Polymeric Coated Reticulated Foam for Mineral Flotation

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Solution Overview

Problem

Existing flotation processes face challenges in efficiently separating valuable materials from unwanted materials in aqueous mixtures due to difficulties in controlling bubble surface area flux and the limitations of using air bubbles.

Innovation Solution

A substrate with a polymeric coating is used in an aqueous slurry, featuring a compliant and tacky surface with low energy to enhance the selective collection of hydrophobic and hydrophobized mineral particles. The polymeric coating is applied to a reticulated foam structure, ensuring homogeneous distribution without blocking pores, and is rendered hydrophobic to attract mineral particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If air bubbles are used in flotation processes, then mineral particles can be separated, but control of bubble surface area flux is difficult

Engineering Contradiction:

Improvemineral separation efficiencyVSAvoidbubble surface area flux control

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent introduces a polymeric coating as an intermediary substance between the substrate and the mineral particles. This coating mediates the interaction by providing specific surface properties (hydrophobicity, tackiness) that enhance particle attachment, thereby improving separation efficiency without relying on difficult-to-control air bubble flux

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the surface parameters of the substrate by applying a polymeric coating with specific properties (hydrophobicity, tackiness, compliance). This parameter change allows the substrate to effectively collect hydrophobic mineral particles without requiring precise control of bubble surface area flux

Inventive Principle:

Principle #35Parameter changes

2Productivity

If polymeric coating is applied to reticulated foam, then selective collection of hydrophobic particles is enhanced, but pores may be blocked

Engineering Contradiction:

Improveparticle collection efficiencyVSAvoidpore openness

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies polymeric coating with specific local qualities (hydrophobicity, tackiness) only on the surface of the reticulated foam substrate. The coating is designed to maintain pore openness while providing the necessary surface properties for particle collection, thus achieving both high collection efficiency and maintained pore functionality

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses reticulated foam as a porous substrate structure that inherently maintains open pores. The polymeric coating is applied in a manner that does not block these pores, allowing the material to benefit from both the surface properties of the coating and the flow properties of the porous substrate

Inventive Principle:

Principle #31Porous materials

3Reliability

If coating is applied to maximize surface area, then adhesion is improved, but coating agglomerates may detach

Engineering Contradiction:

Improveadhesion strengthVSAvoidcoating agglomerate detachment

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent employs a thin polymeric coating film that conformally covers the substrate surface. This thin film approach maximizes surface area utilization for particle adhesion while minimizing the risk of agglomerate formation and detachment that would occur with thicker, non-uniform coatings

Inventive Principle:

Principle #30Flexible shells and thin films

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 polymeric coating effectively enhances the selective collection of hydrophobic mineral particles across a wide range of particle sizes, improving the efficiency of mineral separation in aqueous slurries while minimizing detachment of coating agglomerates.

Implementation Method 1

a polymeric coating to provide a compliant and tacky surface of low energy in order to enhance selective collection of hydrophobic and hydrophobized mineral particles

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

The polymeric coating may be applied to the open-cell foam structure, for example. The coating is arranged to be homogeneously distributed throughout the entire foam surface area while not blocking or plugging cells

Methodology Applied

Scientific EffectHydrophobic interaction: Hydrophobe

Data Source

PatentUS12337344B2Polymer-coated member having a reticulated foam substrate with an open-cell foam structure and at least one polymeric coated surface

Publication Date: 2025.06.24 CIDRA CORP SERVICES INC

AI summary

A substrate for use in an aqueous slurry has a polymeric coating to provide a compliant and sticky surface. The polymer coating has a chemical to render the surface hydrophobic so as to attract hydrophobic or hydrophobized mineral particles in the slurry. The substrate can take the form of a conveyor belt, a bead, a mesh, an impeller, a filter or a flat surface. The substrate can also be an open-cell foam. The polymeric coating can be modified with tackifiers; plasticizers; crosslinking agents; chain transfer agents; chain extenders; adhesion promoters; aryl or alky copolymers; fluorinated copolymers and/or additives; hydrophobizing agents such as hexamethyldisilazane; inorganic particles such as silica, hydrophobic silica, and/or fumed hydrophobic silica; MQ resin; and/or other additives to control and modify the properties of the polymer.