Particle Formation Using Overfilled Recesses for Spherical Shapes
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Solution Overview
Problem
Existing methods for forming particles, such as rotoforming, limit the shapes to dome-shaped particles with a flat surface, resulting in inefficient packing in containers, as these shapes do not optimize packing density compared to more spherical shapes.
Innovation Solution
An apparatus and process that use a cylinder with apertures rotating about a stator to deposit precursor material into recesses on a moving conveyor, allowing for the formation of particles with rounded surfaces that can pack more optimally by overfilling the recesses, which can result in spherical or oblate hemispherical shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If rotoforming is used to deposit melt onto a flat conveyor surface, then particles can be formed with a flat surface, but the particles become dome-shaped and pack inefficiently in containers
Solution Approach 1:
The conveyor surface is modified to include recesses instead of being flat, and the melt is deposited to overfill these recesses, creating particles with curved, rounded surfaces that approximate spherical shapes. This curvature enables the particles to pack more efficiently in containers, resolving the contradiction between achieving a defined particle shape and optimizing packing efficiency.
Solution Approach 2:
The conveyor surface is given non-uniform geometry with specific recesses at defined locations, while the melt deposition process is localized to overfill these specific recesses. This creates particles with controlled rounded surfaces that optimize packing, rather than uniform dome shapes from flat surface deposition.
2Ease of manufacture
If dome-shaped particles with flat surfaces are used, then the particle formation process is simple, but the fill levels in containers are inconsistent
Solution Approach 1:
By forming particles with rounded, curved surfaces through overfilling recesses on the conveyor, the particles achieve more uniform packing behavior. This improves fill level consistency in containers while maintaining a relatively simple manufacturing process, resolving the contradiction between ease of manufacture and manufacturing precision.
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
The process enables the formation of particles that pack more efficiently in containers, achieving consistent fill levels and weights, as the rounded edges allow for better sliding and packing, thereby improving container filling efficiency.
Implementation Method 1
a cylinder rotationally mounted about the stator and rotatable about a longitudinal axis of the cylinder, wherein the cylinder has a periphery and the cylinder comprises a plurality of apertures disposed about the periphery, wherein the apertures are intermittently in fluid communication with the stator as the cylinder rotates about the stator
Implementation Method 2
a conveyor beneath the cylinder and movable in translation relative to the longitudinal axis, wherein the conveyor comprises a plurality of recesses in registration with the apertures
Implementation Method 3
The melt is cooled on the conveyor to form a plurality of particles
Data Source
AI summary
An apparatus and process for forming particles. A precursor material is provided to a rotor-stator construction and fed through apertures in the cylinder. The apertures are in intermittent fluid communication with the stator. A conveyor is provided beneath the cylinder. The conveyor has recesses and the recesses move in registration with the apertures in the cylinder. The precursor material is passed through the apertures and deposited in the recesses in an amount that overfills the recesses. The deposited precursor material is cooled to form a plurality of particles.