Functionalized Open-Cell Foam for Selective Mineral Separation

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Solution Overview

Problem

Existing flotation processes face challenges in controlling air bubble surface area flux and size distribution, leading to inefficiencies in separating valuable material from unwanted material, with no reliable real-time feedback mechanisms for control.

Innovation Solution

Employing an engineered collection medium with a three-dimensional open-cell structure and functionalized molecules to attract and detach mineral particles, using materials like polyurethane and coatings such as poly(dimethylsiloxane) to enhance separation efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If air bubbles are used in flotation cells to carry valuable material to the surface, then separation of valuable material from unwanted material is achieved, but control over air bubble surface area flux and size distribution becomes difficult

Engineering Contradiction:

Improveseparation efficiencyVSAvoidcontrol difficulty

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent introduces an engineered collection medium as an intermediary between the air bubbles and valuable material. This medium consists of porous beads with functionalized surfaces that selectively attract and hold valuable particles. The beads act as mediators that replace direct air-bubble-material interaction, enabling controlled separation while eliminating the control difficulties associated with air bubble flux and size distribution.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical system of air bubbles (gas phase) with a solid-phase collection medium. By substituting air bubbles with porous beads that have controlled physical and chemical properties, the system gains precise control over separation parameters while maintaining the flotation separation mechanism.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If traditional flotation methods are used, then valuable material can be separated, but no dependable real-time feedback mechanisms are available for control

Engineering Contradiction:

Improveseparation capabilityVSAvoidlack of feedback control

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The engineered collection medium enables feedback control by providing a measurable relationship between bead properties and separation performance. The functionalized surfaces of the beads can be designed with specific binding affinities that respond predictably to changes in slurry composition, allowing real-time monitoring and adjustment of separation parameters based on bead behavior.

Inventive Principle:

Principle #23Feedback

3Productivity

If air injection rate is increased to improve surface area flux, then more valuable material can be recovered, but control precision over bubble characteristics deteriorates

Engineering Contradiction:

Improvematerial recovery rateVSAvoidbubble size control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the fundamental parameter from air bubble characteristics (size, flux, distribution) to solid bead characteristics (porosity, surface area, functional group density). This parameter transformation allows precise control over separation efficiency and material recovery rate independently, eliminating the trade-off between productivity and precision that exists in traditional air-based flotation systems.

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

Achieves precise control over bubble size and surface area flux, enabling effective separation of valuable material by tuning bead or bubble size to particle size, optimizing recovery and reducing chemical dependency.

Implementation Method 1

a plurality of molecules provided on the collection surfaces, the molecules comprising a functional group having a chemical bond for attracting one or more mineral particles in an aqueous mixture to the molecules, causing the mineral particles to attached to the collection surfaces

Methodology Applied

Scientific EffectChemical bond: Chemical Bonding

Implementation Method 2

The engineered collection medium includes a coating configured with a hydrophobic chemical selected from a group consisting of poly(dimethylsiloxane), what is commonly known as pressure sensitive adhesives with low surface energy, to provide the molecules

Methodology Applied

Scientific EffectHydrophobic effect: Hydrophobe

Data Source

PatentEP3400091B1Open cell or reticulated foam functionalized open-network structure for selective separation of mineral particles in an aqueous system

Publication Date: 2025.11.19 CIDRA CORP SERVICES INC

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AI summary

An engineered collection medium for use in mineral separation is described. The engineered collection medium has a solid phase body configured with a three- dimensional open-cell structure like foam or sponge to provide collection surfaces. The surfaces are functionalized with a hydrophobic chemical having molecules with a functional group for attaching mineral particles to the collection surfaces. The engineered collection medium can be a foam block, a filter or conveyor belt to be placed in a slurry to collect mineral particles in the slurry. The engineered collection medium carrying the mineral particles is provided to a release apparatus where the mineral particles can be released by using mechanical agitation, sonic agitation and so forth.