Curvilinear Sidewall Hopper for Mass Flow

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Solution Overview

Problem

Existing material handling hoppers face issues with flow obstruction, such as 'ratholes' and 'bridges,' due to non-ideal sidewall configurations, leading to inefficient material transfer and increased space requirements, as well as complex manufacturing and assembly processes.

Innovation Solution

A material handling hopper with a curvilinear sidewall that converges from a larger inlet to a smaller outlet, forming a seamless, integrally formed funnel-shaped body, which promotes mass flow and is manufactured using a spinning process on a lathe to ensure a compact design and reduce manufacturing complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multi-part hopper configuration with hyperbolic outlet component is used, then flow obstruction is reduced, but device complexity and manufacturing complexity increase

Engineering Contradiction:

Improveflow obstruction preventionVSAvoidmulti-part configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (inlet component, transfer section, outlet component) into a single integrally formed hopper body. This eliminates the complexity of assembling multiple parts while maintaining the functional benefits of each section through continuous curvilinear sidewalls that prevent flow obstructions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hopper is designed with distinct functional zones (inlet zone, transfer zone, outlet zone) separated by curvilinear sidewalls with specific geometric properties. Each zone has optimized wall angles and curvature radii to control material flow independently, preventing ratholes and bridges while maintaining a unified single-piece structure.

Inventive Principle:

Principle #1Segmentation

2Reliability

If hyperbolic outlet component is used, then flow obstruction is reduced, but space requirements increase

Engineering Contradiction:

Improveflow obstruction preventionVSAvoidhopper space footprint

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent employs curvilinear sidewalls with specifically controlled curvature radii throughout the hopper structure. The continuous curvature allows material to flow smoothly from the inlet through the transfer section to the outlet without abrupt angle changes, preventing flow obstructions while maintaining a compact footprint compared to traditional hyperbolic designs.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent optimizes geometric parameters including wall angles, curvature radii, and section transitions to achieve efficient material flow in a compact configuration. By carefully controlling these parameters, the hopper prevents ratholes and bridges without requiring the large space footprint associated with traditional multi-component hyperbolic designs.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If non-curvilinear sidewall is used, then manufacturing is simpler, but flow obstruction occurs

Engineering Contradiction:

Improvesidewall fabricationVSAvoidmaterial flow continuity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent utilizes curvilinear sidewalls with continuous curvature throughout the hopper structure. These curved surfaces guide material flow smoothly from the inlet through the transfer section to the outlet, preventing abrupt directional changes that cause ratholes and bridges. The single-piece integral construction accommodates these curves through appropriate manufacturing processes.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent specifies particular geometric parameters for the curvilinear sidewalls including curvature radii and wall angles optimized for material flow. These parameters are designed to work together to ensure continuous material flow while remaining manufacturable as a single integral piece through processes like spinning or forming.

Inventive Principle:

Principle #35Parameter changes

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 curvilinear sidewall design enhances mass flow by preventing flow obstructions and allows for a compact, efficient material transfer system with reduced manufacturing complexity, while the spinning process ensures a seamless and cost-effective production method.

Implementation Method 1

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Data Source

PatentUS10087004B2Material handling hopper

Publication Date: 2018.10.02 GILL DAVID R

AI summary

A material handling hopper includes an integrally formed handling body that defines an inlet, an outlet, and an axis. The handling body has a seamless sidewall extending between the inlet and the outlet. The sidewall is circular in cross section in a plane perpendicular to the axis. The sidewall is curvilinear and defines a first height between an axial location of a first inner diameter and an axial location of a second inner diameter.