 22
which are scattered to the inner surface 11c of the cylinder 11 by the rotation of the rotors
19 and the agitating discs 18, collide with injected slurry and accumulated beads 22, and
crush and disperse the slurry, which is sent toward the outlet 13 side continuously as it
repeats.
The beads 22 appear almost spherical for example, and their average particle size
is set to about 0.2 to 3mm. Furthermore, the beads 22 fill up approximately 65 to 95% of
the volume of the cylinder 11, and the filling percentage is determined appropriately
depending on the nature of the slurry including pigment and the like to be crushed, for
example how easy it is to crush, or the particle size before crushing and the like.
Furthermore, the material of the beads 22 used is selected depending on the properties of
the slurry, for example viscosity, specific gravity, required grain size for pulverization and
dispersion, and the like, and for example, glass beads, zircon beads, zirconia beads, steel
balls or the like are used. However, in general, material that has high specific gravity and
is difficult to abrade is preferable. If the viscosity of slurry, such as ink, is high, beads 22
with high specific gravity are selected.
Since steel beads generally generate black iron powder by collision, friction, and
the like, it is used for India ink type ink, and the like, while in the case of whitish ink,
beads such as zirconia are used. In the case of slurry with low viscosity, glass beads are
used typically.
In general, beads 22 having a particle size five to six times the initial particle size
of the injected slurry may be used. In dispersion processing of slurry, there are both a case
where it is processed to the required particle size by a single stage dispersion apparatus,
and a case where it is passed through a plurality of processing stages using a plurality of
dispersion apparatuses in which beads with different particle sizes are loaded, and it is
dispersed to the required particle size gradually.
In the case where the outside diameter of the rotors 19 is D1, and the inside
diameter of the cylinder 11 is D2, the ratio of the two D1/D2 is set in a range of 0.4 to 0.7.
If the ratio D1/D2 is set in this range, the peripheral speed of the outer periphery of the
rotors 19 can be set high, and furthermore the distance to the internal circumference
surface 11c of the cylinder can be set short. Hence, loss of the kinetic energy for
scattering the beads 22 is low, thus enabling efficient crushing and dispersion of slurry. If
it is below 0.4, since the outside diameter of the rotors 19 is decreased, the distance to the
internal circumference surface 11c of the cylinder increases, the kinetic energy loss of the
beads 22 is high, so that there is a disadvantage in that it causes a short pass and dispersion
failure easily. Furthermore, it is difficult to obtain space for the internal cooling path 16,
so that there is a disadvantage in that sufficient cooling area cannot be obtained on the
surface of the rotors 19 in the structure. If the agitating discs 18 have no slots 21, the
agitation and scattering efficiencies of the beads 22 fall significantly.
In the case where the pitch between adjacent agitating discs 18 is P, the ratio D1/P
with the outside diameter D1 of the rotors 19 is set in a range of 1.4 to 3.0. If the ratio
D1/P is set in this range, motion of the beads 22 in the cylinder 11 can be maintained
satisfactorily, so that it is possible to prevent drift and a phenomenon of choking of the
beads 22 due to the velocity of the injected slurry. If it is 1.4 or more, then the spacing
between the agitating discs 18 is not too large, which prevents the motion of media from
deteriorating, thus enabling the process material to be crushed and dispersed sufficiently.
Moreover, if it is 3.0 or less, then the spacing between the agitating discs 18 is not too
narrow, so that uneven distribution and drift of the media (beads 22) is prevented, thus
enabling stable operation.
In addition, the array pitch P of the agitating members does not always need to be a
fixed spacing, and the spacing may be changed depending on the nature of the process
material. For example, if it narrows from the inlet 12 toward the outlet 13, it is possible to
intensify the dispersion force gradually.
A dispersion apparatus 10 according to the present embodiment has the above-described
structure. Next is a description of a dispersion method.
In the dispersion apparatus 10 shown in FIG. 1 and FIG. 2, the beads 22 are loaded
in advance into the crushing chamber 24 defined by the cylinder internal circumference
surface 11c, the agitating discs 18, and the rotors 19 in the cylinder 11. Slurry is supplied
from the inlet 12 to the cylinder 11 continuously, and at the same time by rotating the
main shaft 15, which is linked to a drive source (not shown in the figure), at a
predetermined speed, the agitating discs 18 and the rotors 19 rotate in unison. At this time,
the speed of the outer periphery of the agitating discs 18 is approximately 7 to 18m/s, and
preferably approximately 10 to 15m/s.
In FIG. 3, by rotating the agitating discs 18 in the direction of the arrow, the slurry
is agitated together with the beads 22 and dispersed. The beads 22 are scattered to the
internal circumference surface 11c of the cylinder 11 by the agitating discs 12, collide
with the slurry and beads 22 accumulating around the internal circumference surface 11c,
and crush and refine the slurry particles. The rotors 19 rotating in unison with the discs 18
have large diameters, so the peripheral speed of the outer peripheral surface is high. Thus
the beads 22 and the slurry accumulating around the outer periphery of the rotors 19 fly
toward the cylinder internal circumference surface 11c by centrifugal force.
Here, in a conventional dispersion apparatus, since the ratio D1/D2 is small, being
0.3 or less, the distance to travel to the cylinder internal circumference surface is long, and
also the kinetic energy loss is high due to the viscoelasticity of slurry which collides while
traveling. Especially in the case where the slurry has high viscosity characteristics, the
energy loss is high. Furthermore, if the periphery of the internal circumference surface
11c of the cylinder 11 is cooled by the external cooling path 20, the viscosity of the slurry
in this region becomes high, thus causing the energy loss to increase further.
However, according to the present embodiment, since the ratio D1/D2 is large,
being 0.4 or more, the cross section (capacity) of the crushing chamber 24 is reduced, but
the kinetic energy of the beads 22, which are scattered by high speed because of the short
distance to the cylinder internal circumference surface 11c, work the slurry, which has
comparatively high viscosity, around the cylinder internal circumference surface 11c
sufficiently to crush it, so that energy loss can be avoided.
In this manner, there is no dead space in the vicinity of the rotors 19 and the
internal circumference surface 11c, the slurry in this space can be dispersed, and the beads
22 can also be moved, thus enabling homogeneous atomization and dispersion of the
slurry.
The beads 22 and the slurry in the crushing chamber 24 of the cylinder 11 are sent
to the outlet 13 side gradually by the supply pressure of the slurry supplied continuously
from the inlet 12. A gap C between the separator 14 and the aperture 13a of the outlet 13
prevents the beads 22 from passing through, but lets atomized slurry pass through, so that
only dispersed slurry is discharged from the outlet 13 and recovered.
That means that the beads 22 left in the vicinity of the outlet 13 accumulate
between the agitating disc 18 on the outlet 13 side and the other end face 11b of the
cylinder as shown in FIG. 1 and FIG. 2, but are returned to the inlet 12 side through
through holes 23 in this agitating disc 18. In this case, if the agitating disc 18 close to the
outlet 13 is fitted slightly off the center of the rotor 19, it is easy to scatter the beads 22,
which enables the degree of recirculation of the beads 22 to be increased. Furthermore, on
the discharge side, the beads 22 are normally in an overfilled state, but if the separator 14
is positioned off the center of the rotor 19, the effect of scattering the beads 22 increases,
which enables the recirculation of the beads to be further increased.
In this manner, while the beads 22 are being circulated in the longitudinal direction
of the rotors 19 in the cylinder 11, slurry supplied continuously from the inlet 12 can be
dispersed and discharged continuously. According to the present embodiment, since the
ratio D1/D2 is set high, the cross section of the crushing chamber 24 is reduced by about
20 to 30% from a conventional dispersion apparatus. However, the outside diameter of
the rotors 19 is increased, and the peripheral speed can be improved by two or more times,
so that dispersion processing efficiency in the cylinder 11 is increased, and the residence
time of the slurry is shortened. Moreover, since the dispersion efficiency is good, better
processing quality can be obtained than with a conventional dispersion apparatus.
Furthermore, in a conventional dispersion apparatus, if the feed rate of slurry is
increased, the internal pressure of the cylinder increases and is converted into thermal
energy, which sometimes affects the physical properties of slurry. However, in the
dispersion apparatus 10 according to the present embodiment, since the accumulation time
of slurry is shortened, the increase of the internal pressure is only in the range of 0 to
0.01MPa with a normal feed rate in the range of 100 to 300kg/h, and hence no problem
occurs. Moreover, in the present embodiment, the increase of the internal temperature can
be suppressed by cooling by the internal cooling path 16 in the rotors 19 as well as by
cooling by the external cooling path 20 of the cylinder 11.
According to the present embodiment described above, high kinetic energy is
given to the beads 22 in the cylinder 11, and at the same time motion loss is reduced, so
that the dispersion processing of crushing and agitating slurry in the cylinder 11 can be
performed efficiently and satisfactorily even though the capacity of the crushing chamber
24 is reduced, and thus processing quality can be improved. Furthermore, no increase in
driving force is required for the processing. Moreover, dispersion processing can be
performed over a wide range from low viscosity (for example, 100mPa·s) slurry to high
viscosity (for example, 100,000mPa·s) slurry.
Next is a description of a second embodiment of the present invention using FIG. 8.
A dispersion apparatus as shown in FIG. 8 has almost the same structure as the
first embodiment, so the same symbols are used for the same parts, and descriptions are
omitted.
In a dispersion apparatus 30 as shown in FIG. 8, a plurality of agitating discs 18 is
fitted on a main shaft 31 installed in a cylinder 11 at a predetermined spacing, and
cylindrical collar rings 32 are mounted on the outer peripheral surface of the main shaft 31
as rotors between adjacent agitating discs 18. The outer peripheral surface of the collar
rings 32 has the same outside diameter D1 as the outer peripheral surfaces of the rotors 19,
and the numerical ranges of ratios D1/D2 and D1/P are the same as in the first
embodiment. The collar rings 32 and the agitating discs 18 rotate in unison with the main
shaft 31.
Therefore, a dispersion apparatus 30 according to the second embodiment exhibits
the same effects as the first embodiment. Specifically according to the present
embodiment, by changing the collar rings 30, it is possible to adjust the outside diameter
D1 and the pitch P of the agitating discs 18, so that there is an advantage in that it can be
adjusted to the type of slurry, degree of dispersion, and the like.
In the embodiments described above, the agitating discs 18 are basically fitted
coaxially on main shafts 15 and 31, but they are not always coaxial, and may be fitted off
center.
Furthermore, the agitating discs 18 and the rotors 19 or the collar rings 32 are not
limited to separate pieces, and they may be constructed as one piece. In this case, the
main shafts 15 and 31 may also be constructed as one piece, or may be separate pieces.
Moreover, it is possible to set the numbers of slots 21 and through holes 23 of the
agitating discs 18 as desired.
In the embodiments described above, printing ink is used as the process material.
However, the present invention is not limited to this, and it may be used for a range of
slurries or process liquids, such as can coatings, metal and automotive coatings, batteries
and magnetic coatings, pulp and the like.
[Experimental Examples]
Next is a description of experimental examples of the present invention.
Examples 1, 2, 3, 4, 5, 6, 7 and 8 and Comparative Examples 1, 2, 3, 4, 5, 6 and 8
have the same structure as the dispersion apparatus 10 according to the first embodiment,
and the outside diameters D1 of the rotors 19 vary as shown in Table 1 and Table 2
following. Accordingly, there are differences in ratios D1/D2 and D1/P, volume of the
crushing chamber 24, shaft power and the like.
Firstly, experiments were performed on Examples 1 to 5 and Comparative
Examples 1 to 5.
(1) Specimens 1 and 2
Gravure base inks having the following compositions were used for
specimens 1
and 2, being slurries.
Specimen 1
Name: Gravure Base Ink Pigment: Copper Phthalocyanine Blue Pigment content 22 weight %, remainder Cellulose Nitrate Resin or
the like Specimen 2
Name: Gravure Base Ink Pigment: Azo Yellow Pigment content 20 weight%, remainder Cellulose Nitrate Resin or
the like
Furthermore, specimens 1 and 2 were created using the following procedure.
The above-described gravure base inks were each charged into a 400L (liter) open
tank, agitated by a single shaft agitator with 10 inch diameter discs at a rotation speed of
1000min-1 for one hour, and 200kg was used for a dispersion test by a dispersion
apparatus (media agitating mill). The viscosities after agitation were 2500mPa·s for
specimen 1, and 1500mPa·s for specimen 2.
The viscosities were measured using a Viscotester VT04 brand of B type
viscometer (manufactured by Rion Co. Ltd.). The measurement temperature was 25°C.
(2) Common Operation Test Conditions of Specimens 1 and 2
Beads 22
Bead Type: Zirconia YTZ (Manufactured by Nikkato Corporation) Bead Diameter: 1mm True Specific Gravity: 6.00 Apparent Specific Gravity: 3.6 Bead Filling Rate: 85%
Peripheral Speed of Outer Peripheral Surface of Agitating Discs 18: 13.5m/s
(3) Evaluation of Dispersibility
1. Comparison of Productivity
The processed specimens 1 and 2 were measured using a grind gage, and the
evaluation was performed based on the amount processed per hour when a maximum of
5µm was reached. The large amount of ink processed indicated a higher capability for the
same quality. For dispersion efficiency, a comparison was made of the same specimen
where:
dispersion efficiency = throughput in the example/throughput in the comparative example.
2. Quality
The gravure base ink obtained by dispersion processing was spread onto a 25µm
PET film by a bar coater #7, and a quality evaluation of the film surface on which the
color was spread was made using a 60° mirror reflectivity gloss meter. The quality of the
gravure ink of specimens 1 and 2 was higher as the brightness value was increased.
A bar coater coats a film to a fixed thickness rapidly and accurately. It has thin
lines circling around the rod surface, and is designated by a number based on the thickness
of the thin lines. The bar coater used was; material: SUS304, Rod: 8mm diameter ×
300mm length (effective length 250 mm), type: No. 7, Manufactured by Dai-Ichi Rika Co.
Ltd.
Furthermore, for the gloss meter, a GM-3 type photometer manufactured by
Murakami Color Research Laboratory was used, and 60° mirror reflectivity was used as
an evaluation value. The method of measuring specular glossiness was JIS Z8741.
(4) Comparative Evaluation
Operations on
specimens 1 and 2 were performed using a dispersion apparatus as
in Example 1 and Comparative Example 1, in which the ratios D1/D2 varied as shown in
the following Table 1, and the results were compared. Similarly, operations were
performed on each of Examples 2 to 5 and Comparative Examples 2 to 5, and the results
were compared.
Next, experiments were performed using other specimens for Examples 6 to 8 and
Comparative Examples 6 and 8.
(1) Specimens 3 and 4
Lithographic base inks having the following compositions were used for
specimens 3 and 4, being slurries.
- Specimen 3
- Name: Lithographic Base Ink
Pigment: Carbon Black
Pigment content 40 weight %, remainder Resin Varnish or the like - Specimen 4
- Name: Lithographic Base Ink
Pigment: Carbon Black
Pigment content 40 weight %, remainder Resin Varnish or the like
Specimens 3 and 4 were created using the following procedure.
Specimen 3 was agitated by a single shaft agitator with 8 inch diameter discs at a
rotation speed of 1000min-1 for two hours, and 50kg was used for a dispersion test by a
dispersion apparatus (media agitating mill). The viscosity of specimen 3 was 58000mPa·s.
Specimen 4 was agitated by a double concentric shaft agitator for two hours. The
inner high-speed agitating blade was rotated at 700min-1, and the outer constant speed
agitating blade at 20min-1. 800kg was used for the dispersion test by a dispersion
apparatus (media agitating mill). The viscosity of the specimen 4 was 15000mPa·s.
Viscosity measurement was performed using the same measuring device as
specimens 1 and 2 under the same conditions.
(2) Common Operation Test Conditions of Specimens 3 and 4
Beads 22
Bead Type: Steel (chromium) SUJ-2 (Manufactured by Daido
Kogyo Co,. Ltd) Bead Diameter: 2mm True Specific Gravity: 8.00 Apparent Specific Gravity: 4.68 Bead Filling Rate: 85%
Peripheral Speed of Outer Peripheral Surface of Agitating Discs 18: 13.5m/s
(3) Evaluation of Dispersibility
1. Comparison of Productivity
The dispersion processed specimens were measured using a grind gage, and the
evaluation was performed based on the amount processed per hour when a maximum of
10µm was reached. Other matters were the same as in the case of specimens 1 and 2. The
method of evaluating malaxation degree by a grind meter was according to 4.3.2 of JIS
K5701-1.
(4) Comparative Evaluation
Operations on specimens 3 and 4 were performed using a dispersion apparatus as
in Examples 6 and 7 and Comparative Example 6, in which the ratios D1/D2 differed as
shown in the following Table 2, and the results were compared. Similarly, operations
were performed on each of Example 8 and Comparative Example 8, and the results were
compared.
In Comparative Example 6, flow congestion (flow failure) occurred, and the
internal pressure of the dispersion apparatus reached 0.4MPa or more, so that the load
increased significantly, and the operation was unable to be continued.
When the examples and comparative examples, which used the same specimens,
were each compared and evaluated according to the above Tables 1 and 2, in the case of
the examples, the throughput (process capability) to obtain the same quality as the
comparative examples was increased by 25 to 40%. In the throughput per single crushing
chamber 24 (milling zone), the efficiency was increased by 48 to 96%. Furthermore, the
shaft power could be reduced by 10 to 20%, so that an energy saving could be achieved.
The throughput per shaft power could be increased by 40 to 85%. In the specimens 1 and
2, the quality (glossiness) of the gravure base ink could be improved along with the
improvement of the throughput.
Moreover, in Examples 6 and 7 in which specimen 3 with high viscosity was used,
it was confirmed that high viscosity slurry could be processed acceptably. In Examples 6
and 7, it was confirmed that high viscosity ink, which could not be processed in the
conventional apparatus as shown in Comparative Example 6, could be produced stably
without causing dispersion failure accompanying bead flow congestion, or internal
pressure and shaft power abnormalities due to local over filling of beads.
Effects of the Invention
Using a dispersion apparatus and a dispersion method according to the present
invention described above, a high kinetic energy is given to media around the outer
peripheral surface of rotors when rotating, which makes them collide with process
material and the like in order to disperse it, and loss of motion can be reduced. Hence the
dispersion process of crushing and agitating the process material in the cylinder can be
performed efficiently even though the capacity of the cylinder is reduced, enabling the
quality of processed material to be improved. Furthermore, no increase in driving force is
required for the processing.
Moreover, in a case where the ratio D1/P of the array pitch P of the agitating
members to the outside diameter D1 is set in a range of 1.4 to 3.0, motion of the media in
the cylinder is good, so the introduced process materials can be dispersed efficiently and at
the same time it is possible to form laminar flow to transport them, so that process
efficiency and quality are improved.