Powder Processing via Heated Metal Sphere Contact

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional methods for processing metal powders, such as those used in aerospace and medical applications, face challenges including high energy consumption, inefficient desorption due to particle contact, and deterioration from oxygen exposure, particularly when dealing with bulk powder flows and complex equipment maintenance.

Innovation Solution

A method and apparatus utilizing a reaction vessel packed with metal spheres to a volumetric proportion of 50-60% for efficient heat transfer and powder processing, where the powder flows under gravity and vibration, allowing intimate contact with heated spheres for degassing and desorption, reducing energy requirements and maintaining powder quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by stationary object

If conventional dry hot air drying is used, then the drying function is provided, but energy consumption is high and process time is long

Engineering Contradiction:

Improveenergy consumptionVSAvoiddrying rate

Core Design Contradiction:

Use of energy by stationary objectVSProductivity

Solution Approach 1:

Metal spheres are introduced as intermediary heat transfer media between the hot air and powder particles. The spheres absorb heat from the air and directly contact the powder, enabling more efficient thermal energy transfer and reducing overall energy consumption while accelerating the drying process.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The conventional direct thermal convection system is replaced with a mechanical contact system where metal spheres physically interact with powder particles. This mechanical substitution enables more effective heat transfer through direct contact, improving both energy efficiency and processing speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If powder flows in bulk mass with particle contact, then gravity flow is maintained, but desorption efficiency is low due to tiny channels between particles

Engineering Contradiction:

Improvedesorption rateVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The bulk powder mass is segmented into individual particles through interaction with metal spheres. This segmentation creates larger effective surface area and improves access to particle surfaces for desorption processes, eliminating the limitation of tiny inter-particle channels while maintaining gravity-driven flow.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Mechanical vibration is applied to the powder-sphere mixture to enhance particle dispersion and prevent agglomeration. This vibration facilitates better contact between powder particles and metal spheres, improving desorption efficiency without requiring excessive energy input.

Inventive Principle:

Principle #18Mechanical vibration

3Temperature

If heating is performed in the presence of air, then drying and heating functions are achieved, but oxygen interaction causes deterioration of powder properties

Engineering Contradiction:

Improveheating efficiencyVSAvoidoxidation damage

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The metal spheres create a protective environment around powder particles during heating, limiting direct exposure to atmospheric oxygen. This effectively creates a localized inert atmosphere that prevents oxidation and property deterioration while maintaining efficient heating through sphere-particle contact.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 approach enhances the rate of degassing, desorption, and drying of metal powders, reducing energy consumption and minimizing oxygen interaction, resulting in improved powder quality suitable for aerospace and medical applications.

Implementation Method 1

compressing the reaction vessel in a direction towards the interior space of the reaction vessel

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

transferring heat from an exterior of the reaction vessel towards the interior space of the reaction vessel, transferring heat from the exterior of the reaction vessel to the plurality of metal spheres

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

flowing powder material into the reaction vessel under gravity and vibration, flowing powder material through the interior of the reaction vessel under gravity and vibration

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 4

flowing powder material into the reaction vessel under gravity and vibration, flowing powder material through the interior of the reaction vessel under gravity and vibration

Methodology Applied

Scientific EffectVibration: Vibration

Implementation Method 5

submitting the reaction vessel to an interior vacuum

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentUS11707782B2System and method for powder processing

Publication Date: 2023.07.25 SAMAROV VIKTOR

AI summary

The present invention may comprise processes, methods, and systems for powder processing aimed at and characterized in reduction of adsorbed gases, vapors, particulates, and moisture through high-temperature vacuum out-gassing by disintegrating the powder bulk or flow into separate particles. Heat may be transferred to powder particles in vacuum by multiple interactions during intimate contact with heated metal balls within a tube or other container.