Spheroidization device

Abstract

This application relates to the field of material spheroidization processing technology, and provides a spheroidization device. The spheroidization device is used to prepare fine-particle-size spheroidized material with a median particle size D50 of 4.0-10 μm. The spheroidization device includes a shell with a cavity, inside which are a grading component and a shaping component. The grading component separates the tail powder from the spheroidized material; the tail powder is discharged from the cavity, and the spheroidized material falls back to the shaping component. The shaping component includes a toothed ring and a rotatable grinding disc structure with a gap between them. The rising airflow at the gap transports the tail powder and spheroidized material to the grading component. The grinding disc structure includes a grinding disc and a first grinding block located at its upper edge. The first grinding block has an arc surface on its windward side, extending radially along the grinding disc, with the rotation axis of the arc surface parallel to the extension direction of the first grinding block. This arc surface allows the material particles to undergo rolling grinding upon impact, prolonging the contact time and enhancing the positive pressure airflow to partially counteract the rising airflow, allowing the material to remain stably in the shaping area and improving the ability of fine particles to be spheroidized.

Description

Technical Field

[0001] This application relates to the field of material spheroidizing processing technology, and in particular to a spheroidizing device. Background Technology

[0002] In industrial production, traditional material spheroidizing devices can reliably achieve a minimum spheroidized particle size (D50) of approximately 9–12 μm, with a lower limit of about 8 μm. Below this particle size, the yield rate drops significantly, making it difficult to obtain qualified spheroidized products and leading to problems such as excessive particle breakage, irregular morphology, and substandard tap density. The core reason for this is that the grinding block structure of traditional devices is simple, and the impact and kneading intensity is too high, easily causing excessive breakage of fine-diameter materials, making it difficult to form complete spheroids. At the same time, the shaping effect on fine particles is insufficient, resulting in low spheroidizing efficiency and failing to meet the stable spheroidizing requirements of even finer-diameter materials.

[0003] The above statements are for the purpose of providing background information in relation to this application only and do not necessarily constitute prior art. Summary of the Invention

[0004] In view of the above problems, embodiments of this application provide a spheroidizing device that can meet the stable spheroidizing requirements of materials with finer particle sizes.

[0005] An embodiment of this application provides a spheroidizing device for preparing fine-particle-size spheroidized material products, wherein the median particle size D50 of the fine-particle-size spheroidized material products is 4.0-10 μm; the spheroidizing device includes a shell with a cavity and a grading component and a shaping component disposed in the cavity; the grading component is located above the shaping component and is configured to separate tail powder and spheroidized material, guide the tail powder to the outside of the cavity, and guide the spheroidized material back to the shaping component; the shaping component includes a gear ring and a grinding disc structure rotatable relative to the gear ring; the gear ring surrounds the outer periphery of the grinding disc structure and two The components are spaced apart by gaps, and an upward airflow is provided in the gaps to transport at least a portion of the tail powder and spheroidized material in the gaps to the grading component; the grinding disc structure includes a grinding disc and grinding blocks, with the grinding blocks arranged along the axial direction of the grinding disc at the upper edge of the grinding disc; wherein, the grinding blocks include a first grinding block, and the first grinding block has an arc surface on one side along the circumferential direction of the grinding disc; the first grinding block rotates in a first direction under the drive of the grinding disc, so that the first grinding block has a windward side, and the arc surface is recessed on the windward side of the first grinding block; the first grinding block extends radially along the grinding disc, and the rotation axis of the arc surface is parallel to the extension direction of the first grinding block.

[0006] In the above technical solution, the first grinding block in the grinding disc structure adopts an arc surface design, which allows the first grinding block to not only impact the material particles, but also guide the material particles to roll and grind on the arc surface, prolonging the contact time between the material and the first grinding block and improving the fullness of shaping. At the same time, the arc surface structure can enhance the positive pressure wind generated by the rotation of the grinding disc, which can offset the rising airflow (negative pressure wind) in the system to a certain extent, so that the fine-diameter material particles can stay more stably in the shaping area and fully contact the arc surface of the first grinding block, thereby improving the shaping and spheroidizing ability of fine-diameter material particles, which helps to prepare fine-diameter spheroidized material products with a median particle size D50 of 4.0–10 μm.

[0007] In addition, the arc surface is located on the windward side of the first grinding block, allowing material particles to contact the arc surface preferentially. The contact advantage of the windward side enhances the receiving and guiding effect, allowing the material particles to roll smoothly along the arc surface for grinding and prolonging the shaping contact time. At the same time, the arc surface conforms to the rotating airflow, optimizing the local flow field and positive pressure wind effect, making the material particles stay more stably in the shaping zone and fully exert their function, enhancing the ability of fine particles to be spherical, and making it easier to obtain fine-diameter spherical finished products with regular morphology.

[0008] In some embodiments, the dimension L1 of the arc surface in the extension direction of the first grinding block satisfies: 90mm≤L1≤110mm; the central angle θ of the arc surface satisfies: 90°≤θ≤120°; and the radius r of the arc surface satisfies: 20mm≤r≤30mm.

[0009] In the above technical solution, after the coordinated optimization of the arc surface layout position and parameters, a rolling shaping space suitable for fine-particle materials can be formed. The reasonable size and curvature can stably receive material particles, maintain smooth rolling grinding, extend the contact time between material particles and grinding blocks, and improve the uniformity of impact and kneading. At the same time, optimizing the rotating flow field and positive pressure can enhance the residence effect and contact degree of material particles in the shaping zone, improve the spheroidization quality of fine particles, and help to obtain fine-particle spheroidized finished products with regular morphology and good sphericity.

[0010] In some embodiments, the grinding block further includes a second grinding block, which is a rectangular structure; the second grinding block extends radially along the grinding disk, and the second grinding block and the first grinding block are spaced apart circumferentially along the grinding disk; wherein, the second grinding block rotates along a first direction under the drive of the grinding disk, so that the second grinding block has a windward side, and the windward side of the second grinding block is a plane.

[0011] In the above technical solution, the second grinding block is rectangular with a flat surface on the windward side, which is suitable for spheroidizing hard material particles. After the material particles impact the flat surface, they are squeezed and ground, which can trim the protruding edges and corners of the surface. It is circumferentially spaced with the first grinding block, forming a composite effect of impact, squeezing and rolling friction in the shaping zone. It takes into account both the trimming of hard particles and the gentle shaping of fine particles, which can improve the uniformity and integrity of spheroidization, and is conducive to producing fine-diameter spheroidized products with regular morphology.

[0012] In some embodiments, the grinding block further includes a third grinding block; the third grinding block extends radially along the grinding disk, and the third grinding block and the first grinding block are spaced apart circumferentially along the grinding disk; wherein, an inclined surface is formed between one side surface of the third grinding block along the circumferential direction of the grinding disk and the top surface of the third grinding block.

[0013] In the above technical solution, the third grinding block is arranged radially and circumferentially spaced from the first grinding block. An inclined surface is formed between its side and top surfaces, which allows the third grinding block to be adapted to spheroidize material particles with slightly lower hardness, and it has the functional characteristics of the first and second grinding blocks. At the same time, the impact of material particles on the side plane can trim protruding edges and corners, and then the inclined rolling grinding can refine the tiny edges and corners, forming a double reshaping effect. In addition, the third grinding block and the first grinding block work together to improve the fineness and comprehensiveness of the material particle shaping, optimize the spheroidizing effect, and facilitate the obtaining of fine-diameter spheroidized finished products with regular morphology.

[0014] In some embodiments, the third grinding block rotates along a first direction under the drive of the grinding disc, so that the third grinding block has a windward side; wherein, the inclined surface is disposed between the windward side surface of the third grinding block and the top surface of the third grinding block.

[0015] In the above technical solution, the inclined surface is located between the windward side and the top surface of the third grinding block. Material particles entering the shaping zone can preferentially contact and smoothly slide to the inclined surface, increasing the contact frequency and effectiveness between the inclined surface and the material particles. The material particles are smoothly rolled and ground on the inclined surface, uniformly trimming small edges and corners. At the same time, the inclined surface can match the rotation direction and airflow direction to stabilize the local flow field and extend the material particles' shaping residence time, effectively enhancing the rolling shaping and edge trimming effect.

[0016] In some embodiments, along the axial direction of the grinding disc, the dimension L2 of the third grinding block satisfies: 30mm≤L2≤50mm; along the axial direction of the grinding disc, the dimension L21 of the inclined surface and the dimension L22 of the windward side surface of the third grinding block satisfy: 0.12≤L21 / L22≤0.2; the included angle α between the inclined surface and the windward side surface of the third grinding block satisfies: 30°≤α≤60°; and along the extension direction of the third grinding block, the dimension L3 of the inclined surface satisfies: 90mm≤L3≤110mm.

[0017] In the above technical solution, by limiting the size, slope height ratio, and slope angle of the third grinding block in its own extension direction and grinding disc axis, a shaping working surface with suitable size and slope angle can be produced. The reasonable ratio can balance the impact and rolling time of material particles, and the slope angle optimizes the smoothness of material particle sliding and shaping force, and stabilizes the trimming of small edges. The synergistic effect of multiple parameters improves the adaptability of material particles and the effect of trimming edges and forming spheres, making it easier to produce fine-diameter spherical finished products with regular morphology.

[0018] In some embodiments, the grinding block further includes a fourth grinding block; the fourth grinding block extends radially along the grinding disk, and the fourth grinding block and the first grinding block are spaced apart circumferentially along the grinding disk; wherein, the fourth grinding block has a concave-convex surface on the side facing the gear ring.

[0019] In the above technical solution, the fourth grinding block is arranged radially and circumferentially spaced from the first grinding block, possessing a shaping capability similar to that of the second grinding block; the fourth grinding block has concave and convex surfaces on the side facing the toothed ring, which can disturb the material particles when rotating, allowing the material particles to form complex movements between the concave and convex surfaces and the toothed ring, increasing the impact, squeezing and kneading effects, while also having a moderate crushing effect, which can meet the needs of simultaneous crushing and spheroidizing of specific materials; after the fourth grinding block and the first grinding block are combined, they integrate strong shaping and gentle rotational molding effects, improving the uniformity and regularity of the spheroidization of material particles, which is conducive to producing fine-diameter spheroidized finished products with excellent morphology.

[0020] In some embodiments, the fourth grinding block has a plurality of tooth structures on the side facing the gear ring; the plurality of tooth structures are distributed circumferentially along the grinding disk, and the surface of the plurality of tooth structures facing the gear ring is a serrated surface to form a concave-convex surface.

[0021] In the above technical solution, the fourth grinding block has a circumferentially arranged tooth structure on the side facing the tooth ring. The sawtooth surface forms a concave-convex surface. When rotating, it can enhance the disturbance effect on the material particles, allowing the material particles to form complex movements between the tooth structure and the tooth ring, and extending the force application stroke. The sawtooth surface provides multi-point and multi-directional force, enhances the impact and grinding effect, improves the material crushing and shaping efficiency, and is suitable for material processing conditions that require strong force.

[0022] In some embodiments, the tooth surface facing the tooth ring includes a tooth face; the fourth grinding block rotates along the first direction under the drive of the grinding disc, so that the fourth grinding block has a windward side; wherein, the minimum included angle between the tooth face and the windward side surface of the fourth grinding block is an acute angle, and one tooth face is in contact with the windward side surface of the fourth grinding block.

[0023] In the above technical solution, the front surface of the tooth structure is connected to the windward side of the fourth grinding block and arranged at an acute angle. When rotating, the windward side can preferentially receive the material, and the material particles follow the tooth surface and move in an orderly manner. The acute angle layout increases the contact area, enhances the impact and grinding force, and can also guide the material particles to move in multiple directions and enrich the force trajectory. In addition, this structural layout can also strengthen the trimming of edges and corners and moderate cracking and shaping, complement the functions of other grinding blocks, and synergistically improve the spheroidizing and shaping quality, making it easier to produce fine-particle-size finished products with regular morphology.

[0024] In some embodiments, the tooth groove angle β between two adjacent tooth structures satisfies: 30°≤β≤60°; and in the extension direction of the fourth grinding block, the tooth structure dimension L4 satisfies: 10mm≤L4≤30mm.

[0025] In the above technical solution, the reasonable limitation of the tooth groove angle and tooth structure dimensions can adapt to the working conditions of the tooth groove and tooth structure. A moderate tooth groove angle can leave suitable space for material particles, which is conducive to multi-directional force on the particles entering the groove and improving the uniformity of impact grinding; the appropriate tooth structure dimensions take into account both its own strength and range of action, ensuring stable impact kneading during rotation and providing a reasonable stroke for the complex movement of material particles. Reasonable parameter limitation can enhance the synergistic ability of the fourth grinding block in crushing and shaping, and when combined with other grinding blocks, it can improve the stability of spheroidizing and shaping, which is conducive to producing fine-particle-size finished products with regular morphology.

[0026] In some embodiments, the toothed ring includes an annular body and a mounting sleeve; a ring of teeth is provided on the inner side of the annular body, and the mounting sleeve is detachably fitted on the outer side of the annular body; the annular body and the mounting sleeve are together fixed to the lower part of the inner wall of the housing.

[0027] In the above technical solution, the gear ring adopts a separate and detachable structure of the annular body and the mounting sleeve. There is no need to replace the entire gear ring. Only the mounting sleeve needs to be replaced to adapt to different equipment, materials and shaping needs, thereby improving versatility and reducing maintenance costs. The combination and fixation of the two can also ensure operational stability, improve the cooperation effect with grinding blocks and materials, adapt to various production conditions, and improve spheroidization quality.

[0028] In some embodiments, the size of the gear ring is larger than the size of the grinding disc structure in the axial direction, and neither end of the grinding disc structure extends beyond the gear ring.

[0029] In the above technical solution, the axial dimension of the gear ring is larger than that of the grinding disc structure and completely covers the grinding disc structure, which can stably maintain the annular gap between the two, allowing the airflow and materials to circulate in an orderly manner; at the same time, it regulates the movement range of material particles, so that the material particles can complete impact, kneading and rotational molding in the mating area, improve the uniformity of contact, improve the spherical morphology, and adapt to the spheroidization processing of fine-particle-size materials.

[0030] In some embodiments, a ring of teeth is provided on the side of the gear ring facing the grinding disc structure, and the ring of teeth is helical.

[0031] In the above technical solution, the inner side of the gear ring is provided with helical teeth, which can change the movement direction of the material particles, form a spiral motion trajectory, prolong the residence time of the material particles in the shaping zone, and increase the contact frequency with the gear ring and grinding block; the helical teeth can apply guidance and force from multiple directions, enhance the impact grinding effect, guide the material particles to circulate in an orderly manner, optimize the internal flow field, improve the uniformity and regularity of the material particles, and are suitable for the preparation of fine-particle-size materials.

[0032] In some embodiments, the cavity is divided into a grading cavity, a circulation cavity, and a shaping cavity from top to bottom; a grading component and a shaping component are respectively disposed in the grading cavity and the shaping cavity; a guide ring is disposed in the circulation cavity, the guide ring having a conical structure that is larger at the top and smaller at the bottom; a guide port is disposed between the upper edge of the guide ring and the cavity wall of the circulation cavity to guide the rising airflow carrying tail powder and spherical material to the grading component; the inner wall of the guide ring is used to guide the spherical material separated by the grading component back to the shaping component.

[0033] In the above technical solution, the cavity is divided into a grading cavity, a circulation cavity, and a shaping cavity, with corresponding components matching to achieve process division and connection. The conical guide ring in the circulation cavity can guide the rising airflow containing tail powder and spherical material to the grading component for separation, while guiding the graded spherical material back to the shaping component; the whole process forms an airflow and material circulation, improving spherical efficiency and finished product quality, achieving tail powder separation, and making the whole process orderly and stable.

[0034] In some embodiments, the grading chamber has a tail powder outlet on its wall for discharging tail powder; the circulation chamber has a feed inlet on its wall for filling the chamber with raw materials; the shaping chamber has a discharge outlet on its wall, located above the shaping assembly, for discharging fine-particle-size spherical material; and an air inlet is provided below the shaping chamber, communicating with the shaping chamber through a gap, with an air inlet on its wall for providing upward airflow.

[0035] In the above technical solution, the grading chamber has a tail powder discharge outlet to promptly remove tail powder and prevent accumulation; the circulation chamber has a feeding inlet to continuously replenish materials and ensure continuous production; the shaping chamber has a discharge outlet to facilitate timely discharge of finished products and improve efficiency; and the bottom air inlet chamber provides a stable upward airflow to power the material circulation and shaping. Furthermore, the rational layout of each chamber forms a closed-loop process of feeding, powder discharge, material discharge, and air supply, ensuring continuous and efficient production and guaranteeing the quality of the finished product.

[0036] In some embodiments, the portion of the shaping cavity located above the shaping component is a variable diameter cavity, and the diameter of the variable diameter cavity increases from bottom to top.

[0037] In the above technical solution, the gradually expanding variable diameter cavity above the shaping cavity can be adapted to the working range of the shaping component, reduce the upward resistance of airflow, make the airflow smoother and more stable, promote the orderly circulation of material particles and fully contact the grinding block, and improve the uniformity of shaping. At the same time, this structural design can increase the working space, reduce the local accumulation of materials, optimize the airflow distribution in the cavity, make the material particles more evenly stressed, enhance the balling effect, and smoothly connect the shaping and grading stages, ensuring the smooth and efficient operation of the whole machine.

[0038] In some embodiments, the grinding block further includes a second grinding block, a third grinding block, and a fourth grinding block. The windward side of the second grinding block is planar and has a rectangular structure. An inclined surface is formed between the windward side and the top surface of the third grinding block. The fourth grinding block has a concave-convex surface on the side facing the gear ring. The first grinding block, the second grinding block, the third grinding block, and the fourth grinding block are arranged at intervals along the circumference of the grinding disc.

[0039] In the above technical solution, the spheroidizing device arranges four types of grinding blocks with different structures at intervals along the circumference of the grinding disc, forming a complementary and synergistic shaping system. The arc surface of the first grinding block guides the rolling grinding of material particles, optimizing the shaping effect; the rectangular plane of the second grinding block facilitates the extrusion grinding of material particles, trimming the edges and corners of the material particles; the inclined surface of the third grinding block serves both impact trimming and rolling refinement; the concave and convex surface of the fourth grinding block can disturb the movement trajectory of material particles, enhancing the impact, extrusion, and kneading effects. The combination of multiple types of grinding blocks adapts to the processing needs of material particles with different characteristics, enriches the force forms and movement paths of particles, improves the uniformity and fineness of the overall spheroidizing and shaping, and is suitable for the stable preparation of finished products with a median particle size D50 of 4.0–10 μm. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0041] Figure 1 This is a schematic diagram of the structure of a spheroidizing system provided according to some embodiments of this application; Figure 2 This is a schematic diagram of the internal structure of a spheroidizing device provided according to some embodiments of this application (the arrows in the diagram indicate the flow direction of the rising airflow within the spheroidizing device). Figure 3 This is a three-dimensional structural schematic diagram of a shaping component provided according to some embodiments of this application; Figure 4 This is a top view of a shaping component provided according to some embodiments of this application; Figure 5 This is a three-dimensional structural schematic diagram of a first grinding block provided according to some embodiments of this application; Figure 6 This is a schematic front view of the first grinding block provided according to some embodiments of this application; Figure 7 This is a side view of a first grinding block provided according to some embodiments of this application; Figure 8This is a three-dimensional structural schematic diagram of a second grinding block provided according to some embodiments of this application; Figure 9 This is a three-dimensional structural schematic diagram of a third grinding block provided according to some embodiments of this application; Figure 10 This is a schematic front view of the third grinding block provided according to some embodiments of this application; Figure 11 This is a side view of a third grinding block provided according to some embodiments of this application; Figure 12 This is a three-dimensional structural schematic diagram of a fourth grinding block provided according to some embodiments of this application; Figure 13 This is a top view of a fourth grinding block provided according to some embodiments of this application; Figure 14 This is a three-dimensional structural schematic diagram of a grinding disc provided according to some embodiments of this application; Figure 15 This is an exploded structural diagram of a gear ring provided according to some embodiments of this application; Figure 16 This is a three-dimensional structural schematic diagram of a flow guide ring provided according to some embodiments of this application; Figure 17 This is a three-dimensional structural schematic diagram of a spheroidizing device provided according to some embodiments of this application; Figure 18 The images are scanning electron microscope images of the finished product obtained by testing the raw material provided in some embodiments of this application using a first spheroidizing device. Figure 19 The images are scanning electron microscope images of the finished product obtained by testing the raw material 2 provided in some embodiments of this application using a second spheroidizing device. Figure 20 The images are scanning electron microscope images of the finished product obtained by testing the raw material 2 provided in some embodiments of this application using a conventional spheroidizing device. Figure 21 The images are scanning electron microscope images of the finished product obtained after testing the raw material three provided in some embodiments of this application using a third spheroidizing device. Figure 22 The images are scanning electron microscope images of the finished product obtained by testing the raw material three provided in some embodiments of this application using a conventional spheroidizing device. Figure 23 Scanning electron microscope (SEM) images of raw material four provided according to some embodiments of this application; Figure 24 The images are scanning electron microscope (SEM) images of the finished product obtained by testing the raw material four provided in some embodiments of this application using a fourth spheroidizing device.

[0042] The attached figures are labeled as follows: 100-Spheroidizing device; 10-Shell, 11-Cavity, 111-Grading cavity, 112-Circulation cavity, 113-Shaping cavity, 12-Tail powder discharge outlet, 13-Inlet, 14-Outlet; 20-Grading components, 21-Main frame, 22-Grid; 30-Shaping component, 31-Gear ring, 311-Annular body, 312-Mounting sleeve, 32-Grinding disc structure, 321-Grinding disc, 3211-First positioning groove, 3212-Second positioning groove, 3213-Third positioning groove, 3214-Fourth positioning groove, 322-First grinding block, 3221-Arc surface, 3221a-Rotating shaft, 323-Second grinding block, 324-Third grinding block, 3241-Inclined surface, 325-Fourth grinding block, 3251-Gear structure, 3251a-Gear front face, 33-Gap; 40 - Flow guide ring, 41 - Flow guide port; 50 - Intake chamber, 51 - Intake port; 200 - Material silo; 300 - Conveyor; 400 - Finished product silo; 500 - Tail powder dust collector; 600 - Exhaust fan. Detailed Implementation

[0043] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0044] Unless otherwise defined, all technical and scientific terms used in the embodiments of this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs; the terminology used in the embodiments of this application is for the purpose of describing specific embodiments only and is not intended to limit this application; the terms "comprising" and "having" and any variations thereof in the specification and the foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0045] The term "embodiment" as used in this application means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this application can be combined with other embodiments.

[0046] The specific term "exemplary" used in the embodiments of this application means "serving as an example, embodiment, or illustration." Any embodiment illustrated as "exemplary" is not necessarily to be construed as superior to or better than other embodiments. Although various aspects of the embodiments are shown in the accompanying drawings, the drawings are not necessarily drawn to scale unless specifically indicated otherwise.

[0047] In the description of the embodiments of this application, the technical terms "first", "second", "third", etc. are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly indicating the number, specific order or primary and secondary relationship of the indicated technical features.

[0048] In the description of the embodiments in this application, the technical term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects are in an "or" relationship.

[0049] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the technical terms "installation," "connection," "joining," "fixing," etc., should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can refer to a mechanical connection or an electrical connection; it can refer to a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0050] In the description of the embodiments of this application, the technical terms "upper", "lower", "inner", "outer", "front", "rear", "left", "right", "top", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship in the working state of the embodiments of this application. They are only used to facilitate the description of the embodiments of this application and to simplify the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0051] In the description of the embodiments of this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0052] In the description of the embodiments of this application, "parallel" includes not only the case of absolute parallelism, but also the case of approximate parallelism as commonly understood in engineering; at the same time, "perpendicular" also includes not only the case of absolute perpendicularity, but also the case of approximate perpendicularity as commonly understood in engineering.

[0053] In the description of the embodiments of this application, "multiple" means two or more (including two), unless otherwise explicitly specified.

[0054] In the description of the embodiments of this application, the same reference numerals denote the same components, and for the sake of brevity, detailed descriptions of the same components are omitted in different embodiments. It should be understood that the thickness, length, and other dimensions of various components in the embodiments of this application shown in the drawings, as well as the overall thickness, length, and other dimensions of the integrated device, are merely illustrative and should not constitute any limitation on this application.

[0055] In the fields of new materials and related industries, spheroidization and shaping of material particles is an important deep processing step. Compared with traditional external circulation spheroidization equipment, internal circulation spheroidization equipment can eliminate the ineffective circulation time of external material pipelines, effectively improving the overall spheroidization efficiency, and has now become the preferred development direction in the industry. Its working principle is as follows: After being classified, the material particles fall and are dispersed in all directions by the rotating grinding disc. The grinding blocks on the grinding disc impact the material particles, and the particles further collide with the toothed ring. Most particles enter the internal classification structure for circulation processing under the action of the rising airflow in the gap between the grinding disc and the toothed ring, while a small number of particles are repeatedly rubbed and impacted between the toothed ring and the grinding blocks. The toothed ring generates shear force with its wave angle, which works in conjunction with the grinding block units, so that the material particles are simultaneously subjected to shear force, impact force, and extrusion force, thereby trimming the surface edges of the particles and realizing the spheroidization and shaping of the material particles.

[0056] Currently, traditional material spheroidizing devices have achieved mature industrial application. In industrial production, the minimum particle size (D50) of materials that can be stably spheroidized is approximately 9-12 μm, with the lower limit of the process reaching only about 8 μm, which is also the current standard technology level in the industry. However, traditional material spheroidizing devices generally suffer from the problem of a single spheroidizing unit structure, making it impossible to adapt and optimize them according to the particle size, brittleness, and morphology requirements of the materials. This lack of equipment versatility also restricts the improvement of spheroidizing yield.

[0057] Meanwhile, the fixed and monotonous structure of traditional grinding blocks makes it difficult to adapt the impact and kneading intensity of material particles to ultra-fine particle size conditions. When processing particles smaller than 8μm, it easily causes excessive particle breakage and is insufficient in trimming and shaping the edges of fine particles, resulting in low pelletizing efficiency. When processing ultra-small particles of 4μm, the yield rate of traditional equipment drops significantly, easily leading to defects such as irregular particle morphology and substandard tap density. It has consistently failed to overcome the industry challenge of stable pelletizing of 4μm ultra-small particles and cannot meet the industrial production needs of ultra-fine particle size materials.

[0058] To address the aforementioned issues, embodiments of this application provide a spheroidizing device for preparing fine-particle-size spheroidized material products. The median particle size (D50) of the fine-particle-size spheroidized material products is 4.0–10 μm. The spheroidizing device includes a shell with a cavity. A grading component is provided in the upper part of the cavity, and a shaping component is provided in the lower part. The grading component separates the tail powder from the spheroidized material. The tail powder is discharged from the cavity, and the spheroidized material falls back to the shaping component. The shaping component includes a toothed ring and a rotatable grinding disc structure, with a gap formed between them. The rising airflow at the gap transports part of the tail powder and spheroidized material to the grading component. The grinding disc structure includes a grinding disc and a first grinding block disposed on its upper edge. The first grinding block has a concave arc surface on its windward side. The first grinding block extends radially along the grinding disc, and the rotation axis of the arc surface is parallel to the extension direction of the first grinding block. This curved surface allows material particles to undergo rolling grinding upon impact, extending contact time, improving the sufficiency of shaping, and also enhancing positive pressure airflow to partially offset the upward airflow, allowing the material to remain stably in the shaping area, improving the ability of fine particles to be sphericalized, and helping to prepare fine-sized spherical material products with the target particle size.

[0059] The technical solution provided in this application is adapted for the fine spheroidizing and shaping of ultrafine material particles with a D50 of 4.0-10μm. It is compatible with the processing of materials with different hardness, brittleness, and morphology requirements. With the complementary functions of multiple types of grinding blocks, it takes into account the edge trimming of hard particles, the gentle shaping of soft particles, and the forced curling of ultrafine particles into spheres. It is especially suitable for the shaping and modification of lithium battery artificial graphite and natural graphite anode powder. It can also cover the spheroidizing and refining production of high-purity graphite micro powder, fine chemical micro powder, new energy inorganic functional powder, and ultrafine powder for energy storage and electronic components. It can meet the preparation requirements of various high-end fine particle size powders for particle sphericity, surface morphology, and tap density.

[0060] refer to Figure 1 , Figure 1The spheroidizing system provided in some embodiments of this application is shown in the structural diagram. The spheroidizing system mainly consists of a spheroidizing device 100, a silo 200, a conveyor 300, a finished product silo 400, a tailings dust collector 500, and an induced draft fan 600. The spheroidizing device 100 is responsible for spheroidizing and shaping the raw materials, and simultaneously achieves the grading and separation of the finished product and tailings. The silo 200 stores the raw materials to be processed, and forms a material conveying path with the spheroidizing device 100 via the conveyor 300, stably conveying the raw materials to the spheroidizing device 100 for processing. The finished product silo 400 connects to the discharge end of the spheroidizing device 100 and is used to collect the qualified spheroidized finished products after shaping and grading. The tail powder dust collector 500 is connected to the tail powder discharge end of the spheroidizing device 100, and is responsible for collecting the fine tail powder generated during processing. The induced draft fan 600 is connected to the rear end of the tail powder dust collector 500, creating a negative pressure environment during operation. This allows the tail powder airflow dispersed within the spheroidizing device 100 to be drawn into the tail powder dust collector 500 for collection and purification. The tail powder dust collector 500 is also connected to the finished product silo 400 via a pipeline. Under the negative pressure of the induced draft fan 600, the fine tail powder carried into the finished product silo 400 by the finished product airflow is simultaneously drawn into the dust collector for collection. At the same time, the negative pressure airflow generated by the induced draft fan 600 also provides conveying power, assisting in the smooth transport of qualified finished products from the spheroidizing device 100 to the finished product silo 400. The entire system, with all its components working in tandem, can complete the entire process of raw material supply, spheroidizing and shaping, finished product collection, and tail powder dust collection and recovery.

[0061] The technical solutions of the embodiments of this application are described in detail below with reference to the accompanying drawings. The technical features involved in the different embodiments of this application described below can be combined with each other as long as they do not conflict with each other.

[0062] refer to Figures 2 to 7 , Figure 14 , Figure 2 This is a schematic diagram of the internal structure of a spheroidizing device provided according to some embodiments of this application (the arrows in the diagram indicate the flow direction of the rising airflow within the spheroidizing device). Figure 3 This is a three-dimensional structural schematic diagram of a shaping component provided according to some embodiments of this application; Figure 4 This is a top view of a shaping component provided according to some embodiments of this application; Figure 5 This is a three-dimensional structural schematic diagram of a first grinding block provided according to some embodiments of this application; Figure 6 This is a schematic front view of the first grinding block provided according to some embodiments of this application; Figure 7 This is a side view of a first grinding block provided according to some embodiments of this application; Figure 14 This is a three-dimensional structural diagram of a grinding disc provided according to some embodiments of this application.

[0063] In a first aspect, embodiments of this application provide a spheroidizing apparatus 100 for preparing fine-particle-size spheroidized material products, wherein the median particle size D50 of the fine-particle-size spheroidized material product is 4.0–10 μm. For example... Figures 2 to 5 As shown, the spheroidizing device 100 includes a housing 10 having a cavity 11, and a grading component 20 and a shaping component 30 disposed within the cavity 11. The grading component 20 is located above the shaping component 30 and is configured to separate tail powder and spheroidized material, guide the tail powder to the outside of the cavity 11, and guide the spheroidized material back to the shaping component 30. The shaping component 30 includes a gear ring 31 and a grinding disc structure 32 rotatable relative to the gear ring 31. The gear ring 31 surrounds the outer periphery of the grinding disc structure 32, and a gap 33 is formed between them. An upward airflow is provided at the gap 33, which is capable of purging at least part of the tail powder located at the gap 33. Powder and spheroidized materials are conveyed to the grading component 20; the grinding disc structure 32 includes a grinding disc 321 and grinding blocks, the grinding blocks being disposed along the axial direction of the grinding disc 321 at the upper edge of the grinding disc 321; the grinding blocks include a first grinding block 322, the first grinding block 322 having an arc surface 3221 disposed on one side of the grinding disc 321 in the circumferential direction; the first grinding block 322 rotates along a first direction under the drive of the grinding disc 321, so that the first grinding block 322 has a windward side, the arc surface 3221 being recessed on the windward side of the first grinding block 322; the first grinding block 322 extends radially along the grinding disc 321, and the rotation axis 3221a of the arc surface 3221 is parallel to the extension direction of the first grinding block 322.

[0064] During the rotation of the grinding disc structure 32, at least some of the spherical material can roll on the arc surface 3221.

[0065] In this embodiment, the tail powder can refer to very fine material particles, such as those with a diameter of less than 3 μm, which are difficult to shape into spheroids. The spheroidized material can refer to material particles that have already been spheroidized or those awaiting spheroidization, such as those with a diameter greater than or equal to 4 μm, which can be shaped into spheroids. The gap 33 can refer to the minimum clearance between the grinding disc structure 32 and the gear ring 31. The rising airflow can be a negative pressure airflow generated by the induced draft fan 600. The grinding disc 321 is generally a disc-shaped structure.

[0066] For example, such as Figure 2As shown, a specific structure of the grading component 20 can be: the grading component 20 includes a main frame 21 and a plurality of grids 22 arranged at intervals around the outer periphery of the main frame 21. Pores are formed between the grids 22, allowing smaller particles of tailing powder to pass through, but restricting larger spherical materials, for separating tailing powder and spherical materials. The main frame 21 of the grading component 20 can also be connected to a grading motor, causing the grading component 20 to rotate, thereby throwing the separated spherical materials to the outer periphery and allowing them to fall back to the shaping component 30. Simultaneously, it can also help the rising airflow carrying tailing powder to be discharged outside the cavity 11.

[0067] For example, such as Figure 2 As shown, in the shaping assembly 30, the gear ring 31 can be fixedly connected to the inner wall of the housing 10, and the grinding disc 321 in the grinding disc structure 32 can be drivenly connected to the shaping motor, so that the grinding disc structure 32 can rotate inside the gear ring 31, and there is no interference between the two during the rotation, and a gap 33 is always maintained.

[0068] Optionally, the value of gap 33 can be in the range of 4-6mm; for example, gap 33 can be 5mm.

[0069] Optionally, the grinding disc 321 can be coaxially arranged with the gear ring 31.

[0070] Alternatively, the grinding disc 321 may share the same axis of rotation with the grading assembly 20.

[0071] It should be noted that the grinding block is set on the upper edge of the grinding disk 321 along the axial direction of the grinding disk 321. The axial direction of the grinding disk 321 can be vertical, so the grinding disk 321 can be understood as being placed horizontally. The upper edge of the grinding disk 321 can be the edge position on the upper surface of the grinding disk 321 near its outer peripheral surface.

[0072] Optionally, such as Figure 4 As shown, the grinding block does not extend beyond the grinding disk 321 in the radial direction. Further optionally, the edge of the grinding block is flush with the outer periphery of the grinding disk 321 in the radial direction.

[0073] Optionally, such as Figure 14 As shown, a first positioning groove 3211 is provided at the upper edge of the grinding disc 321, and the bottom end of the first grinding block 322 can be embedded in the first positioning groove 3211 to realize the positioning and assembly of the first grinding block 322 and the grinding disc 321.

[0074] Optionally, the first grinding block 322 can be divided into an arc-shaped structural part and a connecting part, which can be fixedly connected or integrally manufactured. The arc-shaped structural part has an arc surface 3221 on one side and a connecting part on the other side. The connecting part can be fixedly connected to the grinding disc 321 by a bolt assembly.

[0075] Optionally, there may be multiple first grinding blocks 322, and the multiple first grinding blocks 322 may be distributed at intervals along the circumference of the grinding disk 321. Further optionally, the multiple first grinding blocks 322 may be arranged at equal intervals along the circumference of the grinding disk 321.

[0076] In this embodiment, as Figures 4 to 7 As shown, the first grinding block 322 rotates along the first direction under the drive of the grinding disc 321, so that the first grinding block 322 has a windward side, and the arc surface 3221 is recessed on the windward side of the first grinding block 322.

[0077] The grinding disc 321 can rotate in either the forward or reverse direction around its central axis; the first direction can be understood as one of these directions. It should be noted that during the spheroidizing process, the grinding disc 321 can always rotate in one direction, namely the first direction.

[0078] It is understandable that the first grinding block 322 has two opposing sides on the circumference of the grinding disc 321, one being the windward side and the other the leeward side. Taking the circumferential rotation direction (first direction) of the grinding disc 321 around its own central axis as a reference, as the first grinding block 322 rotates with the grinding disc 321, the windward side can first meet the material particles and airflow, and make collision contact with the material first, compared to the leeward side.

[0079] In this embodiment, as Figures 5 to 7 As shown, the first grinding block 322 extends radially along the grinding disk 321, and the rotation axis 3221a of the arc surface 3221 is parallel to the extension direction of the first grinding block 322.

[0080] It is understandable that the grinding disc 321 has multiple radial directions, and the first grinding block 322 extending radially along the grinding disc 321 can be understood as one first grinding block 322 extending only along one radial direction of the grinding disc 321. The extending direction of the first grinding block 322 is the same as its length direction.

[0081] In the above technical solution, the first grinding block 322 in the grinding disc structure 32 adopts an arc surface 3221 design, which allows the first grinding block 322 to not only impact the material particles, but also guide the material particles to roll and grind on the arc surface 3221, prolonging the contact time between the material and the first grinding block 322 and improving the fullness of shaping. In particular, relying on the smooth transition and stroke adaptation design of the arc surface 3221, the forced curling and rolling shaping effect of fine-diameter material particles can be enhanced, and the fine edges and corners of the particle surface can be precisely trimmed. This can reduce the excessive crushing of fine-diameter material particles due to strong impact, and continuously optimize the sphericity and tap density, achieving stable sphericification of 4μm ultra-small particles that traditional equipment cannot achieve. Meanwhile, the arc surface 3221 structure can enhance the positive pressure wind generated by the rotation of the grinding disc 321, which can offset the rising airflow (negative pressure wind) in the system to a certain extent, so that the fine-diameter material particles can remain more stably in the shaping area and fully contact the arc surface 3221 of the first grinding block 322, thereby improving the ability to shape and spheroidize fine-diameter material particles, which helps to prepare fine-diameter spheroidized material products with a median particle size D50 of 4.0–10 μm.

[0082] Furthermore, by placing the arc surface 3221 on the windward side of the first grinding block 322, the material particles that enter the working area with the rotation of the grinding disc 321 can preferentially contact the structure of the arc surface 3221. Relying on the advantages of the material contact probability and action intensity on the windward side, the receiving and guiding effect of the arc surface 3221 on the material particles can be improved, so that the material particles can be rolled and ground more smoothly along the arc surface 3221, and the effective shaping contact time can be extended.

[0083] Meanwhile, the arc surface 3221 on the windward side can follow the airflow direction generated by the rotation of the grinding disc 321, optimize the local flow field distribution, enhance the effect of positive pressure wind, and make fine-diameter material particles stay more stably in the shaping area and fully interact with the arc surface 3221, thereby strengthening the ability to shape and spheroidize fine-diameter material particles, which is conducive to obtaining fine-diameter spheroidized material products with regular morphology.

[0084] Furthermore, such as Figures 5 to 7 As shown, the dimension L1 of the arc surface 3221 in the extension direction of the first grinding block 322 satisfies: 90mm≤L1≤110mm; the central angle θ of the arc surface 3221 satisfies: 90°≤θ≤120°; the radius r of the arc surface 3221 satisfies: 20mm≤r≤30mm.

[0085] In this embodiment, the value of L1 can be 90mm, 95mm, 100mm, 105mm, 110mm, etc. The value of θ can be 90°, 95°, 100°, 105°, 110°, 115°, 120°, etc. The value of r can be 20mm, 21mm, 22mm, 23mm, 24mm, 25mm, 26mm, 27mm, 28mm, 29mm, 30mm, etc.

[0086] For example, a specific parameter of the arc surface 3221 in the first grinding block 322 may be: L1 is 100mm, θ is 105°, and r is 25mm.

[0087] It should be noted that by coordinating the layout position and related parameters of the arc surface 3221, the arc surface 3221 can form a rolling space and working stroke that are suitable for the shaping requirements of fine-diameter material particles during rotation. The reasonable size and curvature of the arc surface 3221 can stably support the material particles and maintain smooth rolling grinding, extend the effective working time of the material particles and the grinding block, and improve the uniformity of impact and kneading.

[0088] Meanwhile, this structural design can also optimize the rotating flow field and positive pressure distribution, improve the residence stability and contact sufficiency of fine-diameter material particles in the shaping area, thereby improving the spheroidization effect of fine-diameter material particles and helping to obtain fine-diameter spheroidized material products with regular morphology and high sphericity.

[0089] refer to Figure 3 , Figure 4 , Figure 8 and Figure 14 , Figure 8 This is a three-dimensional structural diagram of a second grinding block provided according to some embodiments of this application.

[0090] In some embodiments, such as Figure 3 , Figure 4 and Figure 8 As shown, the grinding block also includes a second grinding block 323, which has a rectangular structure. The second grinding block 323 extends radially along the grinding disk 321, and the second grinding block 323 and the first grinding block 322 are spaced apart circumferentially along the grinding disk 321. The second grinding block 323 rotates along a first direction under the drive of the grinding disk 321, so that the second grinding block 323 has a windward side, which is a plane.

[0091] It is understandable that the grinding disc 321 has multiple radial directions, and the second grinding block 323 extending radially along the grinding disc 321 can be understood as each second grinding block 323 extending only along one radial direction of the grinding disc 321. The extending direction of the second grinding block 323 is its length direction. It should be noted that the second grinding block 323 and the first grinding block 322 are located on different radial directions of the grinding disc 321, thus allowing the second grinding block 323 and the first grinding block 322 to be spaced apart circumferentially along the grinding disc 321.

[0092] It should also be understood that the second grinding block 323 has two opposing sides arranged circumferentially on the grinding disc 321, one being the windward side and the other the leeward side. Taking the circumferential rotation direction (first direction) of the grinding disc 321 around its central axis as a reference, during the rotation of the second grinding block 323 with the grinding disc 321, the windward side, compared to the leeward side, can first encounter the material particles and airflow, and thus first make impact contact with the material. It should be noted that, based on the rectangular structure of the second grinding block 323, both the windward and leeward sides are rectangular planes.

[0093] For example, such as Figure 8 As shown, the second grinding block 323 has a rectangular structure, specifically a cuboid structure, and its specific parameters can be: the length of the second grinding block 323 can be 100mm, the width can be 40mm, and the height can be 40mm.

[0094] Optionally, such as Figure 14 As shown, a second positioning groove 3212 is provided at the upper edge of the grinding disc 321, and the bottom end of the second grinding block 323 can be embedded in the second positioning groove 3212 to realize the positioning and assembly of the second grinding block 323 and the grinding disc 321.

[0095] Optionally, the second grinding block 323 can be fixedly connected to the grinding disc 321 by a bolt assembly.

[0096] Optionally, there may be multiple second grinding blocks 323, and the multiple second grinding blocks 323 may be distributed at intervals along the circumference of the grinding disk 321. More optionally, the multiple second grinding blocks 323 may be arranged at equal intervals along the circumference of the grinding disk 321.

[0097] Optionally, there may be multiple first grinding blocks 322 and multiple second grinding blocks 323, and the number of the two may be the same or different. The multiple first grinding blocks 322 and the multiple second grinding blocks 323 may be arranged at equal intervals along the circumference of the grinding disc 321.

[0098] It should be noted that the second grinding block 323 adopts a rectangular structure and its windward side is a flat surface, which can adapt to the spheroidization treatment requirements of materials with high hardness. After the material particles impact the windward side flat surface of the second grinding block 323, they can be effectively squeezed and ground, which is beneficial to remove the protruding edges on the particle surface.

[0099] Meanwhile, the second grinding block 323 and the first grinding block 322 arranged at intervals along the circumference cooperate with each other to form a composite action mechanism that combines impact, extrusion and rolling friction in the shaping area. This takes into account both the trimming of the edges of hard particles and the gentle shaping of fine particles, improving the uniformity and integrity of the overall spheroidization process, and thus helping to obtain fine-particle-size spheroidized material products with regular morphology.

[0100] refer to Figure 3 , Figure 4 , Figures 9 to 11 as well as Figure 14 , Figure 9 This is a three-dimensional structural schematic diagram of a third grinding block provided according to some embodiments of this application; Figure 10 This is a schematic front view of the third grinding block provided according to some embodiments of this application; Figure 11 This is a side view of a third grinding block provided according to some embodiments of this application.

[0101] In some embodiments, such as Figure 3 , Figure 4 , Figures 9 to 11 As shown, the grinding block also includes a third grinding block 324; the third grinding block 324 is arranged to extend radially along the grinding disk 321, and the third grinding block 324 and the first grinding block 322 are spaced apart along the circumferential direction of the grinding disk 321; an inclined surface 3241 is formed between one side surface of the third grinding block 324 along the circumferential direction of the grinding disk 321 and the top surface of the third grinding block 324.

[0102] During the rotation of the grinding disc structure 32, at least some of the spherical material can roll on the inclined surface 3241.

[0103] It is understandable that the grinding disc 321 has multiple radial directions, and the third grinding block 324 extending radially along the grinding disc 321 can be understood as each third grinding block 324 extending only along one radial direction of the grinding disc 321. The extension direction of the third grinding block 324 is its length direction. It should be noted that the third grinding block 324 and the first grinding block 322 are located on different radial directions of the grinding disc 321, thus allowing the third grinding block 324 and the first grinding block 322 to be spaced apart circumferentially along the grinding disc 321.

[0104] Optionally, such as Figure 14As shown, a third positioning groove 3213 is provided at the upper edge of the grinding disc 321, and the bottom end of the third grinding block 324 can be embedded in the third positioning groove 3213 to realize the positioning and assembly of the third grinding block 324 and the grinding disc 321.

[0105] Optionally, the third grinding block 324 can be fixedly connected to the grinding disc 321 by a bolt assembly.

[0106] Optionally, there may be multiple third grinding blocks 324, and the multiple third grinding blocks 324 may be distributed at intervals along the circumference of the grinding disk 321. Further optionally, the multiple third grinding blocks 324 may be arranged at equal intervals along the circumference of the grinding disk 321.

[0107] Optionally, there may be multiple first grinding blocks 322 and multiple third grinding blocks 324, and the number of the two may be the same or different. The multiple first grinding blocks 322 and the multiple third grinding blocks 324 may be arranged at equal intervals along the circumference of the grinding disc 321.

[0108] It should be noted that the third grinding block 324 extends radially along the grinding disc 321 and is circumferentially spaced from the first grinding block 322. An inclined surface 3241 is formed between its circumferential side plane and top surface, which can be adapted to the spheroidization treatment of material particles with slightly lower hardness. This structure combines the dual functions of the first grinding block 322 and the second grinding block 323. When the material particles impact the circumferential side plane of the third grinding block 324, they can be squeezed and ground to trim the protruding edges on the surface of the material particles. At the same time, after the material particles impact the inclined surface 3241, they can achieve a certain degree of rolling grinding on the inclined surface 3241 to further trim the small edges on the material particles, forming a dual effect of planar impact trimming and rolling grinding on the inclined surface 3241.

[0109] In addition, the third grinding block 324 works in conjunction with the first grinding block 322 to improve the fineness and comprehensiveness of the material particle shaping process, optimize the spheroidization effect of the material particles, and help to obtain fine-diameter spheroidized material products with regular morphology.

[0110] Furthermore, such as Figure 4 As shown, the third grinding block 324 rotates along the first direction under the drive of the grinding disc 321, so that the third grinding block 324 has a windward side; wherein, the inclined surface 3241 is disposed between the windward side surface of the third grinding block 324 and the top surface of the third grinding block 324.

[0111] It is understandable that the third grinding block 324 has two opposing sides on the circumference of the grinding disc 321, one being the windward side and the other the leeward side. Taking the circumferential rotation direction (first direction) of the grinding disc 321 around its own central axis as a reference, as the third grinding block 324 rotates with the grinding disc 321, the windward side can first meet the material particles and airflow, and make collision contact with the material first, compared to the leeward side.

[0112] It should be noted that by setting the inclined surface 3241 between the windward side surface and the top surface of the third grinding block 324, the material particles can first reach the windward side surface when they enter the shaping area as the grinding disc 321 rotates, and can smoothly enter the inclined surface 3241 along the windward side surface, which can improve the contact probability and timeliness of the inclined surface 3241 with the material particles.

[0113] In this process, the material particles can smoothly roll and grind on the windward inclined surface 3241, which is beneficial for the continuous and uniform trimming of the fine edges of the material particles. At the same time, the inclined surface 3241 is in line with the rotation direction of the grinding disc 321 and the airflow direction, which can stabilize the local flow field and prolong the material particle shaping residence time, thus enhancing the dual effect of rolling shaping and edge trimming.

[0114] Furthermore, such as Figures 9 to 11 As shown, in the axial direction of the grinding disc 321, the dimension L2 of the third grinding block 324 satisfies: 30mm≤L2≤50mm; in the axial direction of the grinding disc 321, the dimension L21 of the inclined surface 3241 and the dimension L22 of the windward side surface of the third grinding block 324 satisfy: 0.12≤L21 / L22≤0.2; the included angle α between the inclined surface 3241 and the windward side surface of the third grinding block 324 satisfies: 30°≤α≤60°; in the extending direction of the third grinding block 324, the dimension L3 of the inclined surface 3241 satisfies: 90mm≤L3≤110mm.

[0115] It is understandable that L2 is the axial dimension of the third grinding block 324 on the grinding disc 321, and can be regarded as the height dimension of the third grinding block 324. Similarly, L21 and L22 can be regarded as the height dimension of the inclined surface 3241 and the height dimension of the windward side surface of the third grinding block 324 (excluding the part of the inclined surface 3241), respectively. Among them, L2 is the sum of L21 and L22.

[0116] In this embodiment, the value of L2 can be 30mm, 35mm, 40mm, 45mm, 50mm, etc. The values ​​of L21 / L22 can be 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, etc. The value of α can be 30°, 35°, 40°, 45°, 50°, 55°, 60°, etc. The value of L3 can be 90mm, 95mm, 100mm, 105mm, 110mm, etc.

[0117] For example, a specific parameter of the third grinding block 324 may be: L2 is 40mm, L21 / L22 is 0.14, α is 45°, and L3 is 100mm.

[0118] It should be noted that by limiting the dimension L2 of the third grinding block 324 in the axial direction of the grinding disc 321 to 30mm≤L2≤50mm, and controlling the ratio of the height L21 of the inclined surface 3241 to the height L22 of the windward side surface to 0.12≤L21 / L22≤0.2, while limiting the included angle α between the inclined surface 3241 and the windward side surface to 30°≤α≤60°, and limiting the dimension L3 of the inclined surface 3241 in the extension direction of the third grinding block 324 to 9mm, the following parameters are defined: With L3 ≤ 110 mm, the height ratio and inclination of the inclined plane 3241 can be reasonably determined to form a shaping working surface with appropriate size and inclination angle. The reasonable L21 / L22 ratio can balance the impact and rolling residence time of the material particles, so that the material particles can obtain appropriate rolling grinding on the inclined plane 3241. The reasonable setting of the included angle α can improve the smoothness of the movement of the material particles on the inclined plane 3241 and the shaping force, thereby improving the effect of stable trimming of small edges.

[0119] In addition, the above parameters work together to improve the plasticity of the third grinding block 324 to slightly softer material particles, enhance the edge trimming and spherical rolling effect, and thus help to obtain fine-particle-size spherical material products with more regular morphology.

[0120] refer to Figure 3 , Figure 4 , Figures 12 to 14 , Figure 12 This is a three-dimensional structural schematic diagram of a fourth grinding block provided according to some embodiments of this application; Figure 13 This is a top view of a fourth grinding block provided according to some embodiments of this application.

[0121] In some embodiments, such as Figure 3 , Figure 4 , Figure 12 , Figure 13 As shown, the grinding block also includes a fourth grinding block 325; the fourth grinding block 325 is arranged to extend radially along the grinding disk 321, and the fourth grinding block 325 and the first grinding block 322 are arranged circumferentially apart along the grinding disk 321; the fourth grinding block 325 is provided with a concave-convex surface on the side facing the gear ring 31.

[0122] During the rotation of the grinding disc structure 32, at least some of the spherical material can move between the concave and convex surfaces and the gear ring 31.

[0123] It is understandable that the grinding disc 321 has multiple radial directions, and the fourth grinding block 325 extending radially along the grinding disc 321 can be understood as each fourth grinding block 325 extending only along one radial direction of the grinding disc 321. The extending direction of the fourth grinding block 325 is its length direction. It should be noted that the fourth grinding block 325 and the first grinding block 322 are located on different radial directions of the grinding disc 321, thus allowing the fourth grinding block 325 and the first grinding block 322 to be spaced apart circumferentially along the grinding disc 321.

[0124] Optionally, such as Figure 14 As shown, a fourth positioning groove 3214 is provided at the upper edge of the grinding disc 321, and the bottom end of the fourth grinding block 325 can be embedded in the fourth positioning groove 3214 to realize the positioning and assembly of the fourth grinding block 325 and the grinding disc 321.

[0125] Optionally, the fourth grinding block 325 can be fixedly connected to the grinding disc 321 by a bolt assembly.

[0126] Optionally, there may be multiple fourth grinding blocks 325, and the multiple fourth grinding blocks 325 may be distributed at intervals along the circumference of the grinding disk 321. More optionally, the multiple fourth grinding blocks 325 may be arranged at equal intervals along the circumference of the grinding disk 321.

[0127] Optionally, there may be multiple first grinding blocks 322 and multiple fourth grinding blocks 325, and the number of both may be the same or different. The multiple first grinding blocks 322 and multiple fourth grinding blocks 325 may be arranged at equal intervals along the circumference of the grinding disc 321.

[0128] Optionally, the fourth grinding block 325 is generally a cuboid structure. For example, the length of the fourth grinding block 325 can be 100 mm, the width can be 40 mm, and the height can be 40 mm. In this way, the fourth grinding block 325 can have a strong spheroidizing and shaping capability similar to that of the second grinding block 323.

[0129] It should be noted that the industry's conventional process typically involves crushing followed by spheroidization. After the material is crushed to a suitable particle size range, it is then fed into the spheroidizing device 100 for shaping and modification. In actual production, due to multiple factors such as the operating conditions of the crushing equipment, the matching of process parameters, and the differences in the physical properties of the raw materials, materials that do not meet the crushing requirements are often directly fed into the spheroidizing device 100 as raw materials. These raw materials, which are not sufficiently crushed, have uneven particle size distribution, and contain a large number of large particle agglomerates, are difficult to effectively impact, knead, and shape under the action of the grinding blocks and the toothed ring 31 after entering the spheroidizing device 100. The particles cannot establish a stable state of motion and force, making it difficult to achieve the ideal spheroidizing process conditions. This easily leads to problems such as insufficient shaping, poor sphericity, and uneven particle size, which is not conducive to the stable production of subsequent fine-particle-size qualified finished products.

[0130] To address this issue, this embodiment employs a fourth grinding block 325. Specifically, the fourth grinding block 325 has a concave-convex surface design on the side facing the gear ring 31. This design can disturb the material particles during the rotation of the grinding disc 321, causing them to form more complex and diverse motion trajectories between the concave-convex surface and the gear ring 31. This enhances the impact, compression, and kneading forces on the material particles, resulting in a certain pulverizing effect and adapting to the simultaneous pulverization and balling processing requirements of specific materials.

[0131] In addition, the fourth grinding block 325 and the first grinding block 322 work together to achieve a synergistic effect of strong shaping, complex trajectory motion and gentle rolling shaping, which improves the uniformity and regularity of the spheroidization of material particles and is conducive to obtaining fine-particle-size spheroidized material products with regular morphology.

[0132] Furthermore, such as Figure 3 , Figure 4 , Figure 12 and Figure 13 As shown, the fourth grinding block 325 has multiple tooth structures 3251 on the side facing the gear ring 31; the multiple tooth structures 3251 are distributed circumferentially along the grinding disk 321, and the surface of the multiple tooth structures 3251 facing the gear ring 31 is a serrated surface to form a concave-convex surface.

[0133] It should be noted that the fourth grinding block 325 has multiple tooth structures 3251 distributed circumferentially along the grinding disc 321 on the side facing the tooth ring 31, and the toothed surface forms a concave-convex surface. This can greatly increase the disturbance and action intensity on the material particles during rotation, so that the material particles form a more complex and varied motion trajectory between the tooth structure 3251 and the tooth ring 31, and extend the impact, compression and kneading path of the material particles.

[0134] Meanwhile, the serrated surface can provide a multi-point, multi-directional force interface for material particles, enhance the impact and grinding effect on the material particles, improve the crushing and shaping efficiency of material particles, and adapt to the processing of specific materials that require strong force.

[0135] Furthermore, such as Figure 4 , Figure 12 and Figure 13 As shown, the tooth surface of the tooth structure 3251 facing the tooth ring 31 includes a tooth face 3251a; the fourth grinding block 325 rotates along the first direction under the drive of the grinding disc 321, so that the fourth grinding block 325 has a windward side; wherein, the minimum included angle between the tooth face 3251a and the windward side surface of the fourth grinding block 325 is an acute angle, and one tooth face 3251a is in contact with the windward side surface of the fourth grinding block 325.

[0136] It is understood that the tooth surface of the tooth structure 3251 facing the tooth ring 31 includes a front tooth 3251a and a back tooth. Among them, taking the circumferential rotation direction (first direction) of the grinding disc 321 around its own central axis as a reference, during the rotation of the fourth grinding block 325 with the grinding disc 321, the front tooth 3251a can first meet the material particles and airflow, and make collision contact with the material first, compared to the back tooth.

[0137] Optionally, the windward side surface, tooth front surface 3251a, and tooth back surface of the fourth grinding block 325 are all flat, and the tooth back surface can be set parallel to the windward side surface of the fourth grinding block 325.

[0138] It should be noted that the tooth face 3251a of the tooth structure 3251 is in contact with the windward side surface of the fourth grinding block 325, and the two form an acute angle arrangement. When the grinding disc 321 drives the fourth grinding block 325 to rotate, the windward side can preferentially receive material particles, and the material particles can conform to the tooth face 3251a to form orderly contact and movement. The acute angle configuration can increase the contact area between the material particles and the tooth face 3251a, enhance the impact, grinding and kneading force, and at the same time facilitate the guidance of material particles to form multi-directional movement between the tooth structures 3251, enriching the force form and movement path of the material particles. This structural layout can enhance the edge trimming and moderate cracking and shaping effect of material particles, complement the function of other types of grinding blocks, and synergistically improve the overall spheroidization and shaping quality, helping to produce fine-particle-size spheroidized material products with regular morphology.

[0139] Furthermore, such as Figure 13 As shown, the tooth groove angle β between two adjacent tooth structures 3251 satisfies: 30°≤β≤60°; in the extension direction of the fourth grinding block 325, the dimension L4 of the tooth structure 3251 satisfies: 10mm≤L4≤30mm.

[0140] In this embodiment, the value of β can be 30°, 35°, 40°, 45°, 50°, 55°, 60°, etc. The value of L4 can be 10mm, 15mm, 20mm, 25mm, 30mm, etc.

[0141] For example, a specific parameter of the tooth structure 3251 in the fourth grinding block 325 may be: β is 45° and L4 is 20mm.

[0142] It should be noted that by limiting the tooth groove angle β between two adjacent tooth structures 3251 to 30°≤β≤60°, and limiting the dimension L4 of the tooth structure 3251 in the extension direction of the fourth grinding block 325 to 10mm≤L4≤30mm, the parameters of the tooth structure 3251 and the tooth groove are matched in a coordinated manner. A reasonable tooth groove angle β can provide a suitable space for material particles to be accommodated, which can not only allow material particles to enter the tooth groove smoothly to achieve multi-directional force, but also reduce the situation where the force is insufficient due to the tooth groove being too wide or the material particles are stuck due to the tooth groove being too narrow, thus improving the uniformity of impact and grinding; a suitable dimension L4 can balance the structural strength of the tooth structure 3251 and the material action range, ensuring that the tooth structure 3251 can form a stable impact and kneading on the material during rotation, while providing a reasonable stroke for the complex movement of the material between the tooth ring 31 and the fourth grinding block 325.

[0143] Furthermore, the reasonable limitation of the above parameters can enhance the synergistic effect of crushing and shaping of the fourth grinding block 325, adapt to the processing requirements of specific materials, and work together with the first grinding block 322 and other grinding blocks to further improve the stability and reliability of spheroidizing and shaping, and help obtain fine-particle-size spheroidized material products with regular morphology.

[0144] refer to Figures 2 to 4 , Figure 15 , Figure 15 This is an exploded structural diagram of a gear ring provided according to some embodiments of this application.

[0145] In some embodiments, such as Figure 15 As shown, the toothed ring 31 includes an annular body 311 and a mounting sleeve 312; a ring of teeth is provided on the inner side of the annular body 311, and the mounting sleeve 312 is detachably fitted on the outer side of the annular body 311. The annular body 311 and the mounting sleeve 312 are fixed together to the lower part of the inner wall of the housing 10.

[0146] Optionally, an annular plate is formed on the inner edge of the lower end of the mounting sleeve 312. The annular plate can be used to support the annular body 311 inserted into the mounting sleeve 312 and can realize the positioning and assembly of the mounting sleeve 312 and the annular body 311.

[0147] Optionally, the mounting sleeve 312 and the annular body 311 can be fixed to the lower part of the inner wall of the housing 10 by a bolt assembly.

[0148] It should be noted that the gear ring 31 adopts a split structure of annular body 311 and mounting sleeve 312, which improves the adaptability of the gear ring 31. Since the mounting sleeve 312 and annular body 311 are detachably connected, when it is necessary to adapt to different specifications of equipment, different particle sizes of materials, or different shaping requirements, it is not necessary to replace the entire gear ring 31; only the mounting sleeve 312 of the corresponding specification needs to be replaced. This reduces equipment maintenance costs and improves the versatility of the gear ring 31.

[0149] Meanwhile, the coordinated fixing of the annular body 311 and the mounting sleeve 312 can improve the stability of the gear ring 31 during equipment operation, enhance its cooperation with grinding blocks and material particles, and thus help improve the spheroidizing quality, adapt to the spheroidizing requirements in different scenarios, and enable the gear ring 31 to flexibly adapt to various production conditions.

[0150] In some embodiments, such as Figure 3 As shown, in the axial direction of the gear ring 31, the size of the gear ring 31 is larger than the size of the grinding disc structure 32, and neither end of the grinding disc structure 32 extends beyond the gear ring 31.

[0151] It should be noted that the overall dimension of the gear ring 31 in the axial direction is larger than that of the grinding disc structure 32, and both the upper and lower ends of the grinding disc structure 32 are within the coverage area of ​​the gear ring 31. This layout allows the outer periphery of the grinding disc structure 32 to always be within the enclosure and limit of the gear ring 31 when the grinding disc structure 32 rotates, which can stably maintain the annular gap 33 between the grinding disc structure 32 and the gear ring 31, so that the airflow, tail powder and spherical material can flow and circulate in an orderly manner within the gap 33.

[0152] At the same time, the material particles can be impacted, kneaded and rolled in the mating area of ​​the toothed ring 31 and the grinding disc structure 32 throughout the process, which regulates the range of material movement, improves the uniformity of contact between the material and the grinding block and the toothed ring 31, and helps to steadily improve the spherical morphology of the particles, which is suitable for the spheroidization preparation requirements of fine-particle materials.

[0153] In some embodiments, the toothed ring 31 has a ring of teeth on the side facing the grinding disc structure 32, and the ring of teeth is helical.

[0154] It should be noted that a ring of helical teeth is provided on the side of the toothed ring 31 facing the grinding disc structure 32. When the grinding disc structure 32 drives the material particles to rotate, the inclined configuration of the helical teeth can be used to change the direction of movement of the material particles, so that the material forms a more complex spiral motion trajectory between the toothed ring 31 and the grinding block, prolonging the residence time of the material in the shaping area and increasing the frequency and effectiveness of contact between the material particles and the toothed ring 31 and the grinding block.

[0155] Meanwhile, the helical teeth can guide and exert force on the material particles in multiple directions, which can not only enhance the impact and grinding effect on the material particles, but also help guide the material particles to circulate in an orderly manner, optimize the flow field distribution in the shaping area, further improve the uniformity and regularity of the material particles into spheres, and help prepare fine-particle-size spherical material products.

[0156] refer to Figure 2 , Figure 16 and Figure 17 , Figure 16 This is a three-dimensional structural schematic diagram of a flow guide ring provided according to some embodiments of this application; Figure 17 This is a three-dimensional structural schematic diagram of a spheroidizing device provided according to some embodiments of this application.

[0157] In some embodiments, such as Figure 2 and Figure 16 As shown, the cavity 11 is divided into a grading cavity 111, a circulation cavity 112, and a shaping cavity 113 from top to bottom. A grading component 20 and a shaping component 30 are respectively installed in the grading cavity 111 and the shaping cavity 113. A guide ring 40 is installed in the circulation cavity 112. The guide ring 40 has a conical structure that is larger at the top and smaller at the bottom. A guide port 41 is provided between the upper edge of the guide ring 40 and the cavity wall of the circulation cavity 112 to guide the rising airflow carrying tail powder and spherical material to the grading component 20. The inner wall of the guide ring 40 is used to guide the spherical material separated by the grading component 20 back to the shaping component 30.

[0158] Optionally, such as Figure 16 As shown, there are multiple guide ports 41, and these multiple guide ports 41 are distributed at intervals along the circumference of the guide ring 40. It should be noted that the number and location of the guide ports 41 should enable the guide ports 41 to have a guiding function. Specifically, this guiding function is to guide the rising airflow (carrying tail powder and spherical material) from the shaping component 30 to the classifying component 20. After being classified and separated by the classifying component 20, the airflow is then discharged from the tail powder discharge port 12 to the outside of the cavity 11.

[0159] It should be noted that the cavity 11 is divided into a layered design from top to bottom, consisting of a grading cavity 111, a circulation cavity 112, and a shaping cavity 113. Combined with the corresponding arrangement of the grading component 20 and the shaping component 30, the orderly division of labor in the spheroidization process is realized, ensuring efficient connection between each stage.

[0160] Furthermore, the conical guide ring 40, which is wider at the top and narrower at the bottom, installed inside the circulation chamber 112, can guide the rising airflow carrying tail powder and spheroidized material to the classifying component 20 through the guide port 41 between the upper edge and the wall of the circulation chamber 112, thus achieving effective separation of tail powder and spheroidized material. On the other hand, the inner wall of the guide ring 40 can guide the spheroidized material separated by the classifying component 20 to fall smoothly back to the shaping component 30, ensuring the continuous operation of the shaping process. This structural design allows the airflow and material to form an orderly circulation, improving spheroidization efficiency and finished product quality, while achieving effective separation of tail powder, making the entire spheroidization process more organized and stable.

[0161] Furthermore, such as Figure 2 and Figure 17As shown, the grading chamber 111 has a tail powder outlet 12 on its wall for discharging tail powder; the circulation chamber 112 has a feed inlet 13 on its wall for filling the chamber 11 with raw materials; the shaping chamber 113 has a discharge outlet 14 on its wall, located above the shaping component 30, for discharging fine-particle-size spherical material; an air inlet chamber 50 is provided below the shaping chamber 113, which is connected to the shaping chamber 113 through a gap 33, and an air inlet 51 is provided on the wall of the air inlet chamber 50 for providing upward airflow.

[0162] Understandably, the tail powder discharge port 12, feed port 13, discharge port 14, and air inlet 51 all have independent opening and closing adjustment functions, allowing for individual control of their on / off states and opening degrees. Specifically, the tail powder discharge port 12 can be connected to a tail powder dust collector 500, the feed port 13 is connected to the storage silo 200 via a conveyor 300, and the discharge port 14 connects to the finished product silo 400. Relying on power equipment such as the conveyor 300 and the induced draft fan 600, and with the flexible adjustment of the opening and closing states and amplitudes of each port, the system can precisely match the internal airflow field and material flow state, orderly completing the entire process of continuous raw material replenishment, intracavitary material circulation and spheroidization shaping, as well as the collection of fine tail powder and the collection of qualified finished products. This makes the entire spheroidization production process more flexible in control and more adaptable to different operating conditions.

[0163] It should be noted that a tail powder outlet 12 is provided on the wall of the grading chamber 111 to discharge the separated tail powder in a timely manner, reducing the accumulation of tail powder and affecting the spheroidizing process, and ensuring the smooth progress of the grading and spheroidizing process; the feed inlet 13 on the wall of the circulation chamber 112 provides a convenient channel for raw material filling, and can continuously replenish raw materials for the spheroidizing process to ensure the continuity of production; the discharge outlet 14 on the wall of the shaping chamber 113 is located above the shaping component 30, and can discharge qualified fine-particle-size spheroidized material products in a timely manner after the material has completed spheroidizing and shaping, thereby improving production efficiency; the air inlet chamber 50 below the shaping chamber 113 is connected to the shaping chamber 113 through the gap 33, and the wall of the air inlet chamber 50 is provided with an air inlet 51, which can continuously provide a stable upward airflow, and can provide power support for material circulation and shaping.

[0164] In addition, the rational layout of each opening and chamber enables the orderly connection of raw material filling, tail powder discharge, finished product discharge, and airflow supply, forming a closed loop in the entire spheroidization process, improving the continuity and efficiency of production, and helping to obtain fine-particle-size spheroidized material products that meet the requirements.

[0165] Furthermore, such as Figure 2 As shown, the portion of the shaping cavity 113 located above the shaping component 30 is a variable diameter cavity, and the diameter of the variable diameter cavity increases from bottom to top.

[0166] It should be noted that the variable diameter cavity above the shaping cavity 113 has an increasing diameter design that can adapt to the working range of the shaping component 30, allowing the airflow to flow more smoothly upwards. This helps the material particles to form an orderly circulation within the shaping cavity 113, facilitating full contact between the material particles and the grinding block and improving the uniformity of the shaping. At the same time, the increasing cavity diameter reduces the resistance during the upward airflow process, making the upward airflow more stable. This not only helps to smoothly transport the material particles to the grading area, but also provides more space for the rolling and collision of the material particles, reducing the local accumulation of material particles.

[0167] In addition, the variable diameter structure can work with the air intake system to optimize the airflow distribution in the shaping cavity 113, so that the material particles are subjected to more uniform force during the shaping process, further improving the spheroidizing effect and helping to produce qualified spheroidized materials with regular shape. At the same time, it can also help connect the grading and shaping process to ensure the smooth and efficient operation of the entire spheroidizing process.

[0168] Secondly, refer to Figures 2 to 4 The embodiments of this application also provide a spheroidizing device 100 for preparing fine-particle-size spheroidized material with a median particle size D50 of 4.0-10 μm. The spheroidizing device 100 includes a first grinding block 322, a second grinding block 323, a third grinding block 324, and a fourth grinding block 325. The windward side of the first grinding block 322 is provided with an arc surface 3221; the windward side of the second grinding block 323 is flat and has a rectangular structure; an inclined surface 3241 is formed between the windward side and the top surface of the third grinding block 324; and the fourth grinding block 325 is provided with a concave-convex surface on the side facing the gear ring 31. The first grinding block 322, the second grinding block 323, the third grinding block 324, and the fourth grinding block 325 are arranged at intervals along the circumference of the grinding disc 321.

[0169] It should be noted that the spheroidizing device 100 can achieve differentiated and synergistic shaping by setting four different types of grinding blocks arranged at intervals along the circumference of the grinding disc 321. The arc surface 3221 of the first grinding block 322 can guide the material particles to roll and grind, prolonging the contact time and improving the fullness of shaping; the rectangular plane of the second grinding block 323 can squeeze and grind the material particles, trimming the protruding edges and corners; the inclined surface 3241 of the third grinding block 324 takes into account both squeezing and rolling grinding, refining the small edges and corners of the material particles; the concave and convex surfaces of the fourth grinding block 325 can disturb the movement trajectory of the material particles, enhancing the impact, squeezing and kneading effects.

[0170] In summary, the four types of grinding blocks complement each other and work synergistically to adapt to material particles with different characteristics, improving the uniformity and comprehensiveness of spheroidization and shaping, and facilitating the stable preparation of fine-particle-size spheroidized materials with a median particle size D50 of 4.0–10 μm. Moreover, the differentiated grinding block structure design can match corresponding shaping structures for materials with different hardness and particle size, thus meeting the diverse processing needs of edge trimming of hard particles, gentle shaping of soft particles, and forced spheroidization of ultrafine particles.

[0171] Thirdly, refer to Figures 1 to 17This application provides a spheroidizing device 100 for preparing fine-particle-size spheroidized material with a median particle size D50 of 4.0-10 μm. The spheroidizing device 100 includes a shell 10 having a cavity 11 and a grading component 20 and a shaping component 30 respectively disposed in the upper and lower parts of the cavity 11. The grading component 20 is configured to separate tail powder and spheroidized material, guide the tail powder to the outside of the cavity 11, and guide the spheroidized material back to the shaping component 30. The shaping component 30 includes a toothed ring 31 and a grinding disc structure 32 rotatable relative to the toothed ring 31. The toothed ring 31 surrounds the outer periphery of the grinding disc structure 32, and a gap 33 is formed between them. An upward airflow is provided at the gap 33. It can convey at least part of the tail powder and spheroidized material in the gap 33 to the grading component 20; the grinding disc structure 32 includes a grinding disc 321 and a grinding block, the grinding block is arranged along the axial direction of the grinding disc 321 at the upper edge of the grinding disc 321; wherein, the grinding block includes a first grinding block 322, the first grinding block 322 is provided with an arc surface 3221 on one side of the grinding disc 321 in the circumferential direction; the first grinding block 322 rotates in a first direction under the drive of the grinding disc 321, so that the first grinding block 322 has a windward side, and the arc surface 3221 is recessed on the windward side of the first grinding block 322; the first grinding block 322 extends radially along the grinding disc 321, and the rotation axis 3221a of the arc surface 3221 is parallel to the extension direction of the first grinding block 322. In some embodiments, the grinding block further includes a second grinding block 323, which has a rectangular structure. The second grinding block 323 extends radially along the grinding disk 321, and is spaced apart from the first grinding block 322 circumferentially along the grinding disk 321. The second grinding block 323 rotates in a first direction under the drive of the grinding disk 321, giving it a windward side, which is a plane. In some embodiments, the grinding block further includes a third grinding block 324. The third grinding block 324 extends radially along the grinding disk 321, and is spaced apart from the first grinding block 322 circumferentially along the grinding disk 321. An inclined surface 3241 is formed between one circumferential surface of the third grinding block 324 and its top surface. In some embodiments, the third grinding block 324 rotates along a first direction under the drive of the grinding disc 321, so that the third grinding block 324 has a windward side; wherein, the inclined surface 3241 is disposed between the windward side surface of the third grinding block 324 and the top surface of the third grinding block 324. In some embodiments, the grinding block further includes a fourth grinding block 325; the fourth grinding block 325 is arranged radially along the grinding disc 321, and the fourth grinding block 325 and the first grinding block 322 are spaced apart circumferentially along the grinding disc 321; wherein, the side of the fourth grinding block 325 facing the gear ring 31 is provided with a concave-convex surface.In some embodiments, the fourth grinding block 325 has a plurality of tooth structures 3251 on the side facing the gear ring 31; the plurality of tooth structures 3251 are distributed circumferentially along the grinding disk 321, and the surfaces of the plurality of tooth structures 3251 facing the gear ring 31 are serrated surfaces to form a concave-convex surface. In some embodiments, the tooth surface of the tooth structure 3251 facing the gear ring 31 includes a tooth face 3251a; the fourth grinding block 325 rotates in a first direction under the drive of the grinding disk 321, so that the fourth grinding block 325 has a windward side; wherein, the minimum included angle between the tooth face 3251a and the windward side surface of the fourth grinding block 325 is an acute angle, and one tooth face 3251a is in contact with the windward side surface of the fourth grinding block 325. In some embodiments, the gear ring 31 has a ring of teeth on the side facing the grinding disk structure 32, and the ring of teeth is helical teeth. In some embodiments, the cavity 11 is divided into a grading cavity 111, a circulation cavity 112, and a shaping cavity 113 from top to bottom; a grading component 20 and a shaping component 30 are respectively disposed in the grading cavity 111 and the shaping cavity 113; a guide ring 40 is disposed in the circulation cavity 112, and the guide ring 40 has a conical structure that is larger at the top and smaller at the bottom; a guide port 41 is disposed between the upper edge of the guide ring 40 and the cavity wall of the circulation cavity 112 to guide the rising airflow carrying tail powder and spherical material to the grading component 20; the inner wall of the guide ring 40 is used to guide the spherical material separated by the grading component 20 back to the shaping component 30. In some embodiments, the grading chamber 111 has a tail powder outlet 12 on its wall for discharging tail powder; the circulation chamber 112 has a feed inlet 13 on its wall for filling the chamber 11 with raw materials; the shaping chamber 113 has a discharge outlet 14 on its wall, located above the shaping component 30, for discharging fine-particle-size spheroidized material; an air inlet chamber 50 is provided below the shaping chamber 113, communicating with the shaping chamber 113 through a gap 33, and an air inlet 51 is provided on its wall for providing upward airflow. In some embodiments, the portion of the shaping chamber 113 above the shaping component 30 is a variable-diameter chamber, and the diameter of the variable-diameter chamber increases from bottom to top.

[0172] In the third aspect, the working principle of the spheroidizing device 100 is as follows: Raw materials are fed into the cavity 11 through the feed inlet 13, and airflow is introduced through the bottom air inlet 51. The airflow enters the cavity 11 through the gap 33 between the gear ring 31 and the grinding disc structure 32, forming a stable upward airflow field. This airflow not only provides the core power for the internal circulation of materials, but also deeply integrates with the shaping and grading processes, carrying material particles throughout the process to complete a closed-loop circulation within the cavity, supporting the continuous and efficient operation of the shaping process. The stable upward airflow field within the cavity 11 can be generated by... Figure 1 The induced draft fan 600 in the spheroidizing system shown generates the spheroid.

[0173] The rising airflow carries material particles and rises from the channel between the inner wall of the shell 10 and the guide ring 40, entering the grading chamber 111 at the top of the cavity 11. The grading component 20 rotates at high speed, performing the grading and sorting function. Under the action of centrifugal force, it separates the tail powder that does not meet the requirements of the finished product and the material that is not fully shaped. The sorted material is thrown onto the inner wall of the guide ring 40 by centrifugal force, slides down the inner wall of the guide ring 40, and is precisely guided to the middle area of ​​the grinding disc 321.

[0174] The grinding disc 321 rotates at high speed, throwing the material particles in the middle outwards, so that the material enters the shaping area between the grinding disc 321, the grinding block and the toothed ring 31. During this process, the airflow continuously circulates between the shaping area and the grading chamber 111, carrying the material particles to move repeatedly between the grinding block and the toothed ring 31, so that the material particles continuously collide, squeeze, rub and shear with the grinding block and the toothed ring 31. With the help of the differentiated effects of the grinding blocks with different structures, the edges and corners of the particles are fully trimmed and curled and shaped.

[0175] During the shaping process, the rising airflow continuously carries the material through an internal circulation loop: "middle of the grinding disc → shaping area → grading chamber → guide ring → middle of the grinding disc." This allows the material particles to enter the shaping area multiple times for thorough shaping. The grading component 20 continuously sorts the particles, and the tail powder is discharged and collected through the tail powder outlet 12. The fully shaped and qualified finished product is discharged and collected from the discharge outlet 14 with the assistance of the airflow. Throughout the process, the internal airflow circulation, the rotation of the grading component, and the grinding disc shaping work in synergy to achieve a complete process of material grading, circulating shaping, finished product discharge, and tail powder separation. Ultimately, a fine-particle spheroidized material with uniform particle size, sphericity, and tap density is produced.

[0176] refer to Figures 18 to 24 , Figure 18 The images are scanning electron microscope images of the finished product obtained by testing the raw material provided in some embodiments of this application using a first spheroidizing device. Figure 19 The images are scanning electron microscope images of the finished product obtained by testing the raw material 2 provided in some embodiments of this application using a second spheroidizing device. Figure 20 The images are scanning electron microscope images of the finished product obtained by testing the raw material 2 provided in some embodiments of this application using a conventional spheroidizing device. Figure 21 The images are scanning electron microscope images of the finished product obtained after testing the raw material three provided in some embodiments of this application using a third spheroidizing device. Figure 22 The images are scanning electron microscope images of the finished product obtained by testing the raw material three provided in some embodiments of this application using a conventional spheroidizing device. Figure 23 Scanning electron microscope (SEM) images of raw material four provided according to some embodiments of this application; Figure 24The images are scanning electron microscope (SEM) images of the finished product obtained by testing the raw material four provided in some embodiments of this application using a fourth spheroidizing device.

[0177] To better demonstrate the effects of different grinding blocks in the spheroidizing device 100, the following experimental data are provided: 1) A first spheroidizing device is configured. The main difference between the first spheroidizing device and the spheroidizing device 100 in the third aspect is that the grinding blocks used are only the first grinding blocks 322. There are 16 first grinding blocks 322, which are evenly spaced along the circumference of the grinding disc 321. The first spheroidizing device, compared to traditional spheroidizing devices in the industry, uses materials with a particle size distribution D50 of 2.0–5.0 μm as raw materials and operates continuously according to a single operating parameter. Its particle size, tap density, and some morphological evolution are shown in Table 1 below. Figure 18 As shown.

[0178]

[0179] Based on the experimental data in Table 1 Figure 18 The results analysis shows that the first spheroidizing device can effectively spheroidize and shape the raw material, and can stably produce fine-particle-size spheroidized material with a median particle size D50 of 4.0 μm. In contrast, the traditional spheroidizing device is unable to achieve the ideal spheroidizing and shaping effect on the raw material and cannot complete the effective spheroidizing process of the raw material.

[0180] 2) A second spheroidizing device is configured. The main difference between the second spheroidizing device and the spheroidizing device 100 in the third aspect is that the grinding blocks used are only the second grinding blocks 323. There are 16 second grinding blocks 323, which are evenly spaced along the circumference of the grinding disc 321. The second spheroidizing device, compared to the traditional spheroidizing device in the industry, uses materials with a particle size distribution D50 of 7.5–10.5 μm as raw materials and operates continuously according to a single operating parameter. Its particle size, tap density, and some morphological evolution are shown in Table 2 below. Figure 19 and Figure 20 As shown.

[0181]

[0182] Based on the experimental data in Table 2 Figure 19 and Figure 20 The results analysis shows that both the second spheroidizing device and the traditional spheroidizing device can achieve spheroidization and shaping of raw material 2. Specifically, the second spheroidizing device can produce fine-sized spheroidized material with a median particle size (D50) of 8.9 μm, while the traditional spheroidizing device produces a product with a median particle size (D50) of 9.1 μm. Compared to the traditional spheroidizing device, the second spheroidizing device exhibits superior spheroidization and shaping effects, not only producing finer spheroidized products but also showing a significant improvement in the tap density of the finished product.

[0183] 3) A third spheroidizing device is configured. The main difference between the third spheroidizing device and the spheroidizing device 100 in the third aspect is that only the third grinding block 324 is used. There are 16 third grinding blocks 324, which are evenly spaced along the circumference of the grinding disc 321. The third spheroidizing device, compared with the traditional spheroidizing device in the industry, uses materials with a particle size distribution D50 of 7.5–10.5 μm as raw materials and operates continuously according to a single operating parameter. Its particle size, tap density, and some morphological evolution are shown in Table 3 below. Figure 21 and Figure 22 As shown.

[0184]

[0185] Based on the experimental data in Table 3 Figure 21 and Figure 22 The results analysis shows that both the third spheroidizing device and the traditional spheroidizing device can achieve spheroidization and shaping of the raw materials. Specifically, the third spheroidizing device can produce fine-sized spheroidized material with a median particle size (D50) of 9.4 μm, while the traditional spheroidizing device produces a product with a median particle size (D50) of 9.3 μm. The spheroidizing effects of the two devices are similar; however, compared to the traditional spheroidizing device, the third spheroidizing device significantly improves the tap density of the product.

[0186] 4) A fourth spheroidizing device is configured. The main difference between the fourth spheroidizing device and the spheroidizing device 100 in the third aspect is that only the fourth grinding block 325 is used. There are 16 fourth grinding blocks 325, which are evenly spaced along the circumference of the grinding disc 321. The fourth spheroidizing device differs from traditional spheroidizing devices in the industry. These devices use materials with a particle size distribution D50 of 20–30 μm as raw materials and operate continuously according to a single set of operating parameters. The particle size, tap density, and some morphological evolution are shown in Table 4 below. Figure 23 and Figure 24 As shown.

[0187]

[0188] Based on the experimental data in Table 4 Figure 23 and Figure 24 The results analysis shows that the fourth spheroidizing device can effectively spheroidize and shape raw material four, and can stably produce fine-particle-size spheroidized material with a median particle size D50 of 7.7μm. In contrast, the traditional spheroidizing device is difficult to achieve the ideal spheroidizing and shaping effect on raw material four, and cannot complete the effective spheroidizing process of raw material four.

[0189] The description of the various embodiments above tends to emphasize the differences between the various embodiments. The similarities or similarities between them can be referred to, and for the sake of brevity, they will not be repeated here.

[0190] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and not to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application, and they should all be covered within the scope of the claims and specification of this application. This application is not limited to the specific embodiments applied herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A spheroidizing apparatus for preparing fine-particle-size spheroidized material products, characterized in that, The median particle size D50 of the fine-particle-size spheroidized material product is 4.0-10 μm; The spheroidizing device includes a housing having a cavity and a grading component and a shaping component disposed in the cavity; The grading component is located above the shaping component. The grading component is configured to separate tail powder and spheroidized material, guide the tail powder to the outside of the cavity, and guide the spheroidized material back to the shaping component. The shaping assembly includes a gear ring and a grinding disc structure that can rotate relative to the gear ring; The gear ring is arranged around the outer periphery of the grinding disc structure and a gap is formed between them. An upward airflow is provided in the gap and can transport at least part of the tail powder and the spheroidized material in the gap to the grading component. The grinding disc structure includes a grinding disc and a grinding block, wherein the grinding block is disposed along the axial direction of the grinding disc at the upper edge of the grinding disc; The grinding block includes a first grinding block, which has an arc surface on one side along the circumferential direction of the grinding disc; The first grinding block rotates along a first direction under the drive of the grinding disc, so that the first grinding block has a windward side, and the arc-shaped concave surface is provided on the windward side of the first grinding block. The first grinding block extends radially along the grinding disc, and the rotation axis of the arc surface is parallel to the extension direction of the first grinding block.

2. The spheroidizing device according to claim 1, characterized in that, The dimension L1 of the arc surface in the extension direction of the first grinding block satisfies: 90mm≤L1≤110mm; The central angle θ of the arc surface satisfies: 90°≤θ≤120°; The radius r of the arc surface satisfies: 20mm≤r≤30mm.

3. The spheroidizing device according to claim 1, characterized in that, The grinding block also includes a second grinding block, which has a rectangular structure. The second grinding block extends radially along the grinding disk, and the second grinding block and the first grinding block are spaced apart circumferentially along the grinding disk; The second grinding block rotates along the first direction under the drive of the grinding disc, so that the second grinding block has a windward side, and the windward side of the second grinding block is a plane.

4. The spheroidizing device according to claim 1, characterized in that, The grinding block also includes a third grinding block; The third grinding block extends radially along the grinding disk, and the third grinding block and the first grinding block are spaced apart circumferentially along the grinding disk. The third grinding block has an inclined surface formed between one side surface of the third grinding block along the circumferential direction of the grinding disk and the top surface of the third grinding block.

5. The spheroidizing device according to claim 4, characterized in that, The third grinding block rotates along the first direction under the drive of the grinding disc, so that the third grinding block has a windward side; The inclined surface is disposed between the windward side surface of the third grinding block and the top surface of the third grinding block.

6. The spheroidizing device according to claim 5, characterized in that, Along the axial direction of the grinding disc, the dimension L2 of the third grinding block satisfies: 30mm≤L2≤50mm; Along the axial direction of the grinding disc, the dimension L21 of the inclined surface and the dimension L22 of the windward side surface of the third grinding block satisfy: 0.12≤L21 / L22≤0.2; The included angle α between the inclined surface and the windward side surface of the third grinding block satisfies: 30°≤α≤60°; In the extending direction of the third grinding block, the dimension L3 of the inclined surface satisfies: 90mm≤L3≤110mm.

7. The spheroidizing device according to claim 1, characterized in that, The grinding block also includes a fourth grinding block; The fourth grinding block extends radially along the grinding disk, and the fourth grinding block and the first grinding block are spaced apart circumferentially along the grinding disk. The fourth grinding block has a concave-convex surface on the side facing the gear ring.

8. The spheroidizing device according to claim 7, characterized in that, The fourth grinding block has multiple tooth structures on the side facing the gear ring; The plurality of tooth structures are distributed circumferentially along the grinding disc, and the surface of the plurality of tooth structures facing the tooth ring is a serrated surface to form the concave-convex surface.

9. The spheroidizing device according to claim 8, characterized in that, The tooth structure facing the tooth ring includes the tooth face; The fourth grinding block rotates along the first direction under the drive of the grinding disc, so that the fourth grinding block has a windward side; The minimum included angle between the tooth face and the windward side surface of the fourth grinding block is an acute angle, and one of the tooth faces is in contact with the windward side surface of the fourth grinding block.

10. The spheroidizing device according to claim 8, characterized in that, The tooth groove angle β between two adjacent tooth structures satisfies: 30°≤β≤60°; In the extending direction of the fourth grinding block, the dimension L4 of the tooth structure satisfies: 10mm≤L4≤30mm.

11. The spheroidizing device according to claim 1, characterized in that, The gear ring includes an annular body and a mounting sleeve; The inner side of the annular body is provided with a ring of teeth, and the mounting sleeve is detachably fitted on the outer side of the annular body. The annular body and the mounting sleeve are fixed together to the lower part of the inner wall of the housing.

12. The spheroidizing device according to claim 1, characterized in that, Along the axial direction of the gear ring, the size of the gear ring is larger than the size of the grinding disc structure, and neither end of the grinding disc structure extends beyond the gear ring.

13. The spheroidizing device according to claim 1, characterized in that, The gear ring has a ring of teeth on the side facing the grinding disc structure, and this ring of teeth is helical.

14. The spheroidizing device according to any one of claims 1-13, characterized in that, The cavity is divided into a grading cavity, a circulation cavity, and a shaping cavity from top to bottom; The grading cavity and the shaping cavity are respectively provided with the grading component and the shaping component; The circulation chamber is provided with a flow guide ring, which is a conical structure that is larger at the top and smaller at the bottom; A flow guide is provided between the upper edge of the flow guide ring and the wall of the circulation chamber to guide the rising airflow carrying the tail powder and the spheroidized material to the grading component. The inner wall of the guide ring is used to guide the spheroidized material separated by the grading component back to the shaping component.

15. The spheroidizing device according to claim 14, characterized in that, The grading chamber has a tail powder discharge port on its wall for discharging the tail powder. The circulation chamber has an inlet on its wall for filling the chamber with raw materials; The shaping cavity has a discharge port on its wall, which is located above the shaping component to discharge the fine-particle-size spheroidized material product. An air intake chamber is provided below the shaping cavity. The air intake chamber is connected to the shaping cavity through the gap. An air inlet is provided on the cavity wall of the air intake chamber to provide upward airflow.

16. The spheroidizing device according to claim 14, characterized in that, The portion of the shaping cavity located above the shaping component is a variable diameter cavity, and the diameter of the variable diameter cavity increases from bottom to top.

17. The spheroidizing device according to claim 1, characterized in that, The grinding block also includes: The second grinding block has a flat, rectangular structure on its windward side. The third grinding block has an inclined surface between its windward side and top surface; The fourth grinding block has a concave-convex surface on the side facing the gear ring; The first grinding block, the second grinding block, the third grinding block, and the fourth grinding block are arranged at intervals along the circumference of the grinding disc.

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