Slurry Analysis System for Particle Monitoring Without Dilution

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Solution Overview

Problem

Current optics-based particle detection techniques for monitoring manufacturing fluids, such as slurries, are ineffective at high particle concentrations, requiring dilution that alters the slurry properties and is costly, leading to flawed quality management and increased manufacturing costs.

Innovation Solution

A slurry analysis system that filters the slurry using a slurry filter and estimates characteristics like cake particle packing fraction and particle agglomerate diameter through flow rate, filtration pressure, nominal particle properties, cake thickness, and viscosity, without diluting the slurry, using formulas like ∅⁢c2(1-∅⁢c)3=P⁢Sv2⁢dtdV⁢L and Daggl=∅RCP2(1-∅RCP)3⁢∅C2(1-∅C)3⁢Dpart.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If optics-based particle detection techniques are used to monitor slurry, then particle concentration can be detected, but the slurry must be aggressively diluted which alters the slurry properties and compromises measurement integrity

Engineering Contradiction:

Improveparticle concentration detectionVSAvoidmeasurement integrity

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces optical detection methods with a filtration-based mechanical system. Instead of using light to detect particles, the system uses a filter to physically separate particles from the slurry, measuring filtration pressure and flow rate to infer particle characteristics. This substitution eliminates the need for dilution while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a filter as an intermediary element between the slurry and the measurement system. The filter captures particles and creates a measurable pressure differential, serving as a mediator that allows indirect measurement of slurry properties without directly analyzing the slurry itself, thus avoiding the need for dilution.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Difficulty of detecting and measuring

If the slurry is diluted for optical analysis, then particle detection becomes possible, but the key properties of the slurry are altered before measurement

Engineering Contradiction:

Improveparticle detectionVSAvoidslurry property accuracy

Core Design Contradiction:

Difficulty of detecting and measuringVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent segments the slurry into two distinct phases through filtration: particles that are captured on the filter and a filtrate that passes through. This segmentation allows the system to measure properties of the particle phase indirectly through the filtration process, avoiding the need to dilute the entire slurry and preserve the original slurry properties.

Inventive Principle:

Principle #1Segmentation

3Measurement precision

If optics-based particle detection techniques are used, then particle concentration can be measured, but the system is expensive to make and operate

Engineering Contradiction:

Improveparticle concentration measurementVSAvoidsystem cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent employs a filter that can be easily replaced rather than an expensive optical detection system. The filter is a simple, inexpensive component that can be disposed of or regenerated, eliminating the need for costly optical instruments while providing adequate measurement capability through pressure and flow rate monitoring.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent replaces expensive optical detection systems with a simpler mechanical filtration system. By using basic pressure sensors and flow meters to monitor filtration characteristics, the system achieves particle detection capabilities at a fraction of the cost of optical instruments, making the solution more economically viable for industrial applications.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables accurate monitoring of slurry properties at ready-to-use conditions, improving product quality management, manufacturing efficiency, and reducing costs by providing a non-invasive and cost-effective method for fluid synthesis processes.

Implementation Method 1

a slurry filter that filters the slurry

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS11921025B2Fluid monitoring system

Publication Date: 2024.03.05 NIKON CORP

AI summary

A slurry analysis system (14) for estimating a first characteristic of a slurry (12) having a plurality of particles (18) suspended in a dispersion medium (20) can include a slurry filter (40) that filters the slurry (12); and a control system (26) that estimates the first characteristic of the slurry (12) using a flow rate of a filtrate (50) through the slurry filter (40) and a slurry filtration pressure of the slurry (12).