Modular Screen and Agitator for Simultaneous Powder Sifting and Blending
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Solution Overview
Problem
Existing powder blending technologies, such as tumbling blenders with intensifier bars, often fail to achieve uniform blends due to static charges forming aggregates in micronized active ingredients, which are not effectively broken down, leading to inefficient mixing and the need for time-consuming multiple handling processes that generate dust.
Innovation Solution
An apparatus with multiple section screens and agitators that allow for simultaneous sifting and blending within a tumbling container, where the screen and agitator sections are assembled in a way that facilitates easier installation, operation, and maintenance, ensuring thorough mixing and breaking down of powder lumps without the need for extensive handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single piece screen and single piece paddle are used in large tumbling blenders, then the sifting and blending function is provided, but the installation and removal of these components becomes difficult or impossible through the cover openings
Solution Approach 1:
The screen and paddle are divided into multiple sections that can be assembled in a modular fashion. Each section is small enough to be installed through the cover opening of large tumbling blenders, yet when assembled together they provide the full sifting and blending functionality required for large batch processing.
2Reliability
If multiple handling processes are used to break down powder aggregates, then the powder can be sifted and re-blended, but the process becomes time consuming and generates dust
Solution Approach 1:
The sifting and blending operations are merged into a single simultaneous process. The screen performs sifting while the paddle performs blending, and both functions occur together in one continuous operation rather than as separate sequential steps, eliminating the need for multiple handling processes.
Solution Approach 2:
The sifting and blending occur continuously in one uninterrupted operation. The powder flows through the screen while being continuously agitated by the paddle, maintaining continuous useful action throughout the process rather than requiring intermittent stopping and rehandling.
3Manufacturing precision
If intensive blending is performed to break down aggregates, then mixing uniformity improves, but the complexity of the blending apparatus increases
Solution Approach 1:
The paddle serves multiple functions simultaneously: it agitates the powder for blending, pushes powder through the screen for sifting, and breaks down aggregates. This multi-functionality achieves intensive mixing action without requiring multiple separate components or complex mechanisms.
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 ensures improved mixing efficiency, reduces dust generation, and simplifies maintenance by allowing for safer and more cost-effective assembly and replacement of components, ensuring uniformity in pharmaceutical powder blends.
Implementation Method 1
a tumbling container; wherein the end frames and the screen sections are removeably assembled within the tumbling container for rotation therewith
Implementation Method 2
a first agitator section; g. a second agitator section assembled coaxially to the first agitator section between the first and the second end frames; and h. a shaft for mounting the first and second agitator sections for rotation
Data Source
Figure 1
Figure 2A~2F
Figure 3~4
AI summary
A tumbling container 14 is mounted for rotation with a curved screen 20 fixedly mounted within the tumbling container. A multiple vane paddle 24 is mounted to a shaft 26 that is rotatably mounted to the tumbling container 14. The paddle vanes are formed with angular edges. As the tumbler rotates and the paddle rotates, powder is repeatedly dropped onto the screen to be sifted with the aid of the paddle. Rotating the tumbler further drops unsifted portions of the powder from the screen to mix with additional powder in the tumbler body. Thus, sifting and blending of powders is accomplished in one single operation. The invention utilizes an apparatus having a multiple section screen and a multiple section paddle to enable assembly through the openings 16 in the tumbling container. The screen of a second embodiment has a cowl adjacent to each screen opening to optimize powder lump disintegration.