Apparatus and method for producing granules

Abstract

The present disclosure relates to an apparatus for producing (nano) particles, and optionally to sintering material, and to a method of producing nanoparticles in an upflowing method using such an apparatus. The core of such an apparatus comprises a first disc and a second disc comprising hypersonic vanes arranged in concentric rings and channels between the rings. The first disc and the second disc are arranged such that the channels of each disc at least partially surround the hypersonic vanes of the other disc.

Description

Technical Field

[0001] This application claims priority to European patent application EP 23382949.8, filed on September 19, 2023.

[0002] This disclosure relates to apparatus for producing particles, particularly nanoparticles, and to methods for producing (nano)particles using such apparatus in a top-down manner. Nanoparticles can be produced from materials at the micrometer scale. The apparatus of this disclosure can handle dry materials as well as liquid and gaseous materials. For example, input powders can be processed in a fluid atmosphere. In some examples, slurries or dispersions can also be used as inputs. Background Technology

[0003] Nanoparticles typically have at least one dimension between 1 nm and 100 nm, and optionally all dimensions between 1 nm and 100 nm. Because the surface area to volume ratio of materials becomes significant at the nanoscale, the properties of nanoparticles may differ from those of larger particles. Nanoparticles have applications in a wide range of fields, such as medicine, electronics, materials science, and more.

[0004] Current methods for producing these materials typically involve bottom-up processes or require the use of chemicals and high energy consumption. These processes can be time-consuming and expensive.

[0005] A known top-down method relates to mechanical grinding mills, disclosed in US 11154868 B2 and US 11607693B2. These documents mention two rotors, each comprising aerodynamic blades capable of rotating in opposite directions. However, it has been found that these designs cannot practically produce more than 5% nanoparticles from the input material. Furthermore, blade damage and wear actually occur. The input material collides with the blades, decomposes due to the impact, and also degrades the blades. Material detached from the blades can pollute the environment and may cause the nanoparticles to contain impurities.

[0006] This disclosure aims to address or at least reduce one or more of the aforementioned disadvantages. Summary of the Invention

[0007] In one aspect of this disclosure, an apparatus for producing material particles is provided. The apparatus includes a core for accelerating material and causing material particles to collide to produce smaller particles (particularly nanoparticles), wherein the core includes a first disk and a second disk, and one or more actuators, the second disk facing the first disk, the one or more actuators for rotating the first disk and / or the second disk. The first and second disks include a plurality of concentric rings and a plurality of concentric channels, wherein each ring includes a blade base and a plurality of hypersonic blades arranged at the blade base, the plurality of concentric channels alternating with the plurality of concentric rings. The hypersonic blades include a sharp leading edge, a sharp trailing edge, and suction and pressure surfaces configured to generate expansion waves. Furthermore, the hypersonic blades of the plurality of concentric rings of the first disk are arranged in the channels of the second disk, and the hypersonic blades of the plurality of concentric rings of the second disk are arranged in the channels of the first disk.

[0008] The channel formed on the second disk surrounds, at least partially, the hypersonic blades on the first disk, and vice versa.

[0009] Therefore, in the disks of the core, rings including blades alternate with rings excluding blades. Furthermore, the rings excluding blades form channels such that a height difference exists between the base of the channel and the base on which the blades are disposed, measured herein along the axial direction of the core. In this way, the channel of one disk at least partially surrounds the blades of the other disk.

[0010] In addition, the blades are hypersonic blades. In some examples, the hypersonic blades may include a kite-like or rhomboid shape in cross-section (i.e., in a plane taken perpendicular to the axial direction of the core, and therefore in a plane taken perpendicular to the axial direction of each disk).

[0011] These two aspects—the height difference between the channel base and the blade base, and the shape of the blades—allow the channel (i.e., the second ring separating the first ring) to surround the blades of the other disc. The shape of the blades helps prevent or at least reduce collisions / impacts between the input material and the blades. Instead, some input material collides with other input material to produce smaller pieces of material. As the first and / or second discs rotate, the input material can be drawn into the core and between the two discs. Therefore, the input material can be dragged into the interior of the core, rather than pushed into it.

[0012] Throughout this disclosure, sharp leading and trailing edges mean that the edges are not rounded. For example, an edge may comprise two adjacent edge portions that meet at the tip and have an angle between them (e.g., less than 180° or less than 90°), rather than a localized area where the edges are rounded. The suction and pressure surfaces of the blade may have similar sharp transition points, configured to generate expansion waves.

[0013] Throughout this disclosure, "hypersonic blade" can refer to a blade having the aforementioned shape. At least the blade shape can help accelerate the input material and bring it to a rotational speed similar to that of the material in the disk. Therefore, collisions between the input material and the blade can be avoided or at least reduced.

[0014] The input material can be, in particular, a powder-based material. As explained further below, the input material can be surrounded by surrounding materials, especially by fluids such as gases or liquids. In some examples, the input material can be a dispersion or a slurry. For example, a dispersion containing liquid and dissolved salt minerals and / or biological materials can be used.

[0015] In some examples, the first and / or second discs may include openings, optionally near the center of the discs or a central opening, through which material can be drawn into the core as the first and / or second discs rotate. Thus, material can be dragged between the discs from one axial side of the core, from the other axial side of the core, or even from both axial sides of the core. In some examples, elements for properly introducing and exiting material into and from the core may be provided at the inlet and outlet of the core. For example, ejectors may be provided. Other elements that facilitate the transport of material may be provided.

[0016] In some examples, both disks can rotate. In a preferred example, the two disks can rotate in opposite directions. In other examples, one disk can rotate while the other remains stationary. In some examples, the rotation of at least one disk can occur at more than 25,000 revolutions per minute (rpm), optionally higher than 40,000 rpm, such as about 45,000 rpm or higher. Sufficiently high rotational speeds can accelerate input material to hypersonic speeds (e.g., to speeds exceeding five times the speed of sound or even higher, depending on, for example, the diameter of the disk).

[0017] In some examples, the leading edges of the hypersonic blades in the first disk may point in the same circumferential direction as the first disk, and the leading edges of the hypersonic blades in the second disk may point in the same circumferential direction as the second disk. The leading edges of the blades in the first disk may point in the same or different directions as the leading edges of the blades in the second disk. The orientation of the hypersonic blades in each disk can be adjusted to suit the disk's rotation direction and the input material used. If the disks rotate in opposite directions, the leading edges of the blades in each disk may point in opposite directions. If the disks rotate in the same direction, the leading edges of the blades in each disk may point in the same direction (rotation direction). Moreover, if the disks rotate in the same direction but at different rotational speeds, the leading edges of the blades in each disk may point in opposite directions.

[0018] Suitable drives or actuators can be provided to rotate at least one disc. For example, one or more motors, pneumatic systems, electromagnetic drive systems, etc., can be used to induce rotation. In some examples, a flywheel can be attached to the disc to be rotated to reduce stress during operation.

[0019] In some examples, at least one disc can be rotated using a hydraulic or pneumatic system. In examples where a pneumatic system is provided to rotate the disc, the gas introduced into the core can also be the gas used to drive the disc, and the core can be under a slightly negative pressure relative to the pneumatic system. In this way, material leakage inside the core can be avoided or at least reduced due to the pressure difference between the core and the pneumatic system. Furthermore, contamination can be avoided if gas from the pneumatic system enters the core, since the gas in the pneumatic system and inside the core is the same. In some examples, two tanks of the same gas (e.g., an inert gas) can be provided. Gas from one tank can be introduced into the core to provide a specific atmosphere, while gas from the other tank can be used to drive the pneumatic actuator. In some examples, the pneumatic system can include a turbine and a compressor, such that gas from the respective tanks can be compressed and used to move the turbine, and thus the respective shaft and disc.

[0020] If liquid is to be introduced into the core, the core should be liquid-tight to avoid damaging surrounding components of the equipment. Non-contact couplings can be provided between the drive and the shaft used for rotating shafts. Suitable non-contact couplings can be magnetic couplings. Magnetic couplings can, for example, include permanent magnets or electromagnets. Non-contact couplings can help avoid or at least reduce the risk of liquid or moisture leaking from the core to the drive and damaging it. Because lubricant can be eliminated and because of the lower friction, non-contact couplings can also contribute to smoother operation and more efficient energy transfer from the drive to the shaft.

[0021] In some examples, the chord length between the leading and trailing edges of the hypersonic blades in the first disc decreases from the innermost radial ring towards the outermost radial ring, and the chord length between the leading and trailing edges of the hypersonic blades in the second disc decreases from the innermost radial ring towards the outermost radial ring. This can help generate lower pressure in the outer radial portion of the discs, drawing the input material into the core and accelerating it, and increasing the angular rotational velocity of the material between the discs in the outer radial direction of the core. This allows for faster collisions and fragmentation of the input material to the desired size.

[0022] In some examples, the pitch of the hypersonic blades in the rings of the first disc can increase radially from the innermost ring towards the outermost ring. Similarly, the pitch of the hypersonic blades in the rings of the second disc can increase radially from the innermost ring towards the outermost ring. This can also facilitate dragging the input material between the discs and efficiently breaking it down into smaller pieces.

[0023] In some examples, the first and second discs may comprise ceramic material. Specifically, the first and second discs may be made of ceramic material. In other examples, a ceramic coating may be provided. If the first and second discs comprise, for example, metallic material or are made of metallic material, then collisions with input materials that may exhibit magnetic effects during the use of the core (e.g., materials comprising metals such as iron) may be particularly difficult to handle. Using ceramic material on the discs can facilitate collisions and proper handling of such input materials.

[0024] The device may include one core or multiple cores. Therefore, a core may be referred to as a single-stage core (one core) or a multi-stage core (multiple cores). If the core is multi-stage, multiple pairs of disks may exist, each pair including a first disk and a second disk as described herein. In some examples, all first disks are driven using a single actuator / drive (such as a motor), and all second disks are driven by another actuator (e.g., another motor). As further explained below, when the device includes more than one core, input material can flow sequentially through each core to achieve a desired particle size and distribution. In some examples, the device may be configured such that material after collision can be collected directly from each core. Input material may also be selectively directed to specific cores for collision, without having to flow through all available cores.

[0025] In some examples, the core may also include a housing surrounding the first and second disks. One or more elements may be provided for acting on an atmosphere between the first and second disks and / or on the material when material is introduced between the first and second disks, during an impact process, or when material is discharged between the first and second disks. In some examples, one or more of the elements may be tools.

[0026] For example, multiple lasers can be provided in the housing, optionally arranged in a ring, so that multiple laser beams can be applied to the post-collision material to be removed between the disks. The post-collision material may have a softened lattice after the collision process, and its properties can be influenced by the laser beams. The laser can be used to reduce the post-collision material, i.e., to deoxygenate it. Selective influence / action on the post-collision material can also be performed in other ways when it is still soft and has not yet reached a hardened crystal structure.

[0027] In these or other examples, the housing may include one or more plasma torches. The plasma torches can be used to sinter material introduced between the first and second disks. Still in these or other examples, the housing may include one or more magnetrons. The magnetrons can be used to generate microwaves, which can be used to reduce the humidity level between the first and second disks. Alternatively or additionally, other suitable tools may be provided within the housing of the core.

[0028] Regarding sintering, the housing may include one or more elements suitable for aiding and / or enhancing the sintering of the material. That is, at least some of the one or more elements may be configured to regulate the sintering process within the core. For example, the housing may include one or more elements (e.g., conduits or tubes) for introducing one or more fluids (e.g., gases) that can facilitate the sintering of the material. In some examples, one or more of these elements may be provided near the inlet for introducing the input material into the core. In these or other examples, one or more elements may be provided near the outlet for removing the impacted material from the core. The sintered material can have a high density and stable structure. The housing of the impactor may also include one or more elements for regulating sintering conditions. For example, the temperature and pressure within the core can be regulated using suitable elements or tools. Furthermore, the housing of the core may include one or more elements for introducing electronic dislocations during the impact process, which can enhance the sintering and densification of the sintered material. In the apparatus, elements for aiding and / or enhancing the sintering of the material may also be provided after the outlet of the core, such as an injector arranged after the core.

[0029] Nanoscale materials, as well as materials with larger dimensions (e.g., micron-sized materials), can be used as inputs in the sintering process. Slurries, dispersions, and gas mixtures containing solid materials can also be used as inputs to the core during sintering. Sintered materials can be nanoscale materials, but can also have larger dimensions. Sintered materials can include two or more different materials, such as two or more nanoscale materials or micron-sized materials.

[0030] In addition to being configured for sintering, the equipment can also be configured for synthesizing materials. For example, two or more different materials can be introduced into the core of the equipment, collide, and then combine due to some chemicals or gases also introduced into the core.

[0031] Therefore, the material to be impacted can be introduced and guided into the core. Furthermore, the impacted material can be extracted from the core and guided away from it, for example, by a device. When the impacted material nanoparticles have a desired size (or when the sintered / synthesized material has a desired size and / or properties), they can be removed from the device. In some examples, they can be collected in a collection system or "collector system" and then removed from the device. In some examples, the collection system may include one or more glove boxes (i.e., hermetically sealed housings for ensuring stability) to provide a controlled environment for the nanoparticles and prevent contamination. In other examples, impacted material of the desired size can be removed directly from the core. A collection system that may include one or more ejectors can be connected to the outlet of the core. If the device includes multiple cores, multiple collection systems can be provided, for example, collection systems that can be connected to the outlet of the cores, allowing the impacted material to be removed from each core and directly packaged, for example, palletized.

[0032] The device can be configured to allow material to pass through the core more than once. If, after the collision process within the core, there is material that does not yet have the desired size (e.g., nanometer-scale), this material, which has not yet reached the desired size, can be allowed to pass through the core again. This process can be repeated multiple times.

[0033] In some examples, the device may also include a system for generating a low pressure or “vacuum” to remove impacted material from the core. This can be a suitable and efficient method for removing material from the core. Vacuum can be considered herein as a pressure significantly lower than the operating pressure within the core.

[0034] A vacuum can also be created before the input material to be impacted is introduced to prepare an atmosphere within the apparatus. For example, the interior of the apparatus can be purged, and then a vacuum can be applied before the material to be impacted is introduced to achieve a suitable atmosphere within the apparatus, see also below. In addition to creating a vacuum, or alternatively, one or more gases (e.g., inert gases) can be introduced into the apparatus to prepare an atmosphere. The oxygen level within the apparatus can also be controlled.

[0035] In some embodiments, the device may include a system for separating the impacted material from the surrounding medium. In some of these examples, the system may be the same as a system for generating low pressure to remove the impacted material from the core. Such a system may be, for example, a cyclone separator. Other systems may also be used, such as centrifugal separators, systems that include gravity separation, or systems that include potential separation (using, for example, electrostatic separation).

[0036] The apparatus may also include a system for controlling the atmosphere within the path through which the material travels. For example, the system may be configured to introduce a fluid (optionally a gas) into the apparatus to alter the atmosphere within the apparatus. Introducing nitrogen can help regulate the oxygen level within the apparatus. In some examples, argon is another fluid that can help create a desired and controlled environment. The system may additionally or alternatively be configured to create a vacuum within the apparatus. For example, a vacuum pump may be provided. A controlled and suitable atmosphere for generating nanoparticles can be achieved. The apparatus may also include a drying system and / or a dehumidification system.

[0037] The device may also include a controller. The controller can be configured to control (e.g., manage and coordinate) the operation of the device. The controller may have one or more processors and one or more memories containing instructions that can be executed by the one or more processors. In at least some examples, the device may also include multiple sensors that can be communicatively connected (via wired or wireless) to the controller. Examples of sensors may be temperature sensors, humidity sensors, pressure sensors, etc. The measurements from the sensors can help to accurately control and regulate the operation of the device in real time.

[0038] The device may also include multiple valves that can be opened and closed to operate the device appropriately. Valves can help control the flow of fluid through the device's internal pathways. They can also help regulate pressure.

[0039] The device can be configured to generate hydrogen (H2) gas internally. Bumping the oxidized metal material activates it, allowing the produced nanoparticles to react with water molecules, especially without the addition of alkali (such as potassium hydroxide or sodium hydroxide, KOH, and NaOH). Alkaline water, i.e., water containing hydroxide ions (OH-), can also be used (but is not mandatory). -) exceeds hydrogen ions (H + The term "metallic material" as used herein can include both metals (iron (Fe), aluminum (Al), calcium (Ca), magnesium (Mg), etc.) and metalloids (e.g., silicon (Si)). Metal oxide materials can also include nonmetallic elements or compounds. Additives can be added to improve the reaction between the metal oxide material and water. For example, if the metal oxide material includes silicon, graphene or activated carbon can help improve the reaction between the material and water. These additives can also be included in the metal oxide material. For example, the metal oxide material can include nanoscale activated carbon or graphene. Oxide materials as used herein can refer to materials capable of removing and capturing oxygen from water molecules, thereby generating hydrogen in the process. Other additives that can be used are, for example, iron nanoparticles or nickel (Ni).

[0040] The use of nickel can help weaken the bond between hydrogen and oxygen in water molecules by bonding with hydrogen atoms. Therefore, nickel can help promote the reaction between oxides and water molecules. Furthermore, nickel can help break down water molecules while keeping hydrogen atoms attached to it. This can also increase hydrogen production.

[0041] In some embodiments, nickel may be introduced into the core, for example, in powder form. In other examples, nickel may be attached to the interior of the device. For example, a strip containing nickel (e.g., made of or coated with nickel) or other suitable element may be attached to the device. A suitable location may be at the outlet of the core, such that an aqueous dispersion of impacted oxide material can pass through and come into contact with the nickel.

[0042] The oxide material can be provided and introduced into the core in several ways: for example, it can be fed into the device in powder form and water can be added to introduce a dispersion / slurry including the powder into the core of the device, or a dispersion / slurry of particles in water can be fed into the device, or the powder can be introduced into the core and then water can be added to the nanoparticles after the collision process.

[0043] Therefore, it is possible to obtain nanoparticles that can react with water (e.g., seawater) by colliding oxide materials, without the need for additional chemical elements / compounds. This reaction can efficiently produce hydrogen gas. For example, if silicon is used, the produced silicon nanoparticles can undergo the following reaction: Therefore, hydrogen gas is released. The silanol functional group (Si-OH) of orthosilicic acid (Si(OH)4) can then form a siloxane bond (Si-O-Si) and release water: Subsequently, the released water molecules can react with the unreacted silicon nanoparticles, maintaining hydrogen production until the silicon nanoparticles are completely consumed. .

[0044] The aforementioned chemical reactions can lead to a decrease in pH, and this decrease in pH can increase the kinetics of the reaction. For example, lowering the pH to below 5 can help accelerate the process and increase the reactivity of the silicon nanoparticles. However, this will depend on which additive is added and in what amount (if added). In some examples, the pH may also be increased. In some examples, an acidic solution containing, for example, orthosilicic acid (Si(OH)4) can be added to accelerate the hydrogen production process.

[0045] In some examples, hydrogen can be generated in a cyclone separator (or, for example, in a centrifuge, if such a component is used instead). Hydrogen can be collected from the top of the cyclone separator, and the remaining liquid can be collected from the bottom. In some examples, hydrogen can also be generated in and collected from the core.

[0046] Although not strictly necessary, hydroxide compounds such as KOH or NaOH can be used to initiate or start the production of hydrogen. This can accelerate the process (start-up) because the reaction between water and the metal oxide nanoparticles will begin more quickly. Since KOH or NaOH is only used to start the reaction, not to sustain it, a small amount may be sufficient.

[0047] It should also be noted that nanoparticles suitable for generating hydrogen using the apparatus described herein can also be used externally to the apparatus. For example, the nanoparticles can be mixed with water (e.g., seawater) to generate hydrogen in a suitable container outside the apparatus. For example, a reactor can be used to generate hydrogen. In some examples, the reactor can be operatively connected to the apparatus.

[0048] The core and apparatus described herein can be used to produce particles (optionally nanoparticles) and sintered materials. In particular, smaller particles obtained in the core after the material collides with itself can be sintered. In some embodiments, the produced material can be a dispersion. For example, the produced particles can be dispersed in an aqueous dispersion. In another aspect of the invention, a method is provided. This method includes rotating a first and / or second disk of a core as described throughout this disclosure, drawing material into the core due to the rotation, accelerating the material, and causing the material to collide with itself between a first ring of hypersonic blades of the first disk and a first ring of hypersonic blades of the second disk, adjacent in the radial direction of the core, thereby producing material (nano)particles.

[0049] The method may also include, for example, changing the atmosphere within the core during the rotation of at least one disk. For example, one or more fluids may be introduced into the core.

[0050] This method may further include sintering the particulate material after impact. Sintering can be carried out in the core of the equipment.

[0051] The method may also include, for example, generating hydrogen (gas) from the produced nanoparticles in the core of the device or in the cyclone separator (or centrifuge) of the device. Nanoparticles derived from metal oxide materials can react with surrounding water to produce hydrogen.

[0052] The specific aspects, examples, and elements of the aspects or examples disclosed herein may be combined in any number and order to form new aspects and examples that form part of this disclosure. Attached Figure Description

[0053] Figure 1 A side view and exploded view of an example core are schematically shown, which is used to accelerate material and cause the material to collide with itself to produce particles (optionally nanoparticles).

[0054] Figure 2 schematically shown Figure 1 The image shows a bottom view of the first disc of the hypersonic blades.

[0055] Figure 3 A cross-section of an example of the first and second plates is shown schematically.

[0056] Figure 4 A schematic top view of the first element, which supports... Figure 1 The first disc, including hypersonic blades.

[0057] Figure 5 An example of the geometry and arrangement of hypersonic blades in a disk including the blades is shown schematically.

[0058] Figure 6A A perspective view of a device including a core according to the present disclosure is shown schematically.

[0059] Figure 6B schematically shown Figure 6A The front view of the device.

[0060] Figure 7 Another example of the device is illustrated schematically, which includes multiple cores. Detailed Implementation

[0061] Reference will now be made in detail to embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation only and not as a limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to the present disclosure. For example, features shown or described as part of one embodiment may be used with another embodiment to produce additional embodiments. Therefore, the present disclosure is intended to cover such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0062] Figure 1 A side view and exploded view of an example core 10 are schematically shown, which is used to accelerate material and cause the material to collide with itself to produce particles (optionally nanoparticles). Such a core can be used in equipment for producing smaller particles and / or for sintering materials.

[0063] The core 10 includes a first disk 11 and an opposing second disk 12, the first disk 11 including hypersonic blades and the second disk 12 including hypersonic blades. In this example, the core 10 also includes a first support element 13 for supporting the first disk 11 and a second support element 14 for supporting the second disk 12.

[0064] The core 10 also includes a housing 15 that at least surrounds the first disc 11 and the second disc 12. The housing 15 may form a chamber in which the first disc 11 and the second disc 12 are arranged. A first support element 13 and a second support element 14 may be configured to connect to corresponding portions of the housing 15. Although in the example of this figure the discs are shown as separate parts from their corresponding support elements, in other examples they may be integrally formed, or any suitable support for the first disc 11 and the second disc 12, and any suitable connection between them and, for example, a shaft and / or the housing 15, may be provided.

[0065] In some examples, disks 11 and 12, including hypersonic blades and support elements 13 and 14, can form a rotor. In some examples, disks 11 and 12, including hypersonic blades and support elements 13 and 14, can form a stator. At least one disk 11 or 12 including the blades can be rotatable. Both disks can be rotatable, or one of the disks can be rotatable. If both disks are rotatable, they can rotate in the same direction or in opposite directions. The orientation of the hypersonic blades and the rotation direction of the disks can be adjusted to properly draw and accelerate material inside the core 110 and between the disks 11 and 12 including the hypersonic blades. In the specifically disclosed example, the two disks rotate in opposite directions.

[0066] The paired disks 11, 12, including hypersonic blades and support elements 13, 14, can be directly or indirectly connected to the corresponding shafts. In some examples, the connection between the disks and the corresponding shafts can be via a hydraulic or magnetic connection system. Bearings such as ceramic bearings can be provided. Actuators can be provided to rotate the shafts, and thus rotate the corresponding disks and their hypersonic blades. In some examples, one or more electric motors can be provided. The motors can be AC ​​motors, brushless DC motors, or any suitable motors commonly used to rotate shafts. Alternatively, other suitable actuators can be provided for rotating the shafts at high speeds. One or more actuators can be arranged outside the core 10, and in a preferred example, the connection can be magnetic to avoid any contamination.

[0067] exist Figure 1 In the example, the first tray 11 and the second tray 12 are arranged in a vertical configuration (rotating about a vertical axis). In other examples, the first tray 11 and the second tray 12 may be arranged in a horizontal configuration (rotating about a horizontal axis) or in a different configuration.

[0068] Figure 2 schematically shown Figure 1 The figure shows a bottom view of a first disc 11 including hypersonic blades. The first disc 11 and the second disc 12 include a first plurality of concentric rings 16. Each ring 16 includes a blade base and a plurality of hypersonic blades 17 arranged at the blade base to draw in material to be accelerated and collide with itself. The first disc 11 and the second disc 12 also include a second plurality of concentric channels 18, which alternate with the first plurality of concentric rings 16. A central opening 25 is also visible in the figure, through which material can be drawn into the core 10 as the first disc 11 and / or the second disc 12 rotate.

[0069] Figure 3 A schematic cross-section of an example of a first disk 11 and a second disk 12 facing each other is shown. This cross-section is taken in a plane including the axial and radial directions of the core 11. As can be seen from the figure, channels 18 in each disk alternate with blade rings 16. Furthermore, the channels 18 of the disks at least partially surround the hypersonic blades 17 of the other disk. Each channel 18 includes a channel base 19, and the channel base 19 is offset from the blade base 20 along the axial direction of the core 10. The sidewalls of the blade ring 16 and the sidewalls of the channel ring 18 can be shared; that is, a single wall can form the sidewalls of both the blade ring 16 and the blade ring 18. In some examples, the channels 18 can be U-shaped or cap-shaped.

[0070] As can also be seen from the figure, the hypersonic blades 17 of the first plurality of concentric rings 18 of the first disc 11 are arranged in the channel 18 formed by the second plurality of concentric rings of the second disc 12, such that the channel 18 formed by the second plurality of concentric rings at least partially surrounds the hypersonic blades 17 of the first plurality of concentric rings 16. Similarly, the hypersonic blades 17 of the first plurality of concentric rings 16 of the second disc 12 are arranged in the channel 18 formed by the second plurality of concentric rings of the first disc 11, such that the channel 18 formed by the second plurality of concentric rings at least partially surrounds the hypersonic blades 17 of the first plurality of concentric rings 16.

[0071] The hypersonic blades 17 can be integrally formed with the portion of the disk that supports them, or they can be formed separately and then attached to the corresponding portion of the disk.

[0072] The gap (along the axial direction) between the two disks 11 and 12 can be appropriately set. In some examples, such a gap can be, for example, between 1 micrometer and 2 mm, or between 200 micrometers and 2 mm. In some examples, a gap of 500 micrometers can be used.

[0073] Back Figure 2 For example, the hypersonic blade 17 includes a sharp leading edge 21, a suction surface 22 and a pressure surface 23, and a sharp trailing edge 24, with the suction surface 22 and pressure surface 23 having sharp transition points. This shape facilitates the intake of input material between the first disk 11 and the second disk 12 when at least one disk rotates. The shape and size of the blades 17 in the blade ring 16 can be identical, but in some examples, the shape and / or size of the blades 17 can vary between the blade rings 16. The shape, pitch, chord length, etc., of the blades can be optimized for local conditions in each ring, i.e., the blade's speed will increase with increasing distance from the center.

[0074] The leading edge 23 of the hypersonic blade 17 of the first disc 11 can point in the same circumferential direction as the first disc 11. The leading edge 23 of the hypersonic blade 17 of the second disc 12 can point in the opposite circumferential direction: in this example, the disc with blades rotates in the opposite direction.

[0075] Furthermore, the chord length of the hypersonic blade 17 of the ring 18 of the first disc 11 (i.e., the length between the leading edge 23 and the trailing edge 24) decreases from the innermost radial ring of the first disc 11 toward the outermost radial ring. Similarly, the length between the leading edge 23 and the trailing edge 24v of the hypersonic blade 17 of the ring 16 of the second disc 12 decreases from the innermost radial ring of the second disc 12 toward the outermost radial ring.

[0076] The pitch, which is the circumferential distance between the leading edges of two consecutive blades, can increase radially from the innermost ring of the first disk 11 toward the outermost ring. The same applies to the blades of the second disk.

[0077] In some examples, the first disc 11 and the second disc 12 may comprise a ceramic material, for example, the first disc 11 and the second disc 12 may be made of a ceramic material. This includes blade 17, which may comprise a ceramic material, for example, the blade 17 may be made of a ceramic material.

[0078] Figure 4 schematically shown Figure 1 A top view of the first element 13, which supports a first disk 11 including hypersonic blades 17. As can be seen in the figure, a central opening 26 is provided in this example to allow input material to pass toward the interior of the core 10.

[0079] Figure 5 An example of a specific geometry and arrangement of hypersonic blades 17 in a disk including blades is schematically shown. Several angles and dimensions regarding blades 17 can be seen in this example. The total height 27 of the ring 16 including blades 17 (referring herein to the dimension along the axial direction of the disk) can be approximately 10 mm. The height 28 of the blades can be 4 mm, the height 29 of the ring 16 including blades 17 but in the region between the two blades can be approximately 6 mm, and the height 30 of the ring 18 forming the channel can be 3 mm. Therefore, the axial distance between the channel base 19 and the blade base 20, i.e., the channel depth, can be approximately 3 mm. The diameter of the disk can be approximately 165 mm.

[0080] In some examples, the rotation of the first and second discs can be performed at speeds exceeding 25,000 revolutions per minute (rpm), optionally exceeding 40,000 rpm. For example, approximately 45,000 rpm or higher. Sufficiently high rotational speeds can accelerate the input material to hypersonic speeds (e.g., speeds exceeding five times the speed of sound).

[0081] In other examples, different parameters can be used. Parameters (such as the size and orientation of blade 17) can vary depending on the material being processed.

[0082] In some examples, the housing 15 of the core 10 surrounds the first disk 11 and the second disk 12. The housing 15 of the core 10 may include one or more elements for acting on the atmosphere between the first and second disks and / or on the material when material is introduced between the first and second disks, during the collision process, or when material is discharged from between the first and second disks included in the housing 15. For example, one or more of the following may be provided in the housing 15: a plasma torch, a magnetron, and a laser. A ring arrangement of lasers may be provided in the housing such that the lasers are pointed to a small area through which the material after collision is discharged.

[0083] A cooling system can be provided to cool the core 10. For example, the core 10 can be air-cooled, or the housing can include conduits through which cooling fluid can flow.

[0084] A system for exfoliating graphene can also be provided in the core 10, for example, in its housing 15. This system can be configured to provide high frequency and voltage for this purpose.

[0085] At least some of the one or more elements may be configured to regulate the sintering process within the core 10. These elements may, for example, allow control of one or more of the pressure, temperature, and composition of the atmosphere within the core 10. For example, at least some of the elements may be configured to allow the introduction of a desired fluid, such as a desired gas, into the core 10.

[0086] The core 10 can be incorporated into the device. According to another aspect, a device for obtaining granules from a material is provided. Figure 6A and Figure 6B Examples of devices are provided in the document. Figure 6A A perspective view of a device including a core according to the present disclosure is shown schematically. Figure 6B schematically shown Figure 6A The front view of the device.

[0087] Device 31 includes a core 10 and an inlet 32. The core 10 is as described throughout this disclosure. The inlet 32 ​​is used to introduce materials into the device, specifically to introduce a device path through which the materials can travel. See [reference needed]. Figure 6A Device 31 also includes one or more components that connect inlet 32 ​​and core 10. From Figure 6B As can be seen, material source 32 can provide the material to be introduced into the equipment, so that the material can reach the core 10.

[0088] Device 31 may include a hopper 33. The hopper may hold the material to be impacted introduced therein, and then the material may be dispensed. Device 31 may be configured to meter the material to be introduced into core 10. For example, device 31 may include a system 34 for metering the material to be impacted. Any suitable metering system may be used. For example, a roto valve may be used.

[0089] The device may include systems 39 and 40 for establishing an atmosphere within the path of the material traveling through the device. For example, the system may be configured to introduce a fluid into the device to alter the atmosphere within it. Fluids such as nitrogen (gas) can help maintain controlled oxygen levels during the production of (nano)particles. Fluids such as argon (gas) can help create a controlled environment for certain processing conditions. Other suitable fluids may be used. For example, systems 30 and 40 may be configured to provide liquid nitrogen, which can help achieve cryogenic conditions. In some examples, systems 39 and 40 may include vacuum pumps for generating vacuum conditions.

[0090] exist Figure 6B In one example, element 40 and vacuum pump 39 are shown; element 40 is used to deliver fluid. In this example, element 40 and vacuum pump 39 are fluidly connected to hopper 33. However, in other examples, atmosphere conditioning may be provided at different locations. At least in some examples, atmosphere conditioning may be provided before the material is first drawn into core 10. In some examples, a vacuum may be applied, and then a fluid such as nitrogen may be introduced. Once the desired atmosphere is established, material can be introduced into the device, for example, into hopper 33.

[0091] Therefore, at least in some examples, the material to be collided with can be surrounded by an surrounding medium. Such a medium can include air, but can also include other fluids, such as the fluids introduced by systems 30 and 40 for setting the atmosphere. As will be explained further below, the material after collision can separate from the surrounding medium after leaving the core 10. As described with respect to the core 10, the surrounding medium can also be altered within the core 10 if, for example, a gas or another fluid is introduced into the core 10. In the core 10, both the input material and the surrounding medium can be accelerated.

[0092] The device 31 may also include one or more actuators for rotating at least one of the first disc 11 and the second disc 12. The actuators may be, for example, motors.

[0093] The device 31 may include a system for generating low pressure to remove impacted material from the core 10. Specifically, the system may be configured to generate low pressure at the outlet of the core 10. In addition to helping to remove impacted material from the core 10, this low pressure may also help reduce friction with the core 10 and reduce collisions between the material and the hypersonic blade 17.

[0094] Device 31 may include a system 35 for separating post-collision material from the surrounding medium. An example of such a system may be a cyclone separator. A cyclone separator can remove post-collision material from a fluid such as a gas or liquid. This can be achieved through gravity and rotational effects. In some examples, system 35 (e.g., a cyclone separator) may be configured to separate material by size or density. The post-collision material may have different sizes, and system 35 may separate the post-collision material into two or more groups based on, for example, the size of the material's components. In some examples, system 35 for separating post-collision material from the surrounding medium and system for generating low pressure to remove the post-collision material from core 10 may be the same.

[0095] The material following the collision may include a portion of nanoparticles (or more generally, particles or material) having reached the desired size and thus ready for collection, and may also include a portion of larger nanoparticles or material that have not yet reached the desired size. In some examples, the prepared nanoparticles may be removed directly from device 31. In other examples, device 31 may include system 36 configured to collect nanoparticles that have reached the desired size. Such system 36 may include elements configured to draw nanoparticles toward the interior of system 36. Nanoparticles may reach collection system 46, for example, from a cyclone separator, see [link to relevant documentation]. Figure 6B Arrow 41 in the diagram. System 36 may include a storage element 37 from which nanoparticles can be removed; in some examples, storage element 37 may be removed from collection system 36.

[0096] The portion of material that did not reach the desired size after the collision can be guided to core 10 for another collision, see [reference needed]. Figure 6B Arrow 38 in the diagram. Device 31 can be configured for this purpose. For example, turbine blower 42 can help remove the corresponding impacted material and guide it toward core 10. The medium surrounding the impacted material can also be guided to core 10 after it has separated from the impacted material. In some examples, one or more turbine blowers can be connected to system 35 for separating the impacted material from the surrounding medium.

[0097] In some examples, the produced nanoparticles (or, for example, sintered materials) may be further processed after they have been produced. In other examples, they may be packaged directly after production. Device 31 may include suitable systems for packaging the produced materials (e.g., the produced nanoparticles) in a suitable manner. For example, device 31 may include container-based systems, including, for example, glow boxes for packaging the produced materials. In some examples, the device may be located in a cleanroom. The cleanroom may include one or more systems for controlling air quality (e.g., for filtering air). Blankets, such as water blankets, may be provided for air filtration.

[0098] exist Figure 6B Multiple valves 43 can also be seen. These valves regulate the flow of fluid through the equipment path.

[0099] The device may include more than one core. Figure 7 An example of a device 600 comprising multiple cores (specifically three cores) is schematically shown. Thus, three stages can be provided: In the first stage, input material is introduced into the first core 606. Upon impact, it is introduced into the first cyclone separator 610. In the second stage, the impacted material from the first stage, already separated from the surrounding medium, is introduced into the second core 912. The impacted material then passes through the second cyclone separator 616. And in the third stage, the material is introduced into the third core 618. The impacted material in the third core 618 is again separated from the surrounding medium in the third cyclone separator 622. Figure 7 In the example, multiple actuators 608, such as electric motors, are used to rotate the first and second discs of each core 606, 912, 618.

[0100] The device 600 may include or be connected to a storage container 602, which stores input material (e.g., powder material). The input material may be conveyed to the first core 606 along with an surrounding medium (e.g., gas) via a screw feed system 604.

[0101] The device 600 may also include a fourth cyclone separator 624 and multiple ultrasonic generators 626A, 626B disposed in the fourth cyclone separator 624. When particles exiting from the third cyclone separator 622 pass through the fourth cyclone separator 624, the ultrasound generated by the ultrasonic generators 626A, 626B helps to palletize the produced particles. The pallets may have dimensions of a few micrometers; for example, in some examples, the length of the pallet may be less than 20 micrometers. Multiple pallets may be stored in a box.

[0102] The device 600 may also include a turbine blower 628 for generating low pressure on the fourth cyclone separator 624 and extracting particles from the separator 624, such that if the obtained particle size is larger than the desired particle size, they can be directed toward the first core 606. An actuator 630, such as an electric motor, may be provided to operate the turbine blower 628.

[0103] The apparatus 600 may also include a nitrogen generator 632 for maintaining a low-oxygen atmosphere during pellet production. The nitrogen generator 632 ensures a consistent and controlled oxygen level during pellet production. The apparatus 600 may also include an inert gas tank 634 for providing an inert atmosphere. The nitrogen generator 632 and the inert gas tank 634 can be connected to a vacuum pump 636 via a valve station 638. The vacuum pump 636 can be provided to deprive the entire system of air. In some examples, a vacuum can be created first, and then the path for the pellets can be filled with, for example, nitrogen.

[0104] The device 600 may also include multiple sensors, such as flow sensors, temperature sensors, humidity sensors, pressure sensors, and speed sensors. A sensor control system can be used to control the operation of the sensors. The control unit can control the operation of the device 600 during pellet production based on real-time data obtained from the sensors.

[0105] Figure 7 Various aspects of the equipment can be applied and combined. Figure 6A and Figure 6B The same applies to devices that are [specifically] ... Figure 6A and Figure 6B The equipment may include one or more ultrasonic generators for stacking the produced particles.

[0106] The core and apparatus described herein can be used to produce smaller particles, such as nanoparticles, and to sinter materials from smaller particles obtained through collision. In another aspect, a method is provided. The explanations and details provided regarding the core and apparatus can be applied to this method. The method includes rotating a first and / or second disk of the core as described throughout this disclosure, drawing material into the core due to the rotation, accelerating the material, and causing the material to collide with itself between a first ring of hypersonic blades of the first disk and a first ring of hypersonic blades of the second disk, adjacent in the radial direction of the core, thereby producing material particles, optionally nanoparticles.

[0107] When the material within the core 10 reaches hypersonic speeds, centrifugal force can alter its trajectory and lead to an increase in collision frequency. Furthermore, the collisions release energy, such as the amount of energy that previously held the material together. Since the separated material is typically denser than the surrounding medium, this energy may be difficult to disperse among the surrounding material. Therefore, this energy can affect the material after the collision, for example, causing stress-related cracking and polarization on the surface of the material after the collision.

[0108] The Coanda effect can occur during the use of the core 10 and the device 31. This effect can increase the surface charge of the hypersonic blade 17 and can help repel material away from the blade, thereby helping to reduce blade damage.

[0109] The method may also include altering the atmosphere within the core, for example, during the rotation of at least one disk.

[0110] This written specification uses examples to disclose teachings, including preferred embodiments, and also enables any person skilled in the art to put the teachings into practice, including making and using any device or system and performing any combination of methods. The patentable scope is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims. Aspects from the various embodiments described, and other known equivalents of each such aspect, can be mixed and matched by a person skilled in the art to construct additional embodiments and techniques within the scope of this disclosure. If reference numerals associated with the drawings are placed in brackets within the claims, they are only for the purpose of increasing the comprehensibility of the claims and should not be construed as limiting the scope of the claims.

Claims

1. An apparatus for producing material particles, wherein the particles are optionally nanoparticles, the apparatus comprising: A core for accelerating the material and causing the material particles to collide to produce smaller particles, wherein the core includes a first disk and a second disk, and one or more actuators, the second disk facing the first disk, the one or more actuators for rotating the first disk and / or the second disk, and the first disk and the second disk comprising: Multiple concentric rings, wherein each ring includes a blade base and multiple hypersonic blades, the multiple hypersonic blades being arranged at the blade base; Multiple concentric channels, which alternately interweave with the multiple concentric rings; The hypersonic blade includes a sharp leading edge, a sharp trailing edge, and a suction surface and a pressure surface, wherein the suction surface and the pressure surface are configured to generate an expansion wave. The hypersonic blades of the plurality of concentric rings of the first disk are arranged in the channels of the second disk; and The hypersonic blades of the plurality of concentric rings of the second disk are arranged in the channel of the first disk.

2. The device according to claim 1, wherein, The driver is configured to rotate the first disk in a first direction and to rotate the second disk in a second direction opposite to the first direction.

3. The device according to claim 1 or 2, the device further comprising an inlet and a material guide, the inlet being used to introduce the material into the device, and the material guide being used to guide the material to the core.

4. The device according to any one of claims 1-3, wherein, The first disc and / or the second disc includes an opening through which material can be drawn into the core when the first disc and / or the second disc rotates.

5. The apparatus according to any one of claims 1-4, further comprising a system for setting an atmosphere within the path through which the material travels.

6. The apparatus according to any one of claims 1-5, the apparatus further comprising a system for generating a vacuum to remove impacted material from the core.

7. The apparatus according to any one of claims 1-6, further comprising a separator system for separating the impacted material from the surrounding medium.

8. The apparatus according to any one of claims 1-7, further comprising a collector system configured to collect the produced particles.

9. The device according to any one of claims 1-8, wherein, The chord length of the hypersonic blades of the rings of the first and / or second disks decreases from the innermost radial ring of the respective disk toward the outermost radial ring.

10. The device according to any one of claims 1-9, wherein, The pitch of the hypersonic blades of the first and / or second disk rings increases from the innermost radial ring of the respective disk toward the outermost radial ring.

11. The device according to any one of claims 1-10, wherein, The first and second plates comprise ceramic material, and optionally are made of ceramic material.

12. The device according to any one of claims 1-11, wherein, The core also includes a housing that encloses the first disk and the second disk, wherein the housing further includes one or more elements that act on the atmosphere between the first disk and the second disk and / or on the material when the material is introduced between the first disk and the second disk, during the collision process, or when the material is output from between the first disk and the second disk.

13. The device according to claim 12, wherein, At least some of the elements are configured to regulate the sintering process within the core.

14. A method comprising: The first disk and / or the second disk of the core according to any one of claims 1-13 are rotated, and due to the rotation, material is drawn into the core, the material is accelerated, and the material collides with itself between the first ring of the hypersonic blade of the first disk and the first ring of the hypersonic blade of the second disk, which are adjacent in the radial direction of the core, thereby producing the material particles, optionally producing nanoparticles.

15. The method of claim 14, further comprising altering the atmosphere within the core.

Images