Improved acoustic mixers and related methods

Abstract

Provided herein are systems and methods for various advanced material processing and measurement technologies. A system for scaling material processing comprises stacked vessels inhibiting bridging with cohesive materials. Methods and systems for controlling power or power density in an acoustic mixer involve determining required power density, applying energy, and maintaining uniform power density. Quick-adjust vessel holders feature mechanisms for coarse and fine adjustments. A non-contact displacement sensor system for acoustic mixers includes sensors and accelerometers. Gas vacuum filter systems use reinforced membranes to permit gas escape while blocking solids and liquids, mounting externally for easy cleaning. Methods for measuring displacement and filtering gas in vacuum lines are also disclosed.

Description

LEI0003-401-PCIMPROVED ACOUSTIC MIXERS AND RELATED METHODS

[0001] This application claims the benefit of priority of the United States Provisional Patent Application Serial No. 63 / 681,706 filed on August 9, 2024, the disclosure of which is incorporated by reference in its entirety for all purposes.

[0002] The present disclosure generally relates to machines that use resonance to transfer energy from the machine to a material to be processed, specifically improved acoustic mixers for material processing and resonance-enabled material processors.

[0003] The resonance-enabled machines disclosed herein solve problems by providing more efficient machines, which save money and make power loads on the machines more accessible to meet. In several embodiments, two or masses move out of phase of one another and are tunable to the needs of the workpiece. Spring rates are sized to reduce the net force to or near zero transmitted to the frame and ultimately to the ground.

[0004] The present disclosure provides a system for scaling material processing, comprising a plurality of vessels, each vessel having a diameter and a height, the vessels being vertically stacked upon one another to define a stack; wherein the diameter of each vessel is chosen to inhibit bridging with cohesive materials; and wherein the height of each vessel remains constant relative to the other vessels in the stack.

[0005] The present disclosure provides a method for controlling power or power density in an acoustic mixer, comprising determining the power or power density required for processing a mixture contained in a vessel; applying an energy source to the mixture; and controlling the applied energy to maintain a substantially uniform power or power density input into the mixture.

[0006] The present disclosure provides a system for controlling power or power density in an acoustic mixer, comprising a means for determining the power or power density for processing a mixture contained in a vessel; a means for applying an energy source to the mixture; and a means for controlling the applied energy to maintain a substantially uniform power density input into the mixture.

[0007] The present disclosure provides a quick-adjust vessel holder, comprising a frame supporting a vessel; a threaded rod having self-locking thread, the threaded rod extending vertically as a lead screw; one or more push buttons operatively connected to the vessel holder frame and the push buttons to release the threaded rod for coarse slide adjustment; a knob at the top of the threaded rod configured for fine adjustment by turning after the push button is released; and springs connected to the frame and engaging the threads of theLEI0003-401-PC threaded rod to maintain the threaded rod in position relative to the lead screw when the push buttons are not activated.

[0008] The present disclosure provides a system for quick adjustment of a vessel holder, comprising a means for supporting a vessel; a means for coarse adjustment; a means for fine adjustment; and a means for maintaining relative position of the vessel.

[0009] The present disclosure provides a non-contact displacement sensor system for an acoustic mixer, comprising a sensor configured to detect the movement of a moving mass and an accelerometer positioned adjacent to the sensor to verify the displacement measurement.

[0010] The present disclosure provides a system for measuring displacement in an acoustic mixer, comprising a means for detecting the movement of a moving mass and a means for verifying the displacement measurement positioned adjacent to a means for detecting the movement of a moving mass.

[0011] The present disclosure provides a system for measuring displacement in an acoustic mixer, comprising a means for detecting the movement of a moving mass; and a means for verifying the displacement measurement positioned adjacent to a means for detecting the movement of a moving mass.

[0012] The present disclosure provides a gas vacuum filter system, comprising a membrane or thick sintered filter and / or combination thereof configured to protect a vacuum line by allowing gases to escape the mixing vessel while blocking solids and liquids, a reinforcement structure disposed on the membrane, a housing configured to hold the membrane and the reinforcement, the housing having one or more gas ports, and a means for mounting the system on an external side of a vessel lid.

[0013] The present disclosure provides a method for filtering gas in a vacuum line, comprising protecting a vacuum line with a reinforced membrane by allowing gases to escape the mixing vessel while blocking solids and liquids, and mounting the system on an external side of a vessel lid.

[0014] The present disclosure provides a system for filtering gas in a vacuum line, comprising a means for protecting a vacuum line by allowing gases to escape the mixing vessel while blocking solids and liquids, a means for reinforcing the means for protecting the vacuum line, and a means for mounting the system on an external side of a vessel lid.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate likeLEI0003-401-PC structural elements. The drawings provide exemplary embodiments or aspects of the disclosure and do not limit the disclosure’s scope.

[0016] FIG. 1 shows an acoustic mixer comprising one voice coil actuator mounted on the frame and connected to the second moving mass.

[0017] FIG. 2 shows an acoustic mixer comprising two voice coil actuators, one mounted on the frame and connected to the first moving mass and another mounted on the frame and connected to the second moving mass.

[0018] FIG. 3 shows an acoustic mixer comprising one voice coil actuator mounted on the frame and connected to the first moving mass.

[0019] FIG. 4 shows a small mixing vessel.

[0020] FIG. 5 shows a large mixing vessel.

[0021] FIG. 6 shows a stacked mixing vessel comprising three small, wide mixing vessels with a total volume equivalent to the large mixing vessel of FIG. 5.

[0022] FIG. 7 shows a cross-sectional view of the stacked mixing vessel of FIG. 6.

[0023] FIG. 8 shows a bottom perspective view of a clamp bar.

[0024] FIG. 9 shows a front perspective view of a vessel holder with the clamp plate in a raised position.

[0025] FIG. 10 shows a front perspective view of the vessel holder of FIG. 9 with the clamp plate in a lowered position, clamping the mixing vessel against the base.

[0026] FIG. 11 shows a top perspective view of the vessel holder of FIG. 10.

[0027] FIG. 12 shows a plan view of a non-contact displacement sensor.

[0028] FIG. 13 shows a top perspective view of the non-contact displacement sensor of FIG.12.

[0029] FIG. 14 shows a top perspective view of a mixing vessel fitted with vessel lid comprising a vacuum lid housing and gas ports.

[0030] FIG. 15 shows a top perspective cross-sectional view of the mixing vessel of FIG. 14.

[0031] FIG. 16 shows a bottom perspective cross-sectional view of the mixing vessel of FIG. 14, highlighting the filter membrane.

[0032] FIG. 17 shows the resultant Power to Mix with a set point of 3,200 W.

[0033] FIG. 18 shows three mix data for mixing corn syrup with water to make a paste.

[0034] FIG. 19 shows the acceleration response during FIG. 18 power control.

[0035] Table 1 lists reference numerals used throughout the figures and this disclosure.LEI0003-401-PCTable 1: Reference numeralsLEI0003-401-PCDETAILED DESCRIPTION

[0036] The present disclosure provides a resonance-enabled machine driven by one or more voice coil actuators and two oscillating masses. The oscillating masses are coupled through mechanical springs. The masses are configured to oscillate out of phase and coupled to the housing with resilient members to obtain near-zero result force onto the housing. In some embodiments, a user feels negligible forces because the resulting forces on the housing are greatly reduced. The present disclosure also provides improved acoustic mixers for material processing, including stacked vessels for scaling, closed-loop control for power or energy density to mix, quick-adjust vessel holders, non-contact displacement sensors, and gas vacuum filters.Acoustic Mixer

[0037] A material processor typically drives a pneumatic, electromechanical, or hydraulic machine. These devices process materials using blades or paddles. On the other hand, prior art systems driven with a voice coil 500 placed the voice coil between the first moving mass 210 and the second moving mass 220, thus requiring power transmission to a moving mass. In this configuration, the voice coil moves because it is lighter than the magnet assembly. This arrangement provides the highest performance possible but leads to wire fatigue and is non-resonant.

[0038] As used herein, “acoustic mixer” is interchangeable with the term “resonance-enabled material processor.”

[0039] Referring to FIGS. 1-3, voice coils can also be mounted to push from frame 300 to the first moving mass 210 and another between frame 300 and the second moving mass 220, thus canceling the input forces to frame 300 and driving the system 100.

[0040] In contrast, the disclosed design has voice coils 500 on a non-moving mass 300, thus requiring no moving parts for electrical connections or cables to fatigue or break. The resonance-enabled machines disclosed herein comprise springs 400 and masses 200 arranged to cancel out the motion forces to the ground. The first moving mass 220 is operatively coupled to a mixing vessel 670 via a vessel holder 660.

[0041] In some embodiments, the acoustic mixer 100 comprises a first coil assembly 510 mounted on the frame 300 and a first magnet assembly 515 mounted on the first moving mass 210. In some embodiments, the acoustic mixer 100 comprises a first coil assembly 510 mounted on the frame 300 and a first magnet assembly 515 mounted on the second movingLEI0003-401-PC mass 220. In some embodiments, the acoustic mixer 100 comprises a first coil assembly 510 mounted on the frame 300 and a first magnet assembly 515 mounted on the first moving mass 210, and a second coil assembly 520 mounted on the frame 300 and a second magnet assembly 525 mounted on the second moving mass 220.

[0042] In some embodiments, the acoustic mixer 100 comprises a frame 300 comprising a frame ledge 312. A voice coil actuator 500 comprises a first coil assembly 510 rigidly disposed on the frame 300 and a first magnet assembly 515. A first moving mass 210 is rigidly coupled to the first magnet assembly 515, further coupled to the frame ledge 312 by a plurality of frame-to-first moving mass springs 410, and further coupled to a second moving mass 220 by a plurality of first moving mass-to-second moving mass springs 430. The second moving mass 220 is coupled to the frame ledge 312 by a plurality of frame-to-second moving mass springs 420. A mixing vessel 670 is rigidly coupled to the first moving mass 210 via a vessel holder 660.

[0043] Using a resonance-enabled machine, the mass’s kinetic energy is balanced with the springs’ potential energy. Therefore, performance is no longer tied to the moving mass, enabling the heavier component of the voice coil assembly to be directly coupled to the moving assembly. These embodiments minimize the transmission of forces from the motion forces to the frame and the device’s structure.

[0044] In some embodiments, the resonance-enabled machine operates on or near resonance, conserving energy within the machine by balancing the potential and kinetic energies. Once the machine is charged with energy, it moves the energy back and forth between potential and kinetic energy. Machine losses are minimal with metallic springs (such as steel alloys) and air resistance of the moving masses.

[0045] In some embodiments, magnets are bolted together with no air path up the magnet stack. In some embodiments, off-center holes at the base of the magnet stack allow airflow.

[0046] In some embodiments, the frame does not vibrate to the same degree as prior systems. Less frequent scheduled maintenance is needed, ultimately increasing reliability and decreasing expenses.

[0047] In some embodiments, the sound generation operates at a safer decibel level for the user than prior systems driven by internal combustion engines. Therefore, the disclosed systems reduce noise pollution in the surrounding areas. In some embodiments, the machine’s weight uses smaller batteries than prior battery-operated machines because of the efficiency, making the machine more portable and ergonomic for users.LEI0003-401-PCStacked vessels for scaling

[0048] This disclosure also provides stacked vessels for scaling material processing. In certain embodiments, a system for scaling material processing comprises a plurality of vessels, each vessel having a diameter and a height, the vessels being vertically stacked upon one another to define a stack; wherein the diameter of each vessel is chosen to inhibit bridging with cohesive materials; and wherein the height of each vessel remains constant relative to the other vessels in the stack.

[0049] In some embodiments, larger batch systems are scaled to keep the vessel height the same. For example, a stack of larger-diameter vessels is stacked on top of one another. This allows for similar power density going into the mixture but may require additional processing time based on the aspect ratio of the new vessel. This embodiment also works well for cohesive powders because the wider vessels do not lend themselves to support bridging with cohesive materials.

[0050] Referring to FIG. 4, a small mixing vessel 676 is defined by a mixing vessel 670 having a lid 683, vessel height Zt, and vessel diameter d. Referring to FIG. 5, a large mixing vessel 677 is likewise defined by a mixing vessel 670 having a lid 683, vessel height Zt, and vessel diameter d. Referring to FIGS. 6 and 7, a stacked mixing vessel 679 comprises three small, wide mixing vessels 678 with a total volume equivalent to a large mixing vessel 677. Each small, wide mixing vessel 678 comprises a vessel wall 684, a vessel top mix interface 685, and a vessel bottom mix interface 686. The bottommost small, wide mixing vessel 678 further comprises a vessel bottom 682. The topmost small, wide mixing vessel further comprises a vessel lid 683.

[0051] As used herein, “aspect ratio” refers to the ratio of the height to the diameter of a vessel (h.d), which in certain embodiments remains consistent to ensure uniform processing conditions; for instance, if a vessel has a height of 50 cm and a diameter of 25 cm, the aspect ratio would be 2: 1.

[0052] Aspect ratios influence the flow patterns within the vessel. A taller, narrower vessel creates more vertical flow, whereas a shorter, wider vessel promotes horizontal flow. The aspect ratio also influences the movement dynamics of the powdered material, leading to dead zones where materials are not adequately mixed or regions where materials circulate too rapidly, causing segregation or uneven dispersion. Power density is not evenly transferred throughout a vessel with a changed aspect ratio, creating spots of overmixed or undermixed material. Maintaining a constant aspect ratio ensures that scaling the vessel does not introduce new variables affecting the mixing process. Changing the aspect ratio requiresLEI0003-401-PC recalibration of mixing times, speeds, and energy inputs to achieve the same level of homogeneity, making the process less predictable and introducing variability. The risk of bridging or clumping increases with the wrong aspect ratio for cohesive powders.

[0053] As used herein, “powder,” “powders,” or “powdered material” refers to any material that has been reduced to fine particles or granules, often used in industrial and manufacturing processes. In certain embodiments, powdered materials are processed within vessels to ensure thorough mixing and uniformity, including metal powders, pharmaceuticals, and food-grade powders.

[0054] As used herein, “fine particle” refers to a small, finely divided piece of solid material, typically with a diameter of less than 100 micrometers. It is often used in various industrial applications for its increased surface area.

[0055] As used herein, “granule” refers to a small particle or grain, usually with a size range of 100 micrometers to several millimeters, often used to control flow and consistency.

[0056] As used herein, “power density” refers to the amount of power (the time rate of energy transfer) per unit volume. This metric, typically denoted in watts per cubic meter (W / m3), is a fundamental measure for evaluating the efficacy and capability of various devices, systems, and materials based on their spatial energy distribution.

[0057] In certain embodiments, the system comprises power density applied to the contents of each vessel that is substantially uniform across the height of the stack.

[0058] As used herein, “substantially uniform” refers to a condition where the characteristics or properties of a material or process are consistent to a significant degree, though not necessarily perfectly identical, throughout the relevant context. In these embodiments, uniformity is sufficient to achieve the intended functionality or performance within the described system or process.

[0059] As used herein, “vessel” refers to a container designed to hold and process materials, particularly in scaling mixtures of powdered materials.

[0060] The stacks of materials can be large, accommodating between 1 L to 120 L or more materials during a single batch operation. Each small vessel to be stacked would be weighed individually to the proper constituents based on its batch. This allows many batches to be mixed simultaneously, eliminating the scaling variation by scaling the size to keep the same vessel aspect ratio between scales.

[0061] In certain embodiments, the system comprises the combined volume of the vessels in the stack is between 1 L and 120 L, such as between about 1 L and about 2 L, between about 2 L and about 3 L, between about 3 L and about 4 L, between about 4 L and about 5 L,LEI0003-401-PC between about 5 L and about 6 L, between about 6 L and about 7 L, between about 7 L and about 8 L, between about 8 L and about 9 L, between about 9 L and about 10 L, between about 10 L and about 11 L, between about 10 L and about 20 L, between about 20 L and about 30 L, between about 30 L and about 40 L, between about 40 L and about 50 L, between about 50 L and about 60 L, between about 60 L and about 70 L, between about 70 L and about 80 L, between about 80 L and about 90 L, between about 90 L and about 100 L, between about 100 L and about 110 L, between about 110 L and about 120 L. In some embodiments, the combined volume is at least about 1 L. In other embodiments, the value is not more than about 120 L.

[0062] In certain embodiments, each vessel of the system is adapted to hold a batch operation for processing powdered materials.

[0063] In certain embodiments, each vessel in the stack of the system is independently weighable.

[0064] In certain embodiments, the system further comprises a control system configured to regulate power distribution across the stacked vessels.

[0065] In certain embodiments, each vessel of the system maintains a consistent aspect ratio.Closed-loop control for power or energy density to mix

[0066] Also provided are methods for controlling power or power density in an acoustic mixer, comprising determining the power density required for processing a mixture contained in a vessel, applying an energy source to the mixture, and controlling the applied energy to maintain a substantially uniform power density throughout the mixture.

[0067] Currently, acoustic mixers are controlled via acceleration, and a dependent variable of the system and mix is the power density (W / kg) going into the material being processed. Energy density is a suitable scaling method for controlling the repeatability of the mix and obtaining consistent results. The problem with acceleration control is that different mixed material flow regimes or flow patterns form in the vessel at various acceleration levels.

[0068] However, these flow patterns take different amounts of energy during operation. Sometimes, these flow patterns can transition at other accelerations, which causes some mixes to be processed at different energy states. For example, a mixture could be processed at 50 g of acceleration, taking 50 W / kg of energy. In contrast, another batch could also be processed at 50 g of acceleration, but it takes 150 W / kg this time to mix. Typical processing recipes have acceleration and time, if needed, vacuum (if a vacuum system is used), andLEI0003-401-PC temperature (if a cooling vessel is used). These two batches would have drastically different resultant end temperatures and mixing outcomes. (See FIGS. 17-19.)

[0069] This difference in processing may damage the mix and cause a large variability in the mixing results. The control of power density allows more consistent processing outcomes. The power density control may be controlled via a mechanical system (knob or push buttons) on the side of the machine. The power density control may also be controlled via a machine processing recipe preprogrammed into the machine via the human-machine interface (HMI).

[0070] As used herein, “acoustic power source” refers to a device that generates and transmits sound waves to impart energy into a mixture for processing; in certain embodiments, acoustic power sources are ultrasonic transducers, speakers, or voice coils designed to operate at specific frequencies and intensities.

[0071] In certain embodiments, the method further comprises regulating the power density with a mechanical control system.

[0072] In certain embodiments, the method further comprises inputting a machine processing recipe via a human-machine interface (HMI) to control the power density. In certain embodiments, the HMI is chosen from a touchscreen panel, keypad interface, graphical user interface, voice command system, control panel, remote control interface, or soft key interface.

[0073] In certain embodiments, the method further comprises adjusting the energy based on feedback from sensors monitoring the energy state of the mixture.

[0074] In certain embodiments, the method further comprises maintaining the temperature mixture.

[0075] In certain embodiments, a system for controlling power or power density in an acoustic mixer comprises a means for determining the power density for processing a mixture contained in a vessel; a means for applying an energy source to the mixture; and a means for controlling the applied energy to maintain a substantially uniform power density throughout the mixture.

[0076] In certain embodiments, the system further comprises a means for regulating the power density.

[0077] In certain embodiments, the system further comprises a means for inputting a machine processing recipe to control the power density.

[0078] In certain embodiments, the system further comprises a means for adjusting the energy based on feedback from sensors monitoring an energy state of the mixture.LEI0003-401-PC

[0079] In certain embodiments, the system further comprises a means for maintaining the temperature of the mixture.Vessel holder

[0080] Also provided herein is a quick-adjust vessel holder comprising self-locking threads. It has one or two push buttons to release the threaded rod for coarse slide adjustment and then release to turn the top knob for fine adjustment. A hand knob, as shown, may be used, or a link that a torque wrench can be used with for controlled tightening. The threads engage with springs holding the threads in place on the lead screw.

[0081] In some embodiments, a two-button configuration uses a button on both the front 130 (FIGS. 9 and 10, showing a front perspective) and back 135 (FIG. 11, showing a top perspective view). Referring to FIG. 8, a clamp bar 340 comprises a front push button 130 under tension with a push button spring 131 and a back push button 135. A central aperture 315 comprises self-locking threads 115 for reversibly engaging the threaded rod 110 of the vessel holder 660.

[0082] Referring again to FIGS. 9-11, a quick-adjust vessel holder 660 comprises a base 106 supporting a vessel 670. A pair of standoffs 320 is disposed on the base 106 and supports a bar plate 330, bar clamp 340, and threaded rod 110. The threaded rod 110 has a self-locking thread 115 disposed through central aperture 315 of the clamp bar 340 and terminating at the clamp plate 330. When the threaded rod 110 is lowered, the clamp bar 340 remains fixed while the clamp plate 330 is pushed downward along the standoffs 320 until the clamp plate 330 engages the vessel lid 675. The clamp plate 330 comprises quick-connect fittings 760 for vacuum lines 770 that align with corresponding gas ports 730 in the vessel lid 675.

[0083] One or more push buttons 130 are disposed on the bar clamp 130 and operatively connect to the standoffs 320 and the threaded rod 110 to release the threaded rod 110 for coarse slide adjustment. A knob 150 at the top 112 of threaded rod 110 is configured for fine adjustment by turning after the push button 130 is released.

[0084] In certain embodiments, a quick-adjust vessel holder comprises a knob 150 at the top 112 of threaded rod 110 chosen from a hand knob or a link for use with a torque wrench using a torque wrench port 152.

[0085] In certain embodiments, a system for quick adjustment of a vessel holder comprises a means for supporting a vessel; a means for coarse adjustment; a means for fine adjustment; and a means for maintaining relative position of the vessel.LEI0003-401-PCNon-contact Displacement Sensor

[0086] Also provided herein are non-contact displacement sensors. In some embodiments, the non-contact displacement sensor uses a sensor, such as an eddy-current sensor or an optical sensor, to detect an angled plate as it moves up and down. Referring again to FIGS. 12 and 13, a sensor 800 is disposed in a sensor holder 810 mounted on the frame 300. A sensor target 820 is mounted on the first moving mass 210. While the acoustic mixer 100 is operating, the relative position of the first moving mass 210 to the frame 300 changes. The sensor 800 measures these changes by observing the displacement of the sensor target 820 and the sensor 800. The sensor system gives a near-sinusoidal measurement of the sinusoidal plate displacement motion. An accelerometer is disposed adjacent to the sensor used to verify the method. The non-contact sensor has no wires that may fatigue and break with the moving plates over time.

[0087] As used herein, “accelerometer” refers to a device that measures the proper acceleration of an object on an axis, providing a vector quantity of the acceleration. When the proper acceleration of an object is measured along three perpendicular axes, a “triaxial accelerometer” is used.

[0088] As used herein, “eddy-current sensor” refers to a device that senses displacement based on the eddy-current formation, where eddy-currents are circulating flows of electrons induced within a conductor by the relative motion of a magnetic field and the conductor. In certain embodiments, eddy-current sensors provide measurements with linearity exceeding 0.1%, or speeds above 10 kHz, and / or resolution in the sub-micrometer range. In applications such as measuring the displacement of moving masses in acoustic mixers, the sensor detects secondary magnetic fields created by the induced eddy-currents to determine the distance between the probe and the target material.

[0089] As used herein, “non-contact” refers to a method or device that operates without physical contact between its sensing components and the target object.

[0090] As used herein, “optical sensor” refers to an electro-optical device that converts light, or changes in light, into electronic signals. In certain embodiments, optical signals are detectable across infrared to ultraviolet wavelengths. Such sensors may be integrated into systems that include a light source and an electrical trigger reacting to variations in light signals. Suitable optical sensors include, but are not limited to, photoconductive devices, photovoltaics, photodiodes, phototransistors, and optical switches.LEI0003-401-PC

[0091] In certain embodiments, a sensor system for an acoustic mixer comprises a sensor configured to detect the movement of a moving mass, and an accelerometer positioned adjacent to the sensor to verify the displacement measurement.

[0092] In certain embodiments, the system comprises the sensor being chosen from an eddy- current sensor or an optical sensor.

[0093] In certain embodiments, the system is devoid of wires that may fatigue and break over time due to the movement of the moving mass.

[0094] In certain embodiments, the current sensor provides a near-sinusoidal measurement of sinusoidal plate displacement motion.

[0095] In certain embodiments, the system further comprises a detection module configured to process the near-sinusoidal measurement into readable displacement data.

[0096] In certain embodiments, the system further comprises a acoustic mixer, comprising a frame comprising a frame ledge, a voice coil actuator comprising a coil assembly rigidly disposed on the frame and a magnet assembly, a first moving mass rigidly coupled to the magnet assembly, further coupled to the frame ledge by a plurality of frame-to-first moving mass springs, and further coupled to a second moving mass by a plurality of first moving mass-to-second moving mass springs, and a mixing vessel rigidly coupled to the first or second moving mass via a vessel holder, wherein the sensor detects displacement of the first and second moving masses.

[0097] In certain embodiments, the accelerometer is configured to provide additional displacement data in three orthogonal axes.

[0098] In certain embodiments, the system further comprises a mounting structure for holding the sensor and the accelerometer in place relative to the moving mass.

[0099] In certain embodiments, the displacement data from the accelerometer is used to calibrate the sensor.

[0100] In certain embodiments, a system for measuring displacement in an acoustic mixer comprises a means for detecting the movement of a moving mass and a means for verifying the displacement measurement positioned adjacent to means for detecting the movement of a moving mass.

[0101] In certain embodiments, the system further comprises a means for measuring near- sinusoidal displacement motion.

[0102] In certain embodiments, the system further comprises a means processing the near- sinusoidal measurement into readable displacement data.LEI0003-401-PC

[0103] In certain embodiments, the system further comprises a means for providing additional displacement data in three orthogonal axes.

[0104] In certain embodiments, the system further comprises a means for calibrating the means for detecting the motion of a moving mass with the displacement data from the means for verifying the displacement measurement.Gas Vacuum Filter

[0105] Also provided herein are gas vacuum filters. FIG. 14 shows a top perspective view of a mixing vessel 670 fitted with vessel lid 683 comprising a vacuum lid housing 720 and gas ports 730. FIG. 15 shows a top perspective cross-sectional view of the mixing vessel 670 of FIG. 14. FIG. 16 shows a bottom perspective cross-sectional view of the mixing vessel 670 of FIG. 14, highlighting the filter membrane reinforcements 710.

[0106] The membranes are sized for the application, and the pore sizes of the membrane may vary. The membranes may be reinforced so they do not fatigue out. The system is installed from the external side of the lid and has all wetted parts on the far side of the membrane for easier cleaning and replacement of the membrane between processes. Current processes use the filter and hard-to-clean parts in the wetted area. This minimizes the surface area on the wetted parts and makes it easy to clean. Current vacuum ports are small in surface area, limiting their ability to pull a vacuum. Also, the size of the filter is easily plugged. Systems with filters in the vacuum line help, but the line before the filter is hard to clean. The fitting to the hose is also hard to clean.

[0107] Referring to FIGS. 14-16, a vessel lid 683 comprises a membrane 700 connected to a reinforcement structure 710. Vacuum lid housing 720 is configured to hold the membrane 700 and reinforcement structure 710. The vessel lid 683 has one or more gas ports 730 for entry and exit. O-rings 740 provide seals at several connection points within the vessel lid 683. Threads 750 and quick-connect fitting 760 attach the vacuum line 770 to the vessel lid 675.

[0108] This configuration can also be used to add positive pressure to the vessel. This allows equivalent pressure inside the vessel to be used at higher elevations that match those at lower elevations. It also allows for greater pressures, increasing the energy coupled to the mix from the moving vessel.

[0109] In certain embodiments, a gas vacuum filter system comprises a membrane configured to protect a vacuum line by allowing gases to escape the mixing vessel while blocking solids and liquids, a reinforcement structure disposed on the membrane, a housing configured toLEI0003-401-PC hold the membrane and the reinforcement, the housing having one or more gas ports, and a means for mounting the system on an external side of a vessel lid.

[0110] In certain embodiments, the membrane comprises polytetrafluoroethylene.[OHl] In certain embodiments, the system further comprises threads and a quick-connect fitting for attaching a vacuum line to the vessel lid.

[0112] In certain embodiments, the system is further configured to add positive pressure to the vessel, allowing for equivalent pressure inside at different elevations and increasing energy coupled to the vessel.

[0113] In certain embodiments, a method for filtering gas in a vacuum line comprises protecting a vacuum line with a reinforced membrane by allowing gases to escape the mixing vessel while blocking solids and liquids and mounting the system on an external side of a vessel lid.

[0114] In certain embodiments, the method further comprises attaching the vacuum line to the vessel lid using threads and a quick-connect fitting.

[0115] In certain embodiments, the method further comprises adding positive pressure to the vessel, allowing for equivalent pressure inside at different elevations and increasing energy coupled to the vessel.

[0116] In certain embodiments, a system for filtering gas in a vacuum line comprises a means for protecting a vacuum line by allowing gases to escape the mixing vessel while blocking solids and liquids, a means for reinforcing the means for protecting the vacuum line, and a means for mounting the system on an external side of a vessel lid.

[0117] In certain embodiments, the system further comprises means for attaching the vacuum line to the vessel lid using threads and a quick-connect fitting.

[0118] In certain embodiments, the system further comprises means for adding positive pressure to the vessel, allowing for equivalent pressure inside at different elevations and increasing energy coupled to the vessel.

[0119] FIG. 17 shows the resultant Power to Mix with a set point of 3,200 W. The resultant acceleration mainly tracks that of the Power to Mix.

[0120] FIG. 18 shows three mix data for mixing corn syrup with water to make a paste. The power to mix control set points were as follows: For the first 45 seconds the set point was at 700 Watts, then a slow ramp to 1,200 Watts over 30 seconds. The remainder of the run was using tight / loose control around 1,200 Watts.

[0121] FIG. 19 shows the acceleration response during FIG. 18 power control. The acceleration response varies, but the power control is consistent.

Claims

LEI0003-401-PCCLAIMSWhat is claimed is:

1. A system for scaling material processing, comprising: a plurality of vessels, each vessel having a diameter and a height, the vessels being vertically stacked upon one another to define a stack; wherein the diameter of each vessel is chosen to inhibit bridging with cohesive materials; and wherein the height of each vessel remains constant relative to the other vessels in the stack.

2. The system of claim 1, wherein power density applied to contents of each vessel is substantially uniform across the height of the stack.

3. The system of claim 1 or 2, wherein the combined volume of the vessels in the stack is between 1 L and 120 L.

4. The system of any one of claims 1 to 3, wherein each vessel is adapted to hold a batch operation for processing powdered materials.

5. The system of any one of claims 1 to 4, wherein each vessel in the stack is independently weighable.

6. The system of any one of claims 1 to 5 further comprising a control system configured to regulate power distribution across the stacked vessels.

7. The system of any one of claims 1 to 6, wherein each vessel maintains a consistent aspect ratio.

8. A method for controlling power or power density in an acoustic mixer, comprising: determining the power density required for processing a mixture contained in a vessel; applying an energy source to the mixture; and controlling the applied energy to maintain a substantially uniform power density throughout the mixture.

9. The method of claim 8 further comprising regulating the power density with a mechanical control system.

10. The method of claim 8 or 9 further comprising inputting a machine processing recipe via a human-machine interface (HMI) to control the power density.LEI0003-401-PC11. The method of claim 10, wherein the HMI is chosen from a touchscreen panel, keypad interface, graphical user interface, voice command system, control panel, remote control interface, or soft key interface.

12. The method of any one of claims 8 to 11 further comprising adjusting the energy based on feedback from sensors monitoring an energy state of the mixture.

13. The method of any one of claims 8 to 12 further comprising maintaining the temperature mixture.

14. A system for controlling power or power density in an acoustic mixer, comprising: a means for determining the power density for processing a mixture contained in a vessel; a means for applying an energy source to the mixture; and a means for controlling the applied energy to maintain a substantially uniform power density throughout the mixture.

15. The system of claim 14 further comprising a means for regulating the power density.

16. The system of claim 14 or 15 further comprising a means for inputting a machine processing recipe to control the power density.

17. The system of any one of claims 14 to 16, further comprising a means for adjusting the energy based on feedback from sensors monitoring an energy state of the mixture.

18. The system of any one of claims 14 to 17, further comprising a means for maintaining the temperature of the mixture.

19. A quick-adjust vessel holder, comprising: a frame supporting a vessel; a threaded rod having a self-locking thread, the threaded rod extending vertically through a lead screw; one or more push buttons operatively connected to the frame and the threaded rod to release the threaded rod for coarse slide adjustment; a knob at the top of the threaded rod configured for fine adjustment by turning after the push button is released; springs connected to the frame and engaging the threads of the threaded rod to maintain the threaded rod in position relative to the lead screw when the push buttons are not activated.LEI0003-401-PC20. The holder of claim 19, wherein the knob is chosen from a hand knob or a link for use with a torque wrench.

21. The holder of claim 19 or 20, wherein the one or more push buttons comprise two push buttons, with one positioned on the front of the holder and one positioned on the back of the holder.

22. The holder of claim 19 further comprising a base supporting the frame and the vessel.

23. A system for quick adjustment of a vessel holder, comprising: a means for supporting a vessel; a means for coarse adjustment; a means for fine adjustment; and a means for maintaining relative position of the vessel.

24. A non-contact displacement sensor system for an acoustic mixer, comprising: a sensor configured to detect the movement of a moving mass; and an accelerometer positioned adjacent to the sensor to verify the displacement measurement.

25. The system of claim 24, wherein the sensor is chosen from an eddy-current sensor or an optical sensor.

26. The system of claim 24 or 25 devoid of wires that may fatigue and break over time due to the movement of the moving mass.

27. The system of any one of claims 24 or 26, wherein the current sensor provides a near- sinusoidal measurement of sinusoidal plate displacement motion.

28. The system of claim 27, further comprising a detection module configured to process the near-sinusoidal measurement into readable displacement data.

29. The system of any one of claims 24 to 28, further comprising an acoustic mixer, comprising: a frame comprising a frame ledge; a voice coil actuator comprising a coil assembly rigidly disposed on the frame and a magnet assembly; a first moving mass rigidly coupled to the magnet assembly, further coupled to the frame ledge by a plurality of frame-to-first moving mass springs, and further coupled to a second moving mass by a plurality of first moving mass-to-second moving mass springs; andLEI0003-401-PC a mixing vessel rigidly coupled to the first or second moving mass via a vessel holder; wherein the sensor detects displacement of the first and second moving masses.

30. The system of any one of claims 24 to 29, wherein the accelerometer is configured to provide additional displacement data in three orthogonal axes.

31. The system of any one of claims 24 to 30, further comprising a mounting structure for holding the sensor and the accelerometer in place relative to the moving mass.

32. The system of any one of claims 24 to 31, wherein the displacement data from the accelerometer is used to calibrate the sensor.

33. A system for measuring displacement in an acoustic mixer, comprising: a means for detecting the movement of a moving mass; and a means for verifying the displacement measurement positioned adjacent to means for detecting the movement of a moving mass.

34. The system of claim 33, further comprising a means for measuring near-sinusoidal displacement motion.

35. The system of claim 34, further comprising a means for processing the near- sinusoidal measurement into readable displacement data.

36. The system of any one of claims 33 to 35 further comprising a means for providing additional displacement data in three orthogonal axes.

37. The system of any one of claims 33 to 36 further comprising a means for calibrating the means for detecting the motion of a moving mass with the displacement data from the means for verifying the displacement measurement.

38. A gas vacuum filter system, comprising: a membrane configured to protect a vacuum line by allowing gases to escape the mixing vessel while blocking solids and liquids; a reinforcement structure disposed on the membrane; a frame configured to hold the membrane and the reinforcement, the frame having one or more gas ports; and a means for mounting the system on an external side of a vessel lid.

39. The system of claim 38, wherein membrane comprises chosen from poly tetrafluoroethyl ene .LEI0003-401-PC40. The system of claim 38 or 39 further comprising threads and a quick-connect fitting for attaching a vacuum line to the vessel lid.

41. The system of any one of claims 38 to 40 further configured to add positive pressure to the vessel, allowing for equivalent pressure inside at different elevations and increasing energy coupled to the vessel.

42. A method for filtering gas in a vacuum line, comprising: protecting a vacuum line with a reinforced membrane by allowing gases to escape the mixing vessel while blocking solids and liquids; and mounting the system on an external side of a vessel lid.

43. The method of claim 42, further comprising attaching the vacuum line to the vessel lid using threads and a quick-connect fitting.

44. The method of claim 42 or 43 further comprising adding positive pressure to the vessel, allowing for equivalent pressure inside at different elevations and increasing energy coupled to the vessel.

45. A system for filtering gas in a vacuum line, comprising: a means for protecting a vacuum line by allowing gases to escape the mixing vessel while blocking solids and liquids; a means for reinforcing the means for protecting the vacuum line; and a means for mounting the system on an external side of a vessel lid.

46. The system of claim 45 further comprising means for attaching the vacuum line to the vessel lid using threads and a quick-connect fitting.

47. The system of claim 45 or 46 further comprising means for adding positive pressure to the vessel, allowing for equivalent pressure inside at different elevations and increasing energy coupled to the vessel.

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