Dual-sided compound curve ultrasonic vibration tin powder atomization device and method of use thereof

Abstract

This invention discloses a double-sided composite curve ultrasonic vibration tin powder atomization device and its usage method, belonging to the field of metal powder preparation technology. The device includes a drive module, a accommodating cavity, an ultrasonic vibration transducer, a wireless power transmission device, an amplitude transformer, and a double-sided composite curve atomization disk. The contour curves on both sides of the atomization disk are mirror-symmetrical, and each side contour is composed of three piecewise function curves, used for initial centrifugal transport and pre-dispersion of molten tin, fine control of liquid film thickness, and improvement of liquid film breakage efficiency and particle sphericity. The central axis of the atomization disk is equipped with a slit, symmetrical conical guide tips, and symmetrical threads, allowing for flipping and reuse. In use, the curve parameters are selected according to the target particle size, and the ultrasonic vibration frequency and amplitude are set. Under an inert atmosphere, the molten tin enters the atomization disk through the guide tips and slits, and is cooled and sieved after atomization in the three-segment zone. This invention can improve raw material utilization, atomization efficiency, particle size uniformity and sphericity of tin powder, and reduce particle agglomeration rate.

Description

Technical Field

[0001] This invention relates to the field of metal powder preparation technology, and in particular to a double-sided composite curve ultrasonic vibration tin powder atomization device and its usage method. Background Technology

[0002] Tin powder is a silvery-white powder material that, due to its excellent ductility, thermal conductivity, and electrical conductivity, has become an important industrial raw material in the electronics and metallurgy industries. With the rapid development of related industries, the market has placed higher demands on the particle size distribution, sphericity, and yield of tin powder products. Currently, traditional tin powder preparation mainly employs centrifugal atomization and airflow atomization methods; while these two methods are technically mature and can achieve large-scale production, their inherent process characteristics make it difficult to meet the quality standards of tin powder for specific application scenarios.

[0003] Ultrasonic atomization is a novel tin powder preparation technology that has emerged in recent years. Its core principle is to utilize the high-frequency vibration and shear resistance of ultrasound to break down and refine molten tin into solid tin powder particles. Compared to traditional methods, ultrasonic atomization technology exhibits significant advantages in particle size control, sphericity improvement, and yield. However, currently available ultrasonic atomization devices generally employ a single-sided design with a smooth, flat surface on the atomizing disc, lacking effective structural features. This results in the inability to fully utilize the vibrational energy characteristics of ultrasound, leading to low raw material utilization and failing to fully realize the potential for improving atomization efficiency, particle uniformity, sphericity, and final yield.

[0004] To address the shortcomings of the existing technology, this invention proposes an ultrasonic vibration tin powder atomizing device comprising a double-sided composite curve atomizing disk. This design aims to significantly improve raw material utilization and effectively enhance the atomization efficiency, particle size, sphericity, and yield of tin powder by optimizing the atomizing disk structure, thereby meeting the production requirements of high-quality tin powder. Summary of the Invention

[0005] The purpose of this invention is to provide an ultrasonic vibration tin powder atomizing device with a double-sided composite curve atomizing disk. Through the unique double-sided design and unique curve structure, the material utilization rate, tin powder atomization efficiency, particle size, sphericity and yield are greatly improved.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: A double-sided composite curve ultrasonic vibration tin powder atomizing device, characterized in that it includes a drive module, a accommodating cavity, an ultrasonic vibration transducer, a wireless power transmission device, an amplitude transformer, and a double-sided composite curve atomizing disk. The drive module is coaxially disposed at the lower end of the accommodating cavity to achieve coaxial rotation; The upper end of the accommodating cavity is provided with a cavity, and the front end of the ultrasonic vibration transducer is disposed in the cavity; The ultrasonic vibration transducer is composed of a rear cover plate, a piezoelectric ceramic sheet and a front cover plate in sequence, and is coaxially pressed together by bolts. The wireless power transmission device provides electrical energy. The transmitting end of the wireless power transmission device is sleeved on the outer shell of the drive module, and the receiving end of the wireless power transmission device is disposed on the outer peripheral surface of the accommodating cavity. The two transmit electrical energy through alternating magnetic field coupling. The upper end of the ultrasonic vibration transducer is connected to the amplitude transformer to amplify the amplitude for subsequent atomization. The end of the amplitude transformer is connected to the double-sided composite curve atomizing disk; The rotary drive device includes: a stator and a rotor; the stator is sleeved on the outside of the rotor, and the clamping device and the rotor are coaxially fixed to achieve synchronous rotation; The wireless power transmission device includes: a transmitter and a receiver; the transmitter is disposed on the housing of the rotary drive device, and the receiver is disposed on the outer circumference of the clamping device, with the transmitter and receiver coaxially facing each other and separated by a preset gap; an external power supply supplies power to the transmitter, and the receiver and transmitter transmit electrical energy through alternating magnetic field coupling; the receiver transmits electrical signals to the ultrasonic transducer to generate high-frequency vibration. The clamping device has a cavity inside its front end face, and the front end of the ultrasonic transducer is installed in the cavity; The amplitude transformer is located at the front end of the ultrasonic transducer; The third-order curve atomizing disk is located at the front end of the amplitude transformer; The molten tin supply device includes a melting furnace, a holding furnace, and a nozzle; the nozzle outlet is coaxially aligned with the center of the third-order curve atomizing disk.

[0007] The axis of rotational symmetry of the double-sided composite curve atomizing disk is: y The axis is the radial axis (x-axis), and the contour curves on both sides of the disk surface are... x The axis forms a mirror image; in the plane xOy Within the first quadrant, the unilateral profile curve is described by a piecewise function, the specific expression of which is: ; Section 1 Used to achieve initial centrifugal transport and pre-dispersion of molten tin; Second Section Used to achieve precise control of liquid film thickness; Section 3 Used to improve liquid film breakup efficiency and particle sphericity; m , c , s For non-negative real numbers, D , E , F ,G , H For real numbers, x 1 , x 2 , x max For the section boundary;

[0008] In the double-sided composite curve atomizing disk, the three curve segments connect at the points... x 1 and x 2 The curves are continuous at all points, meaning that at the connection point, the function values ​​of the two curve segments are equal.

[0009] When preparing tin powder using the aforementioned double-sided composite curve ultrasonic vibration tin powder atomization device, by changing... m , c , s , D , E , F , G , H This method alters the curve shape, resulting in a 30%–40% increase in particle size uniformity, an 8%–15% increase in sphericity, an 80%–85% increase in atomization efficiency, a 30%–35% increase in powder yield, a 65%–70% reduction in particle agglomeration rate, and a 200%–220% increase in liquid film breaking efficiency compared to traditional centrifugal atomization.

[0010] The piecewise function parameters of the aforementioned double-sided composite curve atomizing disk satisfy the following range to achieve improved atomization efficiency and solder powder quality: D The value is 0.3~0.8. E The value is between 0.01 and 0.05. F The value is 0.4~0.9. G The value is 0.005~0.02. H The value is 0.1~0.3. m It ranges from 6 to 12. c It is 12~16. s It is between π / 6 and π / 3. x 1 It is 6 mm to 10 mm. x 2 It is 12 mm to 16 mm. x max It is 20 mm to 25 mm.

[0011] According to claim 2, the double-sided composite curve ultrasonic vibration tin powder atomizing device is characterized in that both ends of the double-sided composite curve atomizing disk along the rotation axis (y-axis) are provided with central shafts, and the width of the central shafts is...W satisfy ( A For the amplitude of the variable amplitude rod, f The frequency of ultrasonic vibration. k This is a correction factor, with a value ranging from 0.8 to 1.2.

[0012] The double-sided composite curve atomizing disk has symmetrical conical guide tips at both ends of its central axis; the conical guide tips are in the shape of symmetrical cones with a cone apex angle θ in the range of 30° to 120°, which can initially divert the molten solder and prevent the molten solder from accumulating in the central area.

[0013] The double-sided composite curve atomizing disc has symmetrical threaded structures machined at both ends of its central axis, with a thread accuracy of no less than 6 H / 6 g. Furthermore, the direction of rotation, specifications, and positioning reference of the threads at both ends are completely consistent. This symmetrical thread design allows for direct disassembly and reassembly of the disc when one side fails due to wear, fatigue, or other reasons. The undamaged other side can then be put into use without replacing the entire atomizing disc, increasing raw material utilization by 40% to 60%.

[0014] The amplitude rod connection end is provided with an internal thread that is compatible with the central axis of the double-sided composite curve atomizing disk. The internal thread and the external thread have the same specifications and precision. The internal thread entrance is provided with a chamfer structure (15°~30°), which can guide the central axis of the double-sided composite curve atomizing disk to quickly align and screw in, and can also scrape off any solder dross that may be attached to the thread surface, ensuring the reliability of the connection.

[0015] Furthermore, the operating frequency of the double-sided composite curve atomizing disk is between 20 kHz and 80 kHz; Furthermore, the edges of the double-sided composite curve atomizing disc are all chamfered; Furthermore, the double-sided composite curve atomizing disc and the amplitude transformer are connected by threads; Furthermore, the usage method includes the following steps: Step 1: Configure target particle size parameters: Select appropriate parameters based on the required tin powder particle size. m , c , s , D , E , F , G , H , x 1 , x 2 , x max The value; Step 2: Setting the device's dynamic parameters: Install the double-sided composite curve ultrasonic vibration tin powder atomizing device in the atomization tower and adjust the ultrasonic vibration frequency.f and ultrasonic vibration amplitude A Coaxial calibration drive module and double-sided composite curve atomizing disk; Step 3: Preparation of inert atmosphere in the atomization tower: Adjust the oxygen content in the atomization tower. First, evacuate the atomization tower, then fill the tower with high-purity inert gas (such as nitrogen). Repeat the above process multiple times to reduce the oxygen content in the atomization tower (<100ppm). Finally, fill the tower with inert gas to ensure a slight positive pressure in the tower and ensure a stable inert atmosphere. Monitor the oxygen concentration in real time during the atomization process. If the oxygen concentration exceeds the standard, add inert gas to maintain a low oxygen content. Step 4: Tin molten metal melting and temperature control: The tin raw material is heated to 250~280℃ in the melting furnace, and becomes a molten tin with good fluidity under the temperature control of the holding furnace; Step 5, Core Operation: The molten tin flows into the central conical guide tip at a rate of 30~100 kg / h through a specially designed nozzle. After the initial diversion mentioned above, it enters the double-sided composite curve atomizing disk through the central axis slit. The molten tin is atomized in the double-sided composite curve atomizing disk according to the three-segment function. Under the action of centrifugal force and ultrasonic vibration, it is dispersed into fine liquid particles. It is cooled and solidified into fine tin powder in the inert gas atmosphere of the atomizing tower. Finally, it passes through the ultrasonic vibrating screen under the action of gravity to obtain tin powder with different particle size ranges. Step 6: After preparation is complete, stop the liquid feeding and continue working for 1-2 minutes to empty the residual tin liquid. Pour the remaining tin liquid back into the smelting furnace for recycling, and maintain and clean the equipment for the next use. Attached Figure Description Figure 1 This is a three-dimensional structural schematic diagram of the ultrasonic vibration tin powder atomizing device with a double-sided composite curve atomizing disk as described in an embodiment of the present invention; Figure 2 This is a cross-sectional view of the ultrasonic vibration tin powder atomizing device with a double-sided composite curve atomizing disk described in an embodiment of the present invention. Figure 3 This is a schematic diagram of the ultrasonic vibration tin powder atomizing device with a double-sided composite curve as described in an embodiment of the present invention, inside the atomizing tower; Figure 4 This is a schematic diagram of the single-sided contour curve of the double-sided composite curve atomizing disk described in this embodiment of the invention within the first quadrant; Figure 5 A cross-sectional view of the connection between the nozzle and the double-sided composite curve atomizing disk of the ultrasonic vibration tin powder atomizing device described in this embodiment of the invention; Diagram caption: 1-Drive module, 2-Accommodation cavity, 3-Cavity, 4-Front cover plate, 5-Amplitude rod, 6-Double-sided composite curve atomizing disk, 7-Piezoelectric ceramic sheet, 8-Receiver, 9-Rear cover plate, 10-Transmitter. The dashed line represents molten solder, and point A is the contact point between the molten solder and the first section of the double-sided composite curve atomizing disk. Detailed Implementation

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments: An ultrasonic vibration tin powder atomizing device is characterized by comprising a drive module (1), a accommodating cavity (2), an ultrasonic vibration transducer, a wireless power transmission device, an amplitude transformer (5), and a double-sided composite curve atomizing disk (6). The drive module (1) is coaxially disposed at the lower end of the accommodating cavity (2) to achieve coaxial rotation; The upper end of the accommodating cavity (2) is provided with a cavity (3), and the front end of the ultrasonic vibration transducer is disposed in the cavity (3); The ultrasonic vibration transducer is composed of a rear cover plate (9), a piezoelectric ceramic sheet (7), and a front cover plate (4) in sequence, and is coaxially tightened by bolts. The wireless power transmission device provides electrical energy. The transmitting end (10) of the wireless power transmission device is sleeved on the outer shell of the driving module (1), and the receiving end (8) of the wireless power transmission device is set on the outer peripheral surface of the accommodating cavity (2). The two transmit electrical energy through alternating magnetic field coupling. The upper end of the ultrasonic vibration transducer is connected to the amplitude rod (5) to amplify the amplitude for subsequent atomization; The amplitude rod (5) is connected to the double-sided composite curve atomizing disk (6) at its end. The axis of rotational symmetry of the double-sided composite curve atomizing disk is: y The axis is the radial axis (x-axis), and the contour curves on both sides of the disk surface are... x The axis forms a mirror image; in the plane xOy Within the first quadrant, the unilateral profile curve is described by a piecewise function, the specific expression of which is: ; Section 1 Used to achieve initial centrifugal transport and pre-dispersion of molten tin; Second Section Used to achieve precise control of liquid film thickness; Section 3 Used to improve liquid film breakup efficiency and particle sphericity; m , c , s For non-negative real numbers, D , E ,F , G , H For real numbers, x 1 , x 2 , x max For the section boundary; When preparing tin powder using the aforementioned double-sided composite curve ultrasonic vibration tin powder atomization device, by changing... m , c , s , D , E , F , G , H This alters the curve shape, resulting in a significant improvement in the particle size, sphericity, yield, and atomization efficiency of the atomized tin powder. Specific Implementation Combination Figure 2 , Figure 3 The apparatus shown was used to prepare spherical tin powder with a particle size requirement of 15~45μm. The specific operation procedure and parameter configuration are as follows: Piecewise function parameters: x 1 =8 mm, x 2 =14 mm, x max =24 mm, D =0.8, E =0.01, F =0.75, G =0.015, H =0.2, m =7.75, c =14, s =Π / 6; Central shaft structural parameters: Amplitude of the variable rod A =22 μm, ultrasonic frequency f =28 kHz, take k =1.1, center axis width W =4.6 mm; Conical guide tip: cone apex angle i =60°; The atomizing tower undergoes multiple vacuuming and nitrogen purging cycles to control the oxygen concentration to ≤50 ppm, the melting furnace temperature to 280℃, and the liquid supply rate to 60 kg / h. The molten tin is diverted through a conical guide tip to eliminate central buildup, and then enters the double-sided composite curve atomizing disk through the slit of the central axis. Under the high-frequency action of ultrasonic vibration (such as...), Figure 3 (As shown in the fitted motion trajectory), after the molten tin leaves the central axis slit, it moves along the tangent direction of the contact point A with the first section of the double-sided curve atomizing disk. In the first section, the molten tin is pre-dispersed, and in the second section, a liquid film of uniform thickness is formed. In the third section, the liquid film breaks down to form spherical particles. Compared to traditional smooth, flat single-sided atomizing discs, this double-sided composite curve atomizing disc optimizes the particle size distribution from 10~75 μm to 18~42 μm, improving distribution uniformity by 58.3%; sphericity increases from ≤0.85 to ≥0.93, a 15.9% improvement; atomization efficiency increases by 83.3%, from 12 kg / h to 22 kg / h; yield reaches 90.2%; particle agglomeration rate decreases from 12.3% to 3.5%; and the double-sided flipping design greatly improves raw material utilization to 58.3%. To verify the long-term stability and reusability of the double-sided composite curve atomizing disc, a 1000-hour continuous atomization test was conducted under the same parameters as the previous experiment, and the changes in key indicators were recorded: After 500 hours of continuous operation, the double-sided curve profile was disassembled and inspected: the deviation of the sine curve in the first section was ≤0.02mm, and the deviation of the cubic curve in the third section was ≤0.03mm, which met the atomization accuracy requirements. After a single curved surface fails (surface wear ≥ 0.1 mm), the other curved surface is flipped and reused. After reassembly, the coaxiality deviation is ≤ 0.05 mm, and the reliability of the threaded connection does not decrease (torque retention rate ≥ 95%). During the 1000-hour test cycle, the tin powder particle size distribution range remained within 18~44μm (initially 18~42μm), with an attenuation rate of ≤4.8%; sphericity ≥0.91 (initially 0.93), agglomeration rate ≤4.2% (initially 3.5%), and no significant performance degradation. Traditional single-sided atomizing discs need to be replaced after 500 hours, while this solution can be used for another 500 hours after being flipped on both sides, achieving a raw material utilization rate of 58.3% (compared to 41.7% for traditional single-sided discs), which meets the needs of industrial cost reduction. The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural or procedural changes made in accordance with the contents of the present invention specification and drawings are similarly included within the patent protection scope of the present invention.

Claims

1. A double-sided composite curve ultrasonic vibration tin powder atomization device, characterized in that, Includes a drive module, a housing cavity, an ultrasonic vibration transducer, a wireless power transmission device, an amplitude transformer, and a double-sided composite curve atomizing disk; The drive module is coaxially disposed at the lower end of the accommodating cavity to achieve coaxial rotation; The upper end of the accommodating cavity is provided with a cavity, and the front end of the ultrasonic vibration transducer is disposed in the cavity; The ultrasonic vibration transducer is composed of a rear cover plate, a piezoelectric ceramic sheet and a front cover plate in sequence, and is coaxially pressed together by bolts. The wireless power transmission device provides electrical energy. The transmitting end of the wireless power transmission device is sleeved on the outer shell of the drive module, and the receiving end of the wireless power transmission device is disposed on the outer peripheral surface of the accommodating cavity. The two transmit electrical energy through alternating magnetic field coupling. The upper end of the ultrasonic vibration transducer is connected to the amplitude transformer to amplify the amplitude for subsequent atomization. The end of the amplitude transformer is connected to the double-sided composite curve atomizing disk.

2. The double-sided composite curve ultrasonic vibration tin powder atomization device according to claim 1, characterized in that, The axis of rotational symmetry of the double-sided composite curve atomizing disk is: y The axis is the radial axis (x-axis), and the contour curves on both sides of the disk surface are... x The axis forms a mirror image; in the plane xOy Within the first quadrant, the unilateral profile curve is described by a piecewise function, the specific expression of which is: ； Section 1 Used to achieve initial centrifugal transport and pre-dispersion of molten tin; Second Section Used to achieve precise control of liquid film thickness; Section 3 Used to improve liquid film breakup efficiency and particle sphericity; μ , γ , σ For non-negative real numbers, D , E , F , G , H For real numbers, x 1 , x 2 , x max For the section boundary; When preparing tin powder using the aforementioned double-sided composite curve ultrasonic vibration tin powder atomization device, by changing... μ , γ , σ , D , E , F , G , H To change the shape of the curve.

3. The double-sided composite curve ultrasonic vibration tin powder atomization device according to claim 2, characterized in that, The double-sided composite curve atomizing disk along the rotation axis (y-axis) has a central axis at both ends, and the width of the central axis is... W satisfy ( A For the amplitude of the variable amplitude rod, f The frequency of ultrasonic vibration. k This is a correction factor, with a value ranging from 0.8 to 1.

2.

4. The double-sided composite curve ultrasonic vibration tin powder atomization device according to claim 2, characterized in that, The double-sided composite curve atomizing disk has symmetrical conical guide tips at both ends of its central axis; the conical guide tips are in the shape of symmetrical cones with a cone apex angle θ in the range of 30° to 120°, which can initially divert the molten solder and prevent the molten solder from accumulating in the central area.

5. The double-sided composite curve ultrasonic vibration tin powder atomization device according to claim 2, characterized in that, The central axis of the double-sided composite curve atomizing disc is machined with symmetrical thread structures at both ends, with a thread accuracy of not less than 6 H / 6 g, and the direction, specifications, and positioning reference of the threads at both ends are completely consistent. Through this symmetrical thread design, when one side of the double-sided composite curve atomizing disc fails due to wear, fatigue, or other reasons, it can be directly disassembled, rotated 180°, and reassembled, allowing the undamaged other side to be put into use without replacing the entire atomizing disc, thus increasing the utilization rate of raw materials by 40% to 60%.

6. The double-sided composite curve ultrasonic vibration tin powder atomization device according to claim 2, characterized in that, The amplitude rod connection end is provided with an internal thread that is compatible with the central axis of the double-sided composite curve atomizing disk. The internal thread and the external thread have the same specifications and precision. The internal thread entrance is provided with a chamfer structure (15°~30°), which can guide the central axis of the atomizing disk to be quickly aligned and screwed in, and can also scrape off any solder dross that may be attached to the thread surface, ensuring the reliability of the connection.

7. The double-sided composite curve ultrasonic vibration tin powder atomization device according to claim 2, characterized in that, The operating frequency of the double-sided composite curve atomizing disk is 20 kHz to 80 kHz.

8. The double-sided composite curve ultrasonic vibration tin powder atomization device according to claim 2, characterized in that, The edges of the double-sided composite curve atomizing disc are all chamfered.

9. The double-sided composite curve ultrasonic vibration tin powder atomization device according to claim 2, characterized in that, The double-sided composite curve atomizing disc and the amplitude transformer are connected by threads.

10. The double-sided composite curve ultrasonic vibration tin powder atomization device according to claim 1, characterized in that, Includes the following steps: Step 1: Configure target particle size parameters: Select appropriate parameters based on the required tin powder particle size. μ , γ , σ , D , E , F , G , H , x 1 , x 2 , x max The value; Step 2: Setting the device's dynamic parameters: Install the double-sided composite curve ultrasonic vibration tin powder atomizing device in the atomization tower and adjust the ultrasonic vibration frequency. f and ultrasonic vibration amplitude A Coaxial calibration drive module and double-sided composite curve atomizing disk; Step 3: Preparation of inert atmosphere in the atomization tower: Adjust the oxygen content in the atomization tower. First, evacuate the atomization tower, then fill the tower with high-purity inert gas (such as nitrogen). Repeat the above process multiple times to reduce the oxygen content in the atomization tower (<100 ppm). Finally, fill the tower with inert gas to ensure a slight positive pressure in the tower and ensure a stable inert atmosphere. Monitor the oxygen concentration in real time during the atomization process. If the oxygen concentration exceeds the standard, add inert gas to maintain a low oxygen content. Step 4: Tin molten metal melting and temperature control: The tin raw material is heated to 250~280℃ in the melting furnace, and becomes a molten tin with good fluidity under the temperature control of the holding furnace; Step 5, Core Operation: The molten tin flows into the central conical guide tip at a rate of 30~100 kg / h through a specially designed nozzle. After the initial diversion mentioned above, it enters the double-sided composite curve atomizing disk through the central axis slit. The molten tin is atomized in the double-sided composite curve atomizing disk according to the three-segment function. Under the action of centrifugal force and ultrasonic vibration, it is dispersed into fine liquid particles. It is cooled and solidified into fine tin powder in the inert gas atmosphere of the atomizing tower. Finally, it passes through the ultrasonic vibrating screen under the action of gravity to obtain tin powder with different particle size ranges. Step 6: After preparation is complete, stop the liquid feeding and continue working for 1-2 minutes to empty the residual tin liquid. Pour the remaining tin liquid back into the smelting furnace for recycling, and maintain and clean the equipment for the next use.

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