3D Printed Ore Separation Wheel with Micro Grooves
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Solution Overview
Problem
Existing ore separation systems with round bodies and rigid or square riffle designs fail to efficiently separate ores with negative draft angles, leading to inefficiencies and durability issues in commercial mining settings.
Innovation Solution
A 3D printing method is employed to create a circular ore separation wheel with teeth and valleys, featuring negative draft angles less than 90 degrees, micro grooves, and varying dimensions, allowing for efficient separation of ores with specific gravity of 10.0 or higher.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used to make ore separation wheels, then production time and cost are reduced, but the ability to create negative draft angles less than 90 degrees is lost
Solution Approach 1:
The patent changes the manufacturing method from traditional subtractive or form-based processes to additive manufacturing (3D printing), enabling the creation of complex geometries including negative draft angles less than 90 degrees that were previously impossible to manufacture
Solution Approach 2:
The patent employs curved and complex geometries in the riffle design, specifically implementing negative draft angles and organic shapes that cannot be achieved with traditional flat-pattern manufacturing methods
2Productivity
If rigid or square riffle designs are used, then manufacturing is simpler, but separation efficiency for ores with specific gravity 10.0 or higher deteriorates
Solution Approach 1:
The patent applies different geometries to different parts of the riffle structure, with varying angles and profiles optimized for specific separation functions, rather than using uniform rigid designs throughout
Solution Approach 2:
The riffle design incorporates dynamic flow paths and varying angles that adapt to the movement of ore particles during separation, rather than static rigid structures
3Strength
If conventional 3D printing parameters are used, then printing speed is maintained, but the durability and mechanical strength of the ore separation wheel deteriorate
Solution Approach 1:
The patent optimizes 3D printing parameters including layer height, infill density, and print orientation to achieve the required mechanical strength and durability while maintaining reasonable production time
Solution Approach 2:
The patent uses materials with enhanced mechanical properties suitable for industrial applications, potentially incorporating composite materials or optimized polymer formulations that provide both strength and wear resistance
Data Source
AI summary
A method of making a circular ore separation wheel, for concentration critical stategic rare earths, and preciouse metals, such as gold. The method comprising: 1) forming a base section of the circular ore separation wheel using 3D printing; 2) forming a central hole in the base section being centrally located in the circular ore separation wheel; 3) forming a plurality of teeth, using 3D printing, upon the base section, having a inner end proximate to the central hole and extending therefrom in a circularly radiating direction and having an outer end opposite the inner end with different sizes on the same length of tooth, 4) forming a plurality of micro grooves from about 4.5-0.001 mm partially along outer surfaces of the plurality of teeth extending in a direction from the inner end to the outer end of the plurality of teeth, wherein the plurality of micro grooves are formed by the 3D printing process leaving a small gap located between subsequent extruded layers at the outer surface of the plurality of teeth; and 5) forming a circumferential wall around the ore separation wheel that is proximate to the outer end of the plurality of teeth, and is proximate to the base section. And potentially manufacturing the circular ore separation wheel inside of a pre-made support section with the desired internal concave contours.