Filter Particle Layer for Viscous Liquid Bubble Removal
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Solution Overview
Problem
Existing methods for removing gaseous inclusions from viscous liquids, such as molten glass, are impractical due to high energy costs, complexity, and limitations in scalability, especially at high temperatures, where conventional methods like vacuum systems, centrifuges, and heating are costly and inefficient, and acoustic or ultrasonic approaches struggle to handle large volumes effectively.
Innovation Solution
A method involving a layer of filter particles positioned within the viscous liquid, where gaseous inclusions coalesce and rise to the surface, utilizing Bernoulli's principle, with a two-stage clarification process (coarse and fine) to achieve bubble removal without altering the liquid's temperature or viscosity, using refractory materials to withstand high temperatures and maintain process simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional bubble removal methods (vacuum, centrifuge, heating) are used, then bubble removal speed is improved, but energy cost and capital cost increase substantially
Solution Approach 1:
The patent introduces an intermediary substance (powdered material such as silica, alumina, or zirconia) that acts as a mediator between the bubbles and the liquid flow. The powder particles attach to bubbles and facilitate their removal through the liquid stream without requiring external energy input, thus resolving the contradiction between fast bubble removal and low energy consumption
Solution Approach 2:
The patent replaces complex mechanical systems (vacuum pumps, centrifuges, heating devices) with a simple chemical/physical process involving powder addition. This substitution eliminates the need for expensive mechanical equipment and energy-intensive operations while achieving effective bubble removal
2Reliability
If holding time is extended to allow bubble evolution, then bubble removal is improved, but productivity decreases
Solution Approach 1:
The patent applies preliminary action by adding powder material to the liquid before the bubbles have a chance to rise naturally. The powder particles immediately attach to bubbles, causing them to coalesce and rise faster. This preliminary intervention eliminates the need for extended holding times while ensuring complete bubble removal, thus maintaining both reliability and productivity
3Stability of the object's composition
If liquid viscosity is increased for processing, then material properties are improved, but bubble removal speed decreases
Solution Approach 1:
The powder particles serve as an intermediary that bypasses the viscosity limitation. Instead of relying on natural bubble rise through viscous liquid, the powder-bubble aggregates are carried along with the liquid flow, effectively removing bubbles regardless of the liquid's viscosity. This allows the liquid to maintain high viscosity for processing while still achieving effective bubble removal
4Manufacturing precision
If high temperature processing is used, then material quality is improved, but operational complexity and cost increase
Solution Approach 1:
The patent applies self-service by using the liquid's own flow characteristics to carry the powder-bubble aggregates through the system. The process leverages the existing liquid circulation rather than requiring additional pumping or mechanical assistance, thereby simplifying the equipment needed for high-temperature processing while maintaining glass quality
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
This method effectively removes gaseous inclusions to sub-micron levels without excessive energy consumption or complexity, ensuring reliable operation and scalability for industrial glass production by using refractory materials and maintaining precise temperature control, thus enhancing the quality of glass products.
Implementation Method 1
the gaseous inclusions coalesce within the layer of filter particles, forming larger gaseous inclusions which rise to the top of the viscous liquid and escape therefrom
Implementation Method 2
gaseous inclusions coalesce within the layer of filter particles, forming larger gaseous inclusions which rise to the top of the viscous liquid and escape therefrom
Implementation Method 3
a layer of filter particles is positioned in the viscous fluid and the viscous liquid is passed through the layer of filter particles
Data Source
AI summary
A method for removal of gaseous inclusions from a viscous liquid in which a layer of filter particles is positioned in the viscous liquid and the viscous liquid is passed through the layer of filter particles, whereby the gaseous inclusions combine or coalesce within the layer of filter particles, forming larger gaseous inclusions which rise to the top of the viscous liquid and escape therefrom.