Rotor Processor Dry Powder Feed System
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Solution Overview
Problem
Conventional rotor processors face issues with solvent usage, agglomeration, and powder loss due to the need for soluble polymers and the lack of efficient dry powder introduction, leading to inefficient coating processes and potential hazards.
Innovation Solution
A rotor processor with a separate powder feed system using a screw conveyor, eductor, and ball-mounted powder conduit introduces dry polymers or glidants under positive pressure, creating distinct spray and powder zones within the rotor chamber for efficient coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If polymers are dissolved in solvent solution for coating, then the polymer can be applied as a dilute liquid, but large volumes of solvent are required and the process is slow
Solution Approach 1:
The invention changes the physical state of the polymer from dissolved solution to dry powder form. This parameter change eliminates the need for large volumes of solvent while enabling efficient coating through the interaction of dry powder particles with the circulating particle bed in the rotor processor
Solution Approach 2:
The invention replaces the liquid spray mechanism with a dry powder delivery system. Instead of spraying polymer solution through a spray gun, the system uses a powder feed system that introduces dry polymer powder into the rotor chamber where it coats particles through mechanical interaction with the circulating bed
2Reliability
If glidants are suspended in polymer spray solution to prevent agglomeration, then agglomeration is inhibited, but the suspensions cause buildup in spray guns and blockage during processing
Solution Approach 1:
The invention extracts and removes the problematic glidant suspension component from the coating system. By using dry polymer powder instead of polymer solution with suspended glidants, the system eliminates spray gun blockage and buildup issues while still preventing agglomeration through the dry powder coating mechanism
Solution Approach 2:
The invention uses dry polymer powder as an intermediary material that coats particles without requiring suspension in liquid. This intermediary approach allows glidant functionality to be achieved through the dry powder itself and the coating process mechanics, rather than through suspended particles in solution
3Device complexity
If powder is introduced into the rotor chamber without a closed system, then the powder feed system is simple, but toxic powders present hazards and powder is lost
Solution Approach 1:
The invention uses a ball-mounted powder conduit with a closure system that provides a sealed interface between the powder feed system and the rotor chamber. This flexible sealing mechanism prevents powder leakage and exposure hazards while maintaining a relatively simple overall system design
Solution Approach 2:
The ball-mounted conduit acts as an intermediary sealed interface that allows powder introduction while preventing exposure. The ball mechanism provides a movable seal that maintains containment during operation, eliminating the need for complex fixed sealing systems
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 solution reduces solvent usage, prevents agglomeration, and ensures precise and efficient application of dry powders, minimizing powder loss and enhancing the coating process while maintaining safety.
Implementation Method 1
A dry powder feed system extends through the stator wall and into the rotor chamber to direct dry powder into the bed of particles... The powder is introduced under positive air pressure
Implementation Method 2
Rotation of the rotor imparts centrifugal force to the particles, which are thrown to the wall of the stator
Implementation Method 3
air forced upwardly through the slit lifts the particles upwardly. The width of the slit governs the air velocity for a given air flow, which creates an upward draft which carries the particles upwardly
Implementation Method 4
A spray gun extends through the stator wall and into the rotor chamber to spray a liquid onto the bed of particles
Data Source
AI summary
The improved rotor processor of the present invention includes a stator with a rotatable rotor defining a rotor chamber in which particles are circulated for coating or layering. A spray gun mounted to the stator adjacent the rotor directs liquid into the rotor chamber, while a powder feed system mounted in the stator adjacent the rotor directs dry powder into the rotor chamber. The spray gun and powder feed system are spaced apart circumferentially so as to define a spray zone and a separate powder zone through which the circulating particles repeatedly and sequentially pass. The powder feed system includes a feed screw conveyor, an eductor, and a flexible conduit for delivering micronized powders, such as polymers or glidants, to the rotor chamber.