Vortex Gas Mixing Device for Uniform Cold Spray Powder Distribution
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Solution Overview
Problem
Existing mixing devices for gas and powder streams in cold spray material deposition processes result in concentrated particle distribution, requiring significant overlap for uniform coating and longer spray times, especially when coating larger areas.
Innovation Solution
A mixing device that combines two pressurized gas streams, one carrying particles, using concentric guide structures to create a vortex in a mixing chamber, distributing particles more uniformly across the spray profile with a higher powder loading, allowing for a wider spray spot and reduced coating time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing mixing devices are used to combine gas and powder streams, then the particles are delivered to the spray nozzle, but the particle distribution becomes concentrated, requiring significant overlap for uniform coating and resulting in longer spray times
Solution Approach 1:
The patent employs curved surfaces and vortex flow patterns within the mixing device to redistribute particles. The curved geometry of the mixing chamber and gas flow paths creates rotational motion that disperses particles radially, transforming the concentrated distribution into a uniform spray pattern, thereby increasing coating speed without sacrificing uniformity
Solution Approach 2:
The invention utilizes multiple gas streams with different velocities and pressures introduced through strategically positioned nozzles. The pneumatic interaction between these gas streams and the powder particles creates turbulence and mixing that evenly distributes particles across the spray profile, eliminating concentration effects and reducing required overlap
2Productivity
If existing mixing devices deliver powder to the spray nozzle, then material is deposited, but the powder loading is insufficient and coating time increases for larger areas
Solution Approach 1:
The patent combines multiple gas streams carrying powder particles through a common mixing chamber before delivery to the spray nozzle. This merging of separate powder-laden gas streams increases the total powder loading in the final mixed stream, enabling higher material deposition rates and reduced coating times for large surfaces
Solution Approach 2:
The invention introduces powder particles into the gas flow from multiple spatial dimensions through different inlet nozzles positioned at various locations and angles. This multi-dimensional introduction method maximizes powder loading while maintaining flow stability and preventing clogging, thereby increasing productivity
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 device achieves a more uniform powder distribution across the spray profile, reducing the need for overlap and increasing powder content, thereby improving spray quality and decreasing coating time, especially for larger surfaces.
Implementation Method 1
A portion of the inner gas guide may be positioned in the outer gas guide in a substantially concentric relationship with the outer gas guide to form an annular gap between the inner and outer gas guides, and the annular gap may form a portion of the secondary gas path about the primary gas path to create a vortex in the vortex mixing portion of the mixing chamber to mix the first and second gas streams
Data Source
AI summary
A mixing device may define a mixing chamber including a vortex mixing portion, a primary gas path along which a first gas stream moves to the vortex mixing portion, and a secondary gas path along which a second gas stream moves to the vortex mixing portion. The mixing device may have a mixer body, an outer gas guide positioned in the mixer body to guide the second gas stream to the vortex mixing portion, and an inner gas guide at least partially positioned in the mixer body to guide the first gas stream to the vortex mixing portion. A portion of the inner gas guide may be positioned in the outer gas guide to form an annular gap between the gas guides to define the secondary gas path about the primary gas path to create a vortex of the first and second gas streams in the vortex mixing portion.