Vibratory Acoustic Mixer for Uniform Material Coating
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Solution Overview
Problem
Current methods for spray coating and material combination face challenges in achieving uniform mixing and coating, especially with smaller particles, and are costly and time-consuming, often requiring excess reaction gas that can lead to contamination and waste.
Innovation Solution
The use of vibratory mixing technology that generates a fluidized bed using acoustic energy to mix, coat, dry, combine, and segregate materials without mixing blades or impellers, incorporating a vibratory mixer capable of oscillating at 50 Hz to 70 Hz, and a system with nozzles, filters, heating/cooling, and vacuum/pressure control for uniform mixing and coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spray coating methods are used, then coating application is achieved, but uniform mixing and coating of smaller particles is not produced
Solution Approach 1:
The patent employs mechanical vibration through a vibratory fluidizer that generates oscillatory motion to fluidize particles and create uniform coating. The vibration causes particles to move randomly and collide, ensuring even distribution of coating material throughout the bed, thereby achieving uniform coating without requiring excessive coating material or complex multi-step processes.
Solution Approach 2:
The patent uses pneumatic principles by introducing gas flow through a fluidizer at the bottom of the coating chamber to create a fluidized bed. This gas flow lifts and suspends particles, creating a fluid-like state that enhances mixing and coating uniformity. The pneumatic fluidization works in conjunction with mechanical vibration to achieve superior coating results.
2Reliability
If conventional fluidizers are used, then material fluidization is achieved, but excess reaction gas is wasted and contamination occurs
Solution Approach 1:
The patent makes the fluidizing gas serve multiple functions: it fluidizes the particles for coating, provides inert atmosphere to prevent oxidation, and can be recycled back into the system rather than being vented. This multi-functional use of gas eliminates waste and reduces the need for additional reaction gas, thereby improving reliability while reducing substance loss.
Solution Approach 2:
The patent implements gas recycling by capturing the fluidizing gas that would otherwise be wasted and redirecting it back into the fluidizer or reaction chamber. This recovery process prevents loss of valuable reaction gas and reduces contamination, while the gas can be continuously reused to maintain fluidization effectiveness.
3Manufacturing precision
If mixing blades or impellers are used, then material mixing is achieved, but device complexity increases and uniform mixing of smaller particles is difficult
Solution Approach 1:
The patent removes mixing blades, impellers, and other mechanical mixing components from the system. Instead of using mechanical agitation, it relies on pneumatic fluidization and mechanical vibration to achieve mixing. This extraction of complex mixing mechanisms simplifies the device while achieving superior mixing uniformity through the fluidized bed approach.
Solution Approach 2:
The patent replaces mechanical mixing systems with pneumatic and vibrational mechanisms. The gas flow and vibration create fluid-like motion that mixes particles more effectively than mechanical blades, while avoiding the complexity of mechanical components. This substitution achieves better mixing uniformity with simpler device architecture.
4Manufacturing precision
If traditional coating methods are used, then coating application is achieved, but coating uniformity on smaller particles is insufficient
Solution Approach 1:
The vibratory fluidizer generates continuous oscillatory motion that keeps particles in constant motion and collision. This vibration ensures that coating material is evenly distributed across all particles, including smaller ones, while maintaining high coating speed through continuous processing without requiring pauses for manual intervention or complex multi-stage coating.
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 enables efficient and uniform mixing and coating of materials, reducing waste and contamination by using mechanical fluidization, allowing precise control over pressure and temperature, and achieving consistent material turnover, even with hard-to-fluidize materials.
Implementation Method 1
The application uses an acoustic mixer to produce low frequency acoustic energy that mixes materials in a uniform and even fashion
Implementation Method 2
Vibratory mixing technology provides a unique method to combine, mix, dry, and/or coat materials without the use of mixing blades or impellers
Implementation Method 3
the acoustic means for generating a fluid bed in a mixing vessel is capable of oscillating at a range of about 50 Hz to about 70 Hz
Implementation Method 4
an acoustic means for generating a fluidized bed in a mixing vessel
Implementation Method 5
the system may further comprise a means for heating the mixing vessel coupled to the mixing vessel
Implementation Method 6
the system may further comprise a means for cooling the mixing vessel coupled to the mixing vessel
Implementation Method 7
The mixing vessel may be coupled to a vacuum line that provides a vacuum source
Data Source
AI summary
The present application is directed towards systems and methods for adding components to materials being fluidized in a vibratory mixer by use of atomizers or sprayers. A mechanical system can fluidizes, mix, coat, dry, combine, or segregate materials. The system may comprise a vibratory mixer, mixing vessel containing a first material and a sprayer to introduce a second material. The vibratory mixer may generate a fluidized bed of a first material and the sprayer, coupled to the mixing vessel, may introduce a second material onto the fluidized bed to mix the materials in a uniform and even fashion.