Powder Coating Dispersion Using High-Pressure Gas Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coating apparatuses face challenges with high agglomeration of small particles, long processing times, and collection losses due to spray nozzle attachment, particularly in forming even coating layers on raw material powders.
Innovation Solution
A coating apparatus utilizing a dispersion unit with high-pressure gas flow to disperse a mixture of raw material powder and coating solution, followed by a conveyance unit for drying and a collection unit, eliminating spray nozzles to improve dispersibility and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spray nozzle is used to jet coating solution, then coating solution can be applied to powder, but powder agglomerates due to liquid bridge force and collection loss occurs
Solution Approach 1:
The patent removes the spray nozzle component from the system entirely. Instead of jetting coating solution through a nozzle, the invention uses a fluidized bed where coating solution is applied to fluidized powder particles, eliminating the source of powder agglomeration and collection loss associated with spray nozzles
Solution Approach 2:
The patent employs fluidization technology using gas flow to suspend and disperse powder particles in a fluidized state. This pneumatic approach replaces the mechanical spray nozzle method, allowing coating solution to be applied uniformly to individual particles without causing agglomeration
2Ease of manufacture
If batch coating process is used, then coating can be formed on powder, but processing time becomes long
Solution Approach 1:
The patent implements a continuous coating process where powder is continuously fluidized and coated in a fluidized bed reactor, replacing the batch processing method. This continuous operation significantly reduces processing time and increases productivity while maintaining coating quality
3Speed
If high jetting speed is used for coating solution, then coating solution attaches quickly, but powder agglomerates due to liquid bridge force
Solution Approach 1:
The patent uses fluidization gas flow to suspend powder particles and control coating solution application. This pneumatic approach allows for controlled, uniform coating at lower speeds without causing powder agglomeration, replacing the high-speed spray nozzle method
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 apparatus suppresses agglomeration, enables continuous processing, and enhances powder collection efficiency by using high-pressure gas flows to attach coating solutions uniformly, reducing collection losses.
Implementation Method 1
when the slurry flowing through the flow path passes the collision position, shear force generated by the gas flow is applied to the slurry to disperse the slurry
Implementation Method 2
a conveyance unit that conveys the raw material powder which flows into the conveyance unit from the dispersion unit and to which the film of the coating solution is attached by causing a gas flow to carry the raw material powder and that dries the coating solution during the conveyance
Data Source
AI summary
This coating device comprises dispersing/mixing part, conveying part, and collecting part. A raw material powder and a coating solution are supplied to the dispersing/mixing part as a slurry. In the dispersing/mixing part, the slurry (mixture) of the raw powder and the coating solution is dispersed by air flow of a high-pressure fluid into a powder, a film of the coating solution having adhered to the surface of the powder. The powder is introduced from the dispersing/mixing part to the conveying part and is conveyed with the conveying part oriented toward the collecting part. While the powder is being conveyed, the coating solution that has adhered to the particle surfaces dries, whereby a powder in which the particle surfaces are coated with a precursor is produced. A powder flow introduced into the collecting part passes through a bag filter, causing the powder to be captured by the bag filter.