Acoustic Agitator for Uniform Continuous Material Processing
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Solution Overview
Problem
Current methods for continuous material processing fail to produce uniformly mixed, reacted, coated, or combined materials, and are often costly and time-consuming, with continuous flow reactors resulting in non-uniform reactions and inefficient use of equipment.
Innovation Solution
A mechanical system utilizing acoustic agitation technology to continuously fluidize, mix, coat, dry, combine, chemically react, and segregate materials, featuring an acoustic agitator coupled with a continuous process vessel that generates low-frequency acoustic energy for uniform mixing and processing, equipped with temperature control, vacuum pressure, and filtering mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous flow reactors are used for material processing, then continuous processing is achieved, but uniform mixing and reaction are not produced
Solution Approach 1:
The patent applies mechanical vibration through an acoustic agitator that generates low-frequency acoustic energy (typically 20-100 Hz) to continuously vibrate materials within the process vessel. This vibration induces particle motion and fluid circulation that achieves uniform mixing and reaction throughout the continuous processing stream, resolving the contradiction between continuous processing capability and uniformity of mixing.
Solution Approach 2:
The patent replaces traditional mechanical mixing systems (such as impellers and agitators) with an acoustic field-based system. The acoustic agitator uses sound waves to create vibrational energy that mixes materials without requiring complex mechanical components, thereby achieving both continuous processing and uniform mixing through a simpler, more effective mechanism.
2Productivity
If traditional continuous processing equipment is used, then processing can be performed continuously, but equipment space requirements are excessive
Solution Approach 1:
The acoustic agitator serves multiple functions simultaneously: it mixes materials, facilitates chemical reactions, promotes uniform distribution, and can be integrated with various process vessel configurations. This multi-functionality allows a single compact device to replace multiple separate equipment components, reducing overall equipment space requirements while maintaining continuous processing capability.
Solution Approach 2:
By substituting traditional mechanical mixing equipment with an acoustic field-based system, the patent eliminates the need for large impellers, shafts, and associated mechanical structures. The acoustic energy can be generated by a compact transducer, significantly reducing the footprint of the equipment while preserving continuous processing capabilities.
3Ease of operation
If conventional mixing methods are used, then materials can be mixed, but dead zones and non-uniform distribution occur
Solution Approach 1:
The acoustic agitator generates low-frequency vibrations that propagate through the entire process vessel, creating continuous particle motion and fluid circulation. This comprehensive vibrational field eliminates dead zones by ensuring that all materials, including those in previously stagnant areas, are continuously agitated and distributed uniformly throughout the processing stream.
Solution Approach 2:
The system operates at specific low-frequency parameters (typically 20-100 Hz) that are optimized for generating effective vibrational mixing. By controlling the frequency and intensity of acoustic energy, the system achieves uniform distribution without creating turbulence or chaos, thereby eliminating dead zones while maintaining ease of operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves uniform mixing and reaction, reduces equipment space requirements, and increases processing efficiency by ensuring even acoustic energy distribution throughout the process vessel, minimizing dead zones and enhancing material fluidization and reaction uniformity.
Implementation Method 1
an acoustic agitator capable of being removably coupled to a process vessel... capable of transferring acoustic energy generated by the acoustic agitator into the at least one process ingredient
Implementation Method 2
a plurality of plates configured for directing a flow of the at least one process ingredient through the continuous process vessel and capable of transferring acoustic energy generated by the acoustic agitator into the at least one process ingredient
Implementation Method 3
Mechanical system that continuously processes a combination of materials... continuously fluidize, mix, coat, dry, combine, chemically react and/or segregate materials
Data Source
AI summary
The present application is directed towards systems and methods for continuously reacting a combination of materials by use of an acoustic agitator and a continuous process vessel. The system can react, fluidize, mix, coat, dry, combine or segregate materials. The continuous processing system can include an acoustic agitator capable of being removably coupled to a continuous process vessel. The continuous process vessel can include a first inlet for introducing at least one process ingredient, a plurality of plates configured for directing a flow of the at least one process ingredient through the continuous process vessel and capable of transferring acoustic energy generated by the acoustic agitator into the at least one process ingredient, an outlet for discharging a product of the at least one process ingredient, and a fastener for removable coupling the continuous process vessel to the acoustic agitator.