Cloud Mixer Minimizing Particulate Agglomeration
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Solution Overview
Problem
Existing methods for introducing particulate materials into liquids often result in agglomeration due to harsh handling, especially on a large scale, as they rely on turbulence and high shear, which are not effective for achieving uniform dispersions, particularly for sensitive materials like graphite.
Innovation Solution
A misting apparatus with controlled liquid flow and a chamber design that allows particulate materials to fall through a mist, creating a dispersion, which is then circulated through a mixing chamber using laminar flow to prevent agglomeration and ensure uniform mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If turbulence and high shear methods are used to introduce particulate materials into liquids, then mixing speed is improved, but particle agglomeration increases
Solution Approach 1:
The patent introduces a liquid stream as an intermediary medium that carries particles into the mixing chamber. The liquid acts as a carrier that protects particles from direct harsh contact during introduction, while still enabling rapid mixing. This mediator approach allows fast mixing without direct particle-to-particle collision that causes agglomeration.
Solution Approach 2:
The patent replaces direct mechanical shear and turbulence applied to particles with a fluid dynamic approach. Instead of using mechanical mixers that directly agitate particles, the system uses controlled liquid flow and pressure differentials to transport and disperse particles, substituting mechanical particle handling with fluid-based transport.
2Ease of operation
If vacuum or pressure drop methods are used to pull materials into a stream, then material introduction is achieved, but control over introduction speed is lost
Solution Approach 1:
The patent incorporates feedback control through pressure sensors and flow meters that monitor the rate of material introduction. The system adjusts vacuum or pressure differential in real-time based on measured flow rates, maintaining controlled introduction speed while ensuring complete material transfer. This closed-loop control prevents both agglomeration from too-fast introduction and incomplete mixing from too-slow introduction.
3Ease of manufacture
If uncontrolled amounts of material are exposed to liquid with high pressure and shear, then wetting is achieved, but particle damage occurs
Solution Approach 1:
The patent applies preliminary action by pre-mixing particles with a small amount of liquid or dispersant before introducing them to the main liquid volume. This preliminary wetting step coats particles with a protective liquid layer, preventing direct exposure to harsh high-shear conditions and reducing agglomeration and particle damage during the main mixing process.
Solution Approach 2:
The patent uses a cushioning liquid layer or gas phase buffer between particles and the harsh mixing zone. Particles are introduced through a controlled liquid stream or gas carrier that cushions them during transport and initial contact, protecting them from direct exposure to high-pressure and high-shear regions until they are properly dispersed.
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 method effectively disperses particulate materials without causing physical damage, achieving uniform dispersions and preventing agglomeration, making it suitable for large-scale operations and sensitive materials like nanomaterials.
Implementation Method 1
a high pressure pump for forcing liquid from a storage tank through a plurality of misting nozzles into a chamber
Implementation Method 2
The liquid has a controlled flow through the misting nozzles and into the chamber to form a mist in the chamber
Implementation Method 3
nanomaterial is fed into the top of the chamber at a controlled rate and allowed to fall through the mist to form a dispersion
Implementation Method 4
The dispersion is circulated from the holding tank through an inlet port into the mixing chamber using a high volume pump, wherein the circulating dispersion contacts and mixes with the newly manufactured dispersion through laminar flow
Implementation Method 5
the circulating dispersion contacts and mixes with the newly manufactured dispersion through laminar flow
Data Source
AI summary
An apparatus and a method for dispersing particulate materials prone to agglomeration, in a liquid. Particulate materials are exposed to a liquid and put into that liquid to form a suspension or a dispersion in a controlled method thereby minimizing agglomerates. The method uses mechanical/hydro mixing that prevents the physical deterioration of the particulate material and inhibits agglomeration of the particles. In many cases, these materials may be nanomaterials. Almost all particulate materials, can be handled in this manner. This method has been found to be especially useful for preparing solutions of exfoliated graphene and certain drugs.