How is a vacuum system used with a double planetary disperser

In the field of high-performance mixing and dispersing equipment, the Double Planetary Disperser, with its unique mixing principle, has become an ideal choice for handling high-viscosity, thixotropic materials. However, in many advanced applications, mechanical mixing alone is insufficient. The integration of a vacuum system represents a significant improvement in the equipment, enabling it to meet the most demanding process requirements.

1. Basic Principles and Functions of a Vacuum System

A vacuum system typically consists of a vacuum pump, a vacuum buffer tank, piping, valves, and a vacuum pressure gauge. When connected to the enclosed mixing chamber of a Double Planetary Disperser, its core function is to remove gases from the material. These gases, whether inherent in the raw materials or entrained during the high-speed dispersing process, can negatively impact the quality of the final product.

In a Double Planetary Disperser, the dual planetary impellers and high-speed dispersing disc work together in a complex trajectory, generating high shear forces. While this process is highly efficient, the high-speed rotation of the dispersing disc inevitably creates vortices within the material, which can entrain air. Especially for high-viscosity materials, once air bubbles are trapped, they are difficult to escape naturally due to the material's poor fluidity. The vacuum system intervenes by reducing the pressure within the mixing chamber, causing tiny bubbles in the material to expand and quickly float to the surface, where they are ultimately extracted by the vacuum pump.

2. Core Application Scenarios: Why is Vacuum Operation Necessary?

In many industries, vacuum operation is not just an optional feature; it is critical to ensuring product performance.

a) Electronic Packaging Materials and Semiconductor Industry

In the production of electronic packaging materials such as epoxy resins, silicone gels, and underfills, any tiny air bubbles can lead to reduced insulation performance, uneven thermal conductivity, and even voids after curing, causing product failure. Vacuum operation can completely remove these bubbles, ensuring material uniformity and reliability, significantly improving the yield rate and long-term stability of semiconductor packaging.

b) New Energy Battery Slurry

The preparation of lithium-ion battery slurry is a typical example of a vacuum application. Bubbles in the slurry can affect electrode coating uniformity, leading to inconsistent areal density and, in turn, impacting the battery's internal resistance, capacity, and cycle life. Under vacuum conditions, a dual planetary disperser ensures thorough degassing of both positive and negative electrode slurries during mixing, dispersion, and dissolution, resulting in dense, defect-free coatings that lay the foundation for high-performance, long-life lithium batteries.

c) Pharmaceuticals and Biotechnology

Maintaining a bubble-free environment is crucial when preparing certain medical ointments, biogels, or high-purity solutions. Oxygen in air can oxidize sensitive ingredients, while bubbles themselves can affect the stability and uniformity of the drug's efficacy. Vacuum operation effectively prevents this problem, ensuring that products meet stringent quality standards.

d) High-End Coatings, Inks, and Adhesives

For products requiring optically clear, defect-free surfaces, such as optical adhesives (OCAs), high-gloss coatings, or transparent adhesives, bubbles are a critical defect. Vacuum degassing eliminates these visual imperfections while improving the coating's density and adhesion, enhancing the product's final performance and aesthetics.

3. Other Synergistic Benefits of Vacuum Operation

In addition to its core degassing function, the combination of a vacuum system and a dual planetary disperser offers the following multiple advantages:

a) Reduced Material Volatility

In some production processes, materials contain volatile solvents. Under normal pressure, high-speed dispersion accelerates solvent volatilization, resulting in an imbalance in the material composition. Under vacuum conditions, pressure control can suppress excessive solvent volatilization and maintain formulation accuracy. This is particularly important for products such as solvent-based adhesives and inks.

b) Preventing Material Oxidation

Many chemical raw materials are sensitive to oxygen, such as certain resins, catalysts, and pharmaceutical ingredients. In a vacuum system, oxygen is removed from the mixing chamber, creating an inert or low-oxygen environment. This effectively prevents oxidative degradation of the material during mixing, preserving its activity and performance.

c) Improved Dispersion Efficiency

Under vacuum conditions, the viscosity of the material may change, and the elimination of air bubbles also makes the material flow more smoothly. This helps the agitator and disc of the dual planetary disperser to more effectively apply pressure to the material, improving mixing and dispersion efficiency and shortening production cycle times.

d) Maintaining Cleanliness and Safety

A closed vacuum system prevents material splashing and solvent vapors from escaping into the production environment, minimizing health hazards to operators and maintaining a clean production environment. This is particularly critical for processes involving toxic or hazardous substances.