A modular multi-stage flow field coupled powder aerosolization delivery device

Abstract

The application provides a modular multi-stage flow field coupled powder aerosolization delivery device, comprising: a converging top cover which is a conical structure and is provided with an aerosol output port at the top of the cone; a dispersion cabin which is a cylindrical structure and is tightly connected to the lower edge of the converging top cover; a powder collection cabin which is tightly connected to the lower part of the dispersion cabin through a threaded connecting body, the powder collection cabin has an inverted conical cabin structure and is provided with a sealing cover at the bottom, and the threaded connecting body is provided with a plurality of horizontal opposing airflow inlet pipes which extend into the interior, and the blowing port directions of the plurality of horizontal opposing airflow inlet pipes are opposite. Through the innovative combination of high-energy opposing flow field design and threaded split modular structure, both the efficient de-agglomeration of the powder to ensure the quality of the aerosol and the significant improvement of the process adaptability and maintainability of the equipment are achieved.

Description

Technical Field

[0001] This invention relates to a modular, multi-stage flow field coupled powder aerosol conveying device, belonging to the field of powder conveying, dispersion and aerosol preparation technology. In particular, it relates to a powder conveying device that uses counter-current airflow to break up powder with high energy, de-agglomerate and form aerosol in situ. It is especially suitable for surface coating preparation processes with strict requirements on aerosol concentration, powder dispersion and carrier gas temperature. Background Technology

[0002] In the field of advanced coating preparation technology, the coating preparation of ceramic substrates for semiconductor devices is a typical example. The density, deposition rate, and overall performance of the coating are all closely related to the quality of the aerosol, which directly determines the final effect of the coating preparation. Among them, micro-nano-scale powders such as yttrium oxide are used as core raw materials and are prone to agglomeration during transportation, which is a key factor affecting the quality of aerosol.

[0003] Existing powder feeding devices have significant technical limitations: First, they lack a high-energy crushing mechanism for micro-nano-scale powder agglomeration, failing to effectively disperse already agglomerated powder particles, resulting in uneven distribution of aerosol particles and severely restricting core performance indicators such as coating density and deposition rate; Second, the equipment structure design is rigid, often employing integral welding or fixed structures, making it difficult to adapt to different particle sizes (D50 from 0.3 to 5 μm), carrier gas types (such as helium and nitrogen), or the process parameter optimization (DOE) requirements under wide temperature ranges (25~400℃). Furthermore, they cannot meet the requirements for flexible cleaning, maintenance, and seal replacement, limiting the adaptability and flexibility of the powder feeding device.

[0004] Therefore, there is an urgent need to find a modular powder feeding device that combines high efficiency in de-agglomeration with high maintainability. This device needs to break through the structural and functional limitations of traditional powder feeding equipment, so as to achieve efficient crushing of micro-nano-level powder agglomeration, ensure stable aerosol quality, adapt to different carrier gases and wide temperature range process scenarios through modular design, and meet the flexible needs of equipment cleaning, maintenance and sealing, thereby promoting the efficient and stable development of advanced coating preparation processes. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a modular, multi-stage flow field coupled powder aerosol conveying device, comprising: a tapered top cover, which has a conical structure and an aerosol outlet at the apex; a dispersion chamber, which has a cylindrical structure and is tightly connected to the lower edge of the tapered top cover; a powder collection chamber, which is tightly connected to the lower part of the dispersion chamber via a threaded connector, the powder collection chamber having an inverted conical chamber structure and a sealing cover at the bottom, the threaded connector being provided with four centrally symmetrically distributed horizontally opposing airflow inlets extending into the interior; and a central powder delivery straight pipe, which penetrates the sealing cover and extends upward from the bottom of the powder collection chamber to the top space inside the powder collection chamber, the blowing directions of the two sets of opposing horizontally opposing airflow inlets converging at two points at different heights above the powder outlet at the upper end of the central powder delivery straight pipe.

[0006] The powder is pushed to the powder outlet at the top of the central powder feeding pipe. At the powder outlet, four high-pressure carrier gases are ejected at high speed from the air inlets of four horizontal counter-current airflow pipes, forming a primary counter-current airflow and a secondary counter-current airflow. The primary counter-current airflow is located below the secondary counter-current airflow. The powder ejected from the powder outlet is subjected to extremely strong gas shear force at the primary counter-current airflow, and high-speed collisions occur between particles, thereby breaking the van der Waals forces and achieving de-agglomeration. The secondary counter-current airflow acts as a guide and protective gas, guiding the de-agglomerated powder to flow upward while also forming a dynamic airflow barrier on the inner wall of the dispersion chamber. Subsequently, the powder rises upward in the conical top cover and is guided and accelerated by the top conical structure, forming a uniform aerosol, which is then sent out through the aerosol outlet. Large particles that have not been de-agglomerated settle due to gravity and slide down the smooth inner wall of the conical powder collection chamber to the bottom, avoiding powder bridging and achieving powder recirculation. In some embodiments, the lower edge of the top cover is a flat edge structure, and the upper edge of the dispersion chamber is provided with the same flat edge structure and cooperates with the lower edge of the top cover.

[0007] In some embodiments, the lower edge of the top cover and the upper edge of the dispersion chamber are provided with positioning holes of the same size and corresponding positions. Fasteners are inserted into the positioning holes to form a tight fit between the lower edge of the top cover and the upper edge of the dispersion chamber.

[0008] In some embodiments, the threaded connector includes threaded portions respectively disposed on the upper and lower parts. The threaded portions of the upper and lower parts are respectively connected to the threads at the bottom of the dispersion chamber and the threads at the top of the powder collection chamber, which facilitates loading, unloading, cleaning and adapting to complex thermal conditions. The chamber sections are connected by threads and can also be supplemented with high-temperature resistant sealing rings to form a detachable modular split structure.

[0009] In some embodiments, four horizontally opposed airflow inlets are inserted between the threaded portions of the upper and lower parts of the threaded connector and are symmetrically distributed, with the included angle between two opposing horizontally opposed airflow inlets being 180 degrees.

[0010] In some embodiments, the four horizontally opposed airflow inlet pipes are arranged in a cross shape, and the air outlets of two horizontally opposed airflow inlet pipes are radially opposite each other, with the confluence point located at a small distance directly above the powder outlet of the central powder delivery straight pipe.

[0011] In some embodiments, the threaded connector is provided with four centrally symmetrically distributed insertion ports, and four horizontally opposing airflow inlet pipes can be inserted into the insertion ports respectively.

[0012] In some embodiments, the outlets of the two opposing central powder feeding straight pipes are provided with a first auxiliary pipe radially aligned with the central powder feeding straight pipes. The outlet of the first auxiliary pipe can generate a horizontal primary counter-current airflow and adopts a flow channel structure with a contraction and expansion structure, which can significantly increase the airflow velocity and enhance the impact and de-agglomeration effect on the powder. The outlets of the other two opposing central powder feeding straight pipes are provided with an upwardly bent and inclined second auxiliary pipe (its axis is V-shaped, and the angle can be adjusted by replacement). The outlet of the second auxiliary pipe can spray upwards a secondary counter-current airflow that converges at an angle. Utilizing the radial difference in diameter between the first and second auxiliary pipes, a ring-shaped turbulent field is formed within the powder collection chamber, spreading outwards from the center. This achieves secondary shear dispersion of the agglomerated powder. The residual pressure airflow after the counter-current flows downwards along the chamber wall, forming a dynamic gas film that actively prevents the electrostatic adsorption of ultrafine powder onto the wall surface. Both the first and second auxiliary pipes are equipped with adjustable guide nozzles. The powder is pushed upwards through the central powder feeding pipe. Upon reaching the top, the powder immediately encounters a horizontal primary counter-current airflow and experiences extremely strong gas shear force in the stagnation zone where the airflows converge. High-speed collisions occur between the particles, breaking the van der Waals forces and achieving de-agglomeration. Subsequently, the high-speed de-agglomerated powder enters the secondary counter-current airflow. Due to the upward-sloping velocity component of the secondary counter-current airflow, the powder undergoes high-energy collisions and de-agglomeration in the stagnation zone. This not only forces the scattering direction upwards but also forms a dynamic airflow barrier near the inner wall of the dispersion chamber, completely blocking the powder's adhesion to the wall. The mixed uniform aerosol is then guided and accelerated out through the top conical converging structure.

[0013] In some embodiments, the interior of the tapered top cover has a smoothly transitioning conical converging structure, and the aerosol outlet is located at the apex of the cone.

[0014] In some embodiments, the bottom of the inverted conical chamber of the powder collection chamber is provided with a protrusion that fits tightly with the sealing cover. High-temperature resistant sealing rings, such as fluororubber or perfluoroether O-rings, are provided between the top cover and the dispersion chamber, and between the dispersion chamber and the powder collection chamber, to ensure extreme airtightness under large temperature gradients, forming a detachable modular split structure.

[0015] Advantages and effects of the present invention: This invention addresses the technical shortcomings of traditional powder feeding devices, such as the lack of a high-energy crushing mechanism for micro / nano-level powder agglomeration, the presence of high-density powder adhering to walls and deposition dead zones, insufficient process adaptability (difficult to operate stably under different carrier gases and wide temperature ranges), and inconvenient maintenance. Through an innovative flow field design combining "high-energy counter-current + adjustable flow guidance" and a deep integration of a threaded, modular structure, it achieves both efficient powder de-agglomeration and dead-zone-free dispersion, significantly improving the device's process tolerance and long-term reliability, and fully adapting to the diverse needs of advanced coating preparation. Specifically, it also includes: 1. High-energy collision de-agglomeration, significantly improving dispersion efficiency: Through the 180° counter-current airflow design, the collision kinetic energy between the airflow and particles is fully utilized to construct a powerful breaking mechanism, which can quickly disperse agglomerates formed by micro-nano-scale powders (such as yttrium oxide) during the transportation process. The dispersion efficiency far exceeds that of traditional fluidized beds, effectively solving the core problem of "lack of a high-energy breaking mechanism for powder agglomeration" in the background technology, and providing stable aerosol quality support for key performances such as coating density and deposition rate.

[0016] 2. Multi-level coupling design to completely eliminate wall adhesion and deposition dead zones: The multi-level coupling structure of "opposing collision + axial flow" forms a synergistic force, which not only breaks up agglomerated powder through collision, but also avoids high-density powder from adhering to the inner wall of the dispersion chamber through axial flow. At the same time, it eliminates deposition dead zones in the equipment, solves the problem of uneven dispersion caused by powder wall accumulation in traditional powder feeding devices, and further ensures the uniformity of aerosol particle distribution.

[0017] 3. Multi-dimensional adjustable flow field, adaptable to diverse process scenarios: The innovative design of an adjustable auxiliary flow tube, in conjunction with the counter-current airflow, constructs a three-dimensional composite perturbation flow field, giving the device extremely high process tolerance. When the carrier gas is switched from nitrogen to highly diffusible helium, or when the gas temperature rises to several hundred degrees Celsius causing a change in viscosity, only a slight adjustment to the flow tube angle is needed to reconstruct a stable upward lifting flow field. This perfectly solves the problem of traditional devices being unable to adapt to different carrier gas types and wide-temperature-range process parameter optimization (DOE). 4. Modular structure design, balancing ease of maintenance and stability of use: The modular structure with threaded split design greatly simplifies the process of cleaning powder, maintenance and component replacement after experiments, and completely solves the pain point of inconvenient maintenance of traditional integral welded / fixed structures; at the same time, the threaded connection can flexibly adapt to the thermal expansion stress under different carrier gas temperatures, effectively buffer the structural deformation caused by temperature changes, ensure the airtightness and structural stability of the equipment in long-term use, and adapt to the stringent process requirements of advanced coating preparation. Attached Figure Description

[0018] Figure 1 This is an external schematic diagram of the overall structure of the present invention.

[0019] Figure 2 This is an internal sectional view of the overall structure of the present invention.

[0020] Figure 3 This is a front view of the overall structure of the present invention.

[0021] In the diagram, 1. Top cover; 2. Dispersion chamber; 3. Threaded connector; 4. Horizontal counter-flow air inlet pipe; 5. Central powder delivery straight pipe; 6. Powder collection chamber; 7. Sealing cover; 41. First auxiliary pipe; 42. Second auxiliary pipe. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] In this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] In this invention, the terms "first" and "second" are used only to distinguish similar components / parts in different positions or with different characteristics, and have no other limiting meaning; "upper" refers to the direction in which each component is away from the ground, and "lower" refers to the direction in which each component is away from the ground.

[0025] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature 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 includes the first feature 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.

[0026] This invention provides a modular, multi-stage flow field coupled powder aerosol conveying device. Addressing the shortcomings of traditional powder conveying devices, such as incomplete de-agglomeration, easy powder adhesion to chamber walls, poor airflow guidance, and inconvenient maintenance of the integral structure, this invention innovatively adopts a four-stage counter-current airflow design and a threaded, modular connection structure. Through the synergistic effect of a primary airflow for powerful de-agglomeration and a secondary airflow for guidance and protection, it achieves efficient dispersion and stable conveying of micro-nano-level powders, while also considering ease of equipment maintenance and process adaptability, providing uniform and pure aerosol support for advanced coating preparation. The device includes a top cover (1), a dispersion chamber (2), a threaded connector (3), a horizontal counter-current airflow inlet pipe (4), a central powder delivery straight pipe (5), a powder collection chamber (6), and a sealing cover (7). These components precisely cooperate to construct an integrated powder processing system of "staged de-agglomeration - guidance and protection - reflux recovery."

[0027] The conical top cover 1 has a conical structure with an aerosol outlet at the apex. The dispersion chamber 2 has a cylindrical structure and is tightly connected to the lower edge of the top cover 1. The conical top cover 1 forms a flow channel, and its smooth inner wall reduces airflow resistance and prevents the generation of local eddies. It also naturally accelerates the rising airflow, causing the dispersed fine powder particles to converge evenly along the conical wall, forming an aerosol of uniform concentration that is discharged from the outlet. The cylindrical dispersion chamber 2, as the core area for the interaction between the airflow and the powder, has a high-gloss inner wall to reduce the risk of powder adhesion and retention. It is also tightly connected to the top cover 1 to form a closed space, ensuring stable airflow pressure within the chamber and providing a sealed environment for the staged counter-current airflow to function.

[0028] The powder collection chamber 6 is tightly connected to the lower part of the dispersion chamber 2 via a threaded connector 3. The powder collection chamber 6 has an inverted conical chamber structure and a sealing cover 7 at the bottom. The threaded connector 3 is equipped with four centrally symmetrically distributed horizontally opposing airflow inlet pipes 4 that extend into the interior. The inverted conical powder collection chamber 6 utilizes the principle of gravity guidance, allowing large, unagglomerated powder particles to slide naturally down the smooth inner wall to the bottom, avoiding powder accumulation and bridging, achieving large particle return circulation, and improving powder utilization. The threaded connector 3, as the core connection and installation component, on the one hand, achieves a stable connection between the dispersion chamber 2 and the powder collection chamber 6 through its threaded structure, and can be supplemented with a high-temperature resistant sealing ring to enhance airtightness. On the other hand, its four centrally symmetrical insertion ports provide precise positioning for the horizontally opposing airflow inlet pipes 4, ensuring that the four airflows converge at a preset angle and height, maximizing airflow efficiency. The sealing cover 7 seals the bottom of the powder collection chamber 6, preventing powder leakage and facilitating periodic opening for cleaning of returned large powder particles, making maintenance convenient.

[0029] A central powder delivery straight pipe 5 is installed through the sealing cover 7 and extends upward from the bottom of the powder collection chamber 6 to the top space inside the powder collection chamber 6. The blowing ports of two sets of horizontally opposed airflow inlets 4 are respectively located at two points at different heights above the powder outlet at the upper end of the central powder delivery straight pipe 5. The central powder delivery straight pipe 5 adopts a vertical through-type design, which ensures that the powder is stably delivered to the powder outlet along the axial direction, avoiding uneven dispersion caused by deviation of the delivery path. Its powder outlet and the intersection point of the two sets of opposing airflows form a precise spatial fit. The intersection point of the first-stage opposing airflow is close to the powder outlet, ensuring that the powder is subjected to strong shear force as soon as it leaves the straight pipe. The intersection point of the second-stage opposing airflow is located above, realizing the functions of diversion and protection. This height difference design makes the airflow action clearly divided, which not only ensures the de-agglomeration effect, but also strengthens the subsequent guidance and protection.

[0030] The powder is pushed to the powder outlet at the top of the central powder feeding pipe 5. At the powder outlet, four high-pressure carrier gases are ejected at high speed from the air inlets of four horizontal counter-current airflow inlets 4, forming a primary counter-current airflow and a secondary counter-current airflow. The primary counter-current airflow is located below the secondary counter-current airflow. The powder ejected from the powder outlet is subjected to extremely strong gas shear force at the primary counter-current airflow, and high-speed collisions occur between particles, thereby breaking the van der Waals forces and achieving de-agglomeration. The secondary counter-current airflow acts as a guide and protective gas, guiding the de-agglomerated powder to flow upward while also forming a dynamic airflow barrier on the inner wall of the dispersion chamber 2. Subsequently, the powder rises upward in the conical top cover 1, and through the guiding and acceleration effect formed by the convergence of the top conical structure, it forms a uniform aerosol and is sent out through the aerosol outlet. Large particles that have not been de-agglomerated settle due to gravity and slide down to the bottom along the smooth inner wall of the conical powder collection chamber 6, avoiding powder bridging and realizing powder reflux circulation. The entire workflow forms a closed loop of "stable powder feeding - graded counter-agglomeration (de-agglomeration + flow guidance and protection) - conical flow guidance - reflux and recycling". This design also brings the core effect of graded counter-agglomeration and de-agglomeration, and dual improvement of dispersion efficiency and uniformity: through the division of labor and cooperation of two sets of counter-agglomeration airflows at different heights, the first-stage airflow focuses on powerfully breaking up agglomerates. Utilizing the extremely strong shear force generated by high-velocity collisions, it quickly disperses the micro-nano-level powder agglomeration structure, with a dispersion efficiency far exceeding that of traditional single-stage airflow and fluidized beds; the second-stage airflow receives and optimizes the delivery of fine powder, making the aerosol concentration and particle distribution more uniform, providing stable support for key performances such as coating density and deposition rate.

[0031] In some embodiments, the four horizontally opposed airflow inlet pipes 4 are divided into two groups of inlet pipes arranged opposite each other. The axes of the two horizontally opposed airflow inlet pipes 4 in the first group are collinear, and the axes of the two horizontally opposed airflow inlet pipes 4 in the second group are collinear. The height difference design of the two groups of inlet pipes allows the primary and secondary opposing airflows to perform their respective functions. The primary opposing point is close to the powder outlet, ensuring that the agglomerates are subjected to the strongest shear force before their kinetic energy diffuses, maximizing the deagglomeration efficiency. The secondary opposing point is located higher, which can both receive the fine powder after primary dispersion and guide it to flow upward, and form an airflow barrier covering the entire cross-section of the dispersion chamber, preventing the fine powder from diffusing and adhering to the chamber wall. The collinear design ensures that the collision intensity of each group of airflows is uniform, ensuring that the powder is subjected to balanced force and consistent dispersion effect. The dynamic air curtain formed by the secondary counter-current airflow is the key to solving the problem of powder buildup on the chamber walls. This dynamic air curtain can isolate the powder from direct contact with the inner wall of the dispersion chamber 2, thus preventing powder adhesion and retention at the source. At the same time, in conjunction with the inverted conical reflux structure of the powder collection chamber 6, it can achieve efficient recovery of large particles, ensuring the long-term operational stability of the equipment and improving the powder utilization rate.

[0032] In some embodiments, the four insertion ports of the threaded connector 3 are evenly distributed, and after the horizontally opposed airflow inlet pipe 4 is inserted, an airtight seal is achieved through the sealing ring. The evenly distributed insertion ports provide a symmetrical layout basis for the four airflows, ensuring a balanced flow field distribution within the chamber and avoiding local airflow turbulence; the matching design of the sealing ring can effectively prevent high-pressure carrier gas from leaking from the gap between the inlet pipe and the insertion ports, ensuring stable airflow pressure, while preventing powder from overflowing from the gap, thus improving the safety and sealing performance of the equipment.

[0033] In some embodiments, the air inlet of the horizontal counter-current airflow inlet 4 is provided with a tapered nozzle structure. The tapered nozzle can increase the airflow velocity, enhance shear force and diversion effect, and adapt to the functional requirements of staged airflow.

[0034] In some embodiments, both the lower edge of the top cover 1 and the upper edge of the dispersion chamber 2 are provided with flat edge structures, and corresponding positioning holes are opened on the flat edges. Fasteners are passed through the positioning holes to achieve tight fixation between the two. The flat edge structure increases the contact area of ​​the mating surfaces, improves the connection sealing performance, and avoids leakage of high-pressure airflow. The cooperation between the positioning holes and the fasteners ensures that the axes of the top cover 1 and the dispersion chamber 2 are precisely aligned, preventing the flow guiding effect from decreasing due to assembly misalignment. At the same time, it enables a detachable connection, facilitating later cleaning and maintenance.

[0035] In some embodiments, the inverted conical inner wall of the powder collection chamber 6 is polished. Polishing further reduces the coefficient of friction of the inner wall, reduces the resistance to the sliding of large powder particles, avoids accumulation, and achieves a balance between structural compactness and practicality.

[0036] In some embodiments, the powder outlet of the central powder feeding straight pipe 5 is provided with a flared structure, and the flared direction is upward. The flared structure enables the powder to form a slight diffusion when it is output from the straight pipe, ensuring that the powder can fully enter the effective range of the primary countercurrent airflow and avoiding the loss of some powder due to deagglomeration caused by concentrated spraying; the upward flared design guides the powder to move naturally upward, consistent with the direction of the subsequent countercurrent airflow, thereby improving energy utilization.

[0037] In some embodiments, sealing rings are provided at the connection points between the threaded connector 3 and the dispersion chamber 2 and the powder collection chamber 6, and anti-slip textures are provided on the outer periphery of the threaded connector 3. This threaded, split, modular design constitutes the core of the device's modular structure, which is adaptable to multiple scenarios and balances ease of maintenance and stability: each chamber and component can be detachably connected, greatly simplifying the powder cleaning, maintenance, and component replacement processes, and solving the problem of inconvenient maintenance of traditional integral welded / fixed structures; at the same time, the threaded connection, combined with the sealing ring, can flexibly adapt to the process requirements of different temperature ranges and different carrier gas types, effectively buffering thermal expansion stress, ensuring the airtightness and long-term stability of the equipment under various process parameter optimization scenarios, and perfectly adapting to the diverse process requirements of advanced coating preparation.

[0038] In some embodiments, a sealing ring is provided at the connection between the sealing cover 7 and the bottom of the powder collection chamber 6, and the sealing cover 7 is detachably connected to the powder collection chamber 6 via a threaded structure. The threaded connection ensures the secure fixation of the sealing cover 7, while facilitating quick disassembly and cleaning of the returned powder; the sealing ring further enhances the bottom sealing performance, preventing powder leakage and the entry of outside air, and ensuring the stability of airflow inside the chamber.

[0039] In some embodiments, the lower edge of the tapered top cover 1 is a flat edge structure, and the upper edge of the dispersion chamber 2 is provided with the same flat edge structure and mates with the lower edge of the tapered top cover 1. The flat edge structure ensures that the mating surfaces of the tapered top cover 1 and the dispersion chamber 2 are completely fitted, increasing the contact area, improving the connection sealing, preventing high-pressure airflow from leaking from the mating gap, and ensuring stable flow field pressure inside the chamber; at the same time, the flat edge structure is easy to process and facilitates precise positioning through fasteners, ensuring that the axis of the conical top cover coincides with the axis of the cylindrical dispersion chamber, and avoiding a decrease in the flow guiding effect due to assembly misalignment.

[0040] In some embodiments, the lower edge of the top cover 1 and the upper edge of the dispersion chamber 2 are each provided with corresponding positioning holes of the same size. Fasteners are inserted into the positioning holes to form a tight fit between the lower edge of the top cover 1 and the upper edge of the dispersion chamber 2. The fit between the positioning holes and the fasteners enables the top cover 1 and the dispersion chamber 2 to be detachably fixed, ensuring both connection stability and facilitating subsequent disassembly, cleaning, or replacement of parts. The positioning hole design with corresponding positions and the same size ensures precise alignment during each assembly, avoiding structural offset caused by repeated assembly and ensuring consistent equipment operation.

[0041] In some embodiments, the threaded connector 3 includes threaded portions respectively disposed at the upper and lower parts. The upper and lower threaded portions are respectively connected to the threads at the bottom of the dispersion chamber 2 and the top of the powder collection chamber 6, facilitating loading, unloading, cleaning, and adaptation to complex thermal environments. The chamber sections are connected by threads and can also be supplemented with high-temperature resistant sealing rings, forming a detachable modular split structure. This design constitutes the core of the device's modular adaptability to multiple scenarios. It not only greatly simplifies the post-experiment powder cleaning, maintenance, and component replacement processes, solving the problem of inconvenient maintenance of traditional integral welded / fixed structures; but also allows the threaded connection method to flexibly adapt to thermal expansion stress in a wide temperature range of 25~400℃, effectively buffering structural deformation caused by temperature changes, ensuring the airtightness and long-term stability of the equipment under different carrier gas types (such as helium and nitrogen) and process parameter optimization (DOE) scenarios, perfectly adapting to the diverse process requirements of advanced coating preparation.

[0042] In some embodiments, four horizontally opposed airflow inlet pipes 4 are inserted between the threaded portions of the upper and lower parts of the threaded connector 3 and are symmetrically distributed, with the included angle between two opposing horizontally opposed airflow inlet pipes 4 being 180 degrees.

[0043] In some embodiments, the four horizontally opposed airflow inlet pipes 4 are arranged in a cross shape and the air outlets of two horizontally opposed airflow inlet pipes 4 are radially opposite each other, and the confluence point is located at a small distance directly above the powder outlet of the central powder delivery straight pipe 5.

[0044] In some embodiments, the threaded connector 3 is provided with four centrally symmetrically distributed insertion ports, and four horizontally opposing airflow inlet pipes 4 can be inserted into the insertion ports respectively.

[0045] In some embodiments, the outlets of the two opposing central powder feeding straight pipes 5 are provided with a first auxiliary pipe 41 that is radially aligned with the central powder feeding straight pipe 5. The outlet of the first auxiliary pipe 41 can generate a horizontal primary counter-current airflow and adopts a flow channel structure with a contraction and expansion structure, which can significantly increase the airflow velocity and enhance the impact and de-agglomeration effect on the powder. The outlets of the other two opposing central powder feeding straight pipes 5 are provided with an upwardly bent and inclined second auxiliary pipe 42, whose axis is V-shaped and whose angle can be adjusted by replacement. The outlet of the second auxiliary pipe 42 can spray an upwardly inclined and converging secondary counter-current airflow. The outlets of the first auxiliary pipe 41 and the second auxiliary pipe 42 are both provided with adjustable guide nozzles.

[0046] The powder is pushed upwards through the central powder feeding pipe 5. Upon reaching the top, the powder immediately encounters a horizontal primary countercurrent airflow and experiences extremely strong gas shear force in the stagnation zone where the airflows converge. High-speed collisions occur between particles, breaking the van der Waals forces and achieving deagglomeration. Immediately afterwards, the high-speed deagglomerated powder enters the secondary countercurrent airflow. Due to the upward-sloping velocity component of the secondary countercurrent airflow, the powder undergoes high-energy collisions and deagglomeration in the stagnation zone. This not only forces the powder's scattering direction upwards but also forms a dynamic airflow barrier near the inner wall of the dispersion chamber 2, completely preventing powder adhesion to the wall. The mixed, uniform aerosol is then guided and accelerated out through the top conical converging structure. Utilizing the radial difference in diameter between the first auxiliary pipe 41 and the second auxiliary pipe 42, a ring-shaped turbulent field spreading outwards from the center is formed within the powder collection chamber, achieving secondary shear dispersion of the agglomerated powder.

[0047] In some embodiments, the interior of the tapered top cover 1 has a smoothly transitioning conical converging structure, and the aerosol outlet is located at the apex of the cone.

[0048] In some embodiments, the bottom of the inverted conical chamber of the powder collection chamber 6 is provided with a protrusion that fits tightly with the sealing cover 7. High-temperature resistant sealing rings are provided between the top cover 1 and the dispersion chamber 2, and between the dispersion chamber 2 and the powder collection chamber 6, to ensure extreme airtightness under a large temperature gradient, thus forming a detachable modular split structure.

[0049] In some embodiments, both the lower edge of the top cover 1 and the upper edge of the dispersion chamber 2 are provided with flat edge structures, and corresponding positioning holes are opened on the flat edges. Fasteners are passed through the positioning holes to achieve tight fixation between the two. The flat edge structure increases the contact area of ​​the mating surfaces, improves the connection sealing performance, and avoids leakage of high-pressure airflow. The cooperation between the positioning holes and the fasteners ensures that the axes of the top cover 1 and the dispersion chamber 2 are precisely aligned, preventing the flow guiding effect from decreasing due to assembly misalignment. At the same time, it enables a detachable connection, facilitating later cleaning and maintenance.

[0050] In some embodiments, the inverted conical inner wall of the powder collection chamber 6 is smooth, further reducing the coefficient of friction of the inner wall, reducing the resistance to the sliding of large powder particles, and preventing accumulation.

[0051] In some embodiments, the connection between the threaded connector 3 and the dispersion chamber 2 and the powder collection chamber 6 is equipped with a sealing structure, and the outer periphery of the threaded connector 3 is provided with anti-slip texture. This design relies on the advantages of modular structure to adapt to multiple scenarios, and to balance maintenance convenience and stability: each chamber and component can be detachably connected, which greatly simplifies the powder cleaning, maintenance and component replacement process, and solves the problem of inconvenient maintenance of traditional integral welded / fixed structures; at the same time, the threaded connection combined with the sealing structure can adapt to the process requirements of different temperature ranges and different carrier gas types, effectively buffering thermal expansion stress, ensuring the airtightness and long-term stability of the equipment under various process parameter optimization scenarios, and adapting to the diverse process requirements of advanced coating preparation.

[0052] In some embodiments, the connection between the sealing cover 7 and the bottom of the powder collection chamber 6 is provided with a sealing structure, and the sealing cover 7 is detachably connected to the powder collection chamber 6 through a threaded structure, which facilitates quick disassembly and cleaning of the returned powder, while ensuring the bottom is airtight to prevent powder leakage and the entry of outside air, and maintain stable airflow inside the chamber.

[0053] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention should be determined by the claims.

Claims

1. A modular, multi-stage flow field coupled powder aerosol conveying device, characterized in that, include: The top cover has a conical structure and an aerosol outlet at the top of the cone; The dispersion chamber is a cylindrical structure that is tightly connected to the lower edge of the tapered top cover; The powder collection chamber is tightly connected to the lower part of the dispersion chamber via a threaded connector. The powder collection chamber has an inverted conical chamber structure and a sealed cover at the bottom. The threaded connector is equipped with four centrally symmetrically distributed horizontal counter-current airflow inlets extending into the interior. A central powder delivery straight pipe passes through the sealed cover and extends upwards from the bottom of the powder collection chamber to the top space inside. The blowing directions of the two sets of opposing horizontal counter-current airflow inlets converge at two points at different heights above the powder outlet at the upper end of the central powder delivery straight pipe. Powder is pushed through the central powder delivery straight pipe to the powder outlet at the top of the central powder delivery straight pipe. At the powder outlet, four high-pressure carrier gases are ejected at high speed from the blowing ports of the four horizontal counter-current airflow inlets, forming a primary counter-current gas flow. The dispersion chamber consists of a primary airflow and a secondary counter-current airflow. The primary counter-current airflow is located below the secondary counter-current airflow. The powder ejected from the powder outlet is subjected to extremely strong gas shear force at the primary counter-current airflow, causing high-speed collisions between particles and breaking van der Waals forces, thus achieving de-agglomeration. The secondary counter-current airflow acts as a guide and protective gas, guiding the de-agglomerated powder upwards while also forming a dynamic airflow barrier on the inner wall of the dispersion chamber. Subsequently, the powder rises upwards within the conical top cover, and through the guiding and accelerating effect of the top conical structure, it forms a uniform aerosol and is delivered through the aerosol outlet. Large particles that have not been de-agglomerated settle under gravity and slide down the smooth inner wall of the conical powder collection chamber to the bottom, avoiding powder bridging and achieving powder recirculation.

2. The modular multi-stage flow field coupled powder aerosol conveying device according to claim 1, characterized in that, The lower edge of the top cover is a flat edge structure, and the upper edge of the dispersion chamber has the same flat edge structure and matches the lower edge of the top cover.

3. The modular multi-stage flow field coupled powder aerosol conveying device according to claim 2, characterized in that, The lower edge of the top cover and the upper edge of the dispersion chamber are both provided with positioning holes of the same size and corresponding positions. Fasteners are inserted into the positioning holes to form a tight fit between the lower edge of the top cover and the upper edge of the dispersion chamber.

4. The modular multi-stage flow field coupled powder aerosol conveying device according to claim 1, characterized in that, The threaded connector includes threaded portions located at the upper and lower parts, which are respectively connected to the threads at the bottom of the dispersion chamber and the top of the powder collection chamber.

5. The modular multi-stage flow field coupled powder aerosol conveying device according to claim 4, characterized in that, Four horizontally opposed airflow inlet pipes are inserted between the upper and lower threaded parts of the threaded connector and are symmetrically distributed. The included angle between two opposite horizontally opposed airflow inlet pipes is 180 degrees.

6. The modular multi-stage flow field coupled powder aerosol conveying device according to claim 5, characterized in that, The four horizontally opposed airflow inlet pipes are arranged in a cross shape, and the air outlets of two horizontally opposed airflow inlet pipes are radially opposite each other. The confluence point is located at a small distance directly above the powder outlet of the central powder delivery straight pipe.

7. The modular multi-stage flow field coupled powder aerosol conveying device according to claim 5, characterized in that, The threaded connector is provided with four centrally symmetrically distributed insertion ports, and four horizontally opposing airflow inlet pipes can be inserted into the insertion ports respectively.

8. The modular multi-stage flow field coupled powder aerosol conveying device according to claim 7, characterized in that, Two opposing central powder feeding pipes have a first auxiliary pipe at their outlets, radially aligned with the central powder feeding pipe. The outlet of the first auxiliary pipe generates a horizontal primary counter-current airflow and employs a flow channel structure with a retractable flow pattern. The other two opposing central powder feeding pipes have an upwardly bent and inclined second auxiliary pipe at their outlets. The outlet of the second auxiliary pipe ejects an upwardly converging secondary counter-current airflow. Utilizing the radial difference in diameter between the first and second auxiliary pipes, a ring-shaped turbulent flow field spreading outwards from the center is formed within the powder collection chamber, achieving secondary shearing and dispersion of the agglomerated powder. Both the first and second auxiliary pipes have adjustable guide nozzles at their outlets. The powder is pushed upward through the central powder feeding pipe. Upon reaching the top, the powder immediately encounters a horizontal primary countercurrent airflow and experiences extremely strong gas shear force in the stagnation zone where the airflows converge. High-speed collisions occur between the particles, breaking the van der Waals forces and achieving deagglomeration. Immediately afterwards, the high-speed deagglomerated powder enters the secondary countercurrent airflow. Because the secondary countercurrent airflow has an upward velocity component, the powder undergoes high-energy collisions and deagglomeration in the stagnation zone. This not only forces the scattering direction to be directed upwards but also forms a dynamic airflow barrier near the inner wall of the dispersion chamber, completely blocking the powder's adhesion to the wall. The mixed uniform aerosol is then accelerated and delivered through the guide of the top conical converging structure.

9. The modular multi-stage flow field coupled powder aerosol conveying device according to claim 1, characterized in that, The interior of the tapered top cover has a smoothly transitioning conical converging structure, with the aerosol outlet located at the apex of the cone.

10. The modular multi-stage flow field coupled powder aerosol conveying device according to claim 1, characterized in that, The bottom of the inverted conical chamber of the powder collection chamber is provided with a protrusion that fits tightly with the sealing cover. High-temperature resistant sealing rings are provided between the top cover and the dispersion chamber, and between the dispersion chamber and the powder collection chamber.

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