Injector Head Splitter Bars for Uniform Particulate Coating

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Solution Overview

Problem

Existing coating technologies for particulate materials, such as sand used in fracking, often result in uneven coatings due to limited exposure of particles to the coating spray, leading to agglomeration and contamination issues.

Innovation Solution

The use of an injector head with lateral splitter bars and associated spray nozzles that increase the surface area exposure of particulate material to the coating, ensuring a uniform coating by dividing the flow and spraying on both sides and ends of the splitter bars, while maintaining a self-cleaning design to prevent dust and spray agglomeration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If particles are sprayed with coating material as they cascade over baffles in a tumbler or tower, then coating is applied to particulate material, but the coating is uneven due to limited surface area exposure

Engineering Contradiction:

Improvecoating uniformityVSAvoidsurface area exposure

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The particulate material flow is segmented into multiple streams by the splitter bars, creating separate flow paths that allow coating material to be applied to each segment. This segmentation increases the effective surface area exposed to coating spray and ensures more uniform coating distribution across all particles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The splitter bars extend laterally into the flow path, adding a spatial dimension to the coating process. By positioning nozzles to spray laterally relative to the splitter bars, the system creates multiple spray zones that coat particles from different angles and positions, dramatically increasing surface area exposure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If high volume of particulate material is coated quickly, then productivity increases, but agglomeration and contamination issues worsen

Engineering Contradiction:

Improvecoating rateVSAvoidagglomeration and contamination

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The splitter bars divide the high-volume particle flow into multiple smaller streams, allowing coating material to be applied more effectively to each stream. This prevents particles from clumping together (agglomeration) while maintaining high overall throughput, as each segmented stream receives adequate coating coverage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system maintains continuous coating application across all particle streams simultaneously through multiple nozzles operating in parallel. This continuous action ensures particles are coated quickly during flow without interruption, preventing agglomeration while achieving high productivity.

Inventive Principle:

Principle #20Continuity of useful action

3Area of stationary object

If coating material is sprayed laterally relative to splitter bars, then surface area exposure increases, but device complexity increases

Engineering Contradiction:

Improvesurface area exposureVSAvoidnumber of splitter bars and nozzles

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The splitter bars serve multiple functions simultaneously: they segment the particle flow, provide structural support for nozzle mounting, and create the geometric configuration necessary for lateral spray exposure. This multi-functionality reduces overall device complexity despite the addition of multiple components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The functions of flow segmentation and coating application are merged into a single integrated structure where splitter bars and nozzles work together as one system. The lateral orientation of both splitter bars and nozzles creates a unified geometric arrangement that maximizes surface area exposure while minimizing the number of separate components needed.

Inventive Principle:

Principle #5Merging (Combining)

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 solution achieves a uniform and efficient coating of particulate materials at high rates, minimizing agglomeration and contamination, with the ability to coat materials like sand at 8 to 30 tons per minute, and allows for easy maintenance and cleaning of components.

Implementation Method 1

Spray nozzles mounted to said sidewalls below said splitter bars spray coating material generally laterally relative to said sidewalls and generally laterally relative to the length of said splitter bars so as to coat particulate material

Methodology Applied

Scientific EffectSpray: Fluid Spray

Data Source

PatentUS9731304B2Apparatus for coating particulate material flowing through a chute

Publication Date: 2017.08.15 PARIS JAMES L

AI summary

An injector head for delivering particulate material from a feeder source to a receiver is fitted with a plurality of splitter bars extending generally laterally from the sidewalls thereof into the space through which particulate material is fed as it flows into a receiver. Spray nozzles mounted to said sidewalls below said splitter bars spray coating material generally laterally relative to said sidewalls and generally laterally relative to the length of said splitter bars so as to coat particulate material as it passes over and to the sides and ends of said splitter bars.