Atomization technique for producing fine particles

• US 20050050993A1
• Filed: 09/09/2003
• Published: 03/10/2005
• Est. Priority Date: 09/09/2003
• Status: Active Grant

• Current Assignee: John R. Scattergood
• Original Assignee: John R. Scattergood
• Inventors: Scattergood, John R.
• Granted Patent: US 7,131,597 B2
• Time in Patent Office: Days
• US Class Current: 75/338
• CPC Class Codes: B22F 2009/084 combination of methods
• CPC Class Codes: B22F 9/082 atomising using a fluid using centrifugal force B22F9/10
• CPC Class Codes: B22F 9/10 using centrifugal force

Abstract

This disclosure relates to a novel process for atomizing a liquid material or a mixture of liquid materials. More specifically, this disclosure advances the art by utilizing the inertial forces created in an elevated acceleration environment to further miniaturize and enhance the characteristics of particles resulting from atomization. The key to this disclosure is to subject a melt material to an elevated acceleration and pass a fluid over the surface of the melt. The purpose of the elevated acceleration is to elevate the relative importance of gravitational forces in the melt thus miniaturizing any gravity influenced disturbance. This elevated acceleration environment leads to miniaturization of gravitationally dependent phenomena thus leading to smaller particle creation. The purpose of the atomizing fluid is to impart kinetic energy onto the melt thereby causing disturbances and to act as a heat transfer media to cool the particles. In other words, this disclosure teaches not only utilizing bursting bubbles, surface waves, and splashes to create fine particles by purposely introducing gas flow on the liquid material(s) to be atomized but further enhancing the process by facilitating that these material(s) are simultaneously at elevated acceleration. The novel aspects of this disclosure significantly enhance the physical characteristics of the resulting particles, by allowing smaller particles to be produced, by cooling the particles more rapidly and by reducing contamination threats by avoiding physical contact between the material(s) being atomized and any refractive materials.

Claims

1. An atomizer system comprising:

a) a melt material to be atomized;

b.) a containment portion for securing the melt material;

c.) a unit which accelerates the environment of the melt material such that the gravitational forces experienced by the melt material are elevated relative to Earth'"'"'s standard gravitational force; and

d.) atomizing fluid that flows across an exposed surface of the melt material facilitating the establishment of liquid droplets that aerosolize and create fine particulates.

2. The atomizer system of claim 1 further comprises means to introduce relative motion between the containment portion and the melt material.

3. The atomizer system of claim 2 wherein elements of the atomizer system rotate on more than one axis.

4. The atomizer system of claim 3 wherein the containment portion spins as a liquid melt material is introduced into it.

5. The atomizer system of claim 3 wherein the melt material is exposed to an acceleration that has components both normal and perpendicular to a retaining surface of the containment portion.

6. The atomizer system of claim 1 wherein the unit accelerating the environment of the melt material is a centrifuge.

7. The atomizer system of claim 1 further comprising a source of vibration to introduce disturbances within the melt material.

8. The atomizer system of claim 1 wherein the flow of atomization fluid is non-continuous.

9. The atomizer system of claim 1 wherein the containment portion is made of a solid form of the melt material itself.

10. The atomizer system of claim 1 is capable of processing entrained (non-dissolved) fluid within the melt material to facilitate atomization for at least a portion of the overall atomization process.

11. The atomizer system of claim 1 wherein the atomizing fluid is a gas.

12. The atomizer system of claim 11 wherein the gas that is the atomizing fluid is inert.

13. The atomizer system of claim 11 wherein the gas that is the atomizing fluid is oxidizing.

14. The atomizer system of claim 11 wherein the gas that is the atomizing fluid is reducing.

15. The atomizer system of claim 1 wherein the atomizing fluid is a liquid.

16. The atomizer system of claim 15 wherein the liquid that is the atomizing fluid is inert.

17. The atomizer system of claim 15 wherein the liquid that is the atomizing fluid is oxidizing.

18. The atomizer system of claim 15 wherein the liquid that is the atomizing fluid is reducing.

19. The atomizer system of claim 1 wherein the atomizing fluid contains particulates therein.

20. The atomizer system of claim 1 wherein the thermodynamic conditions, i.e. temperature, pressure, and density, as well as velocity (axial and angular) of the atomizing fluid are user selectable.

21. The atomizer system of claim 1 further comprising a cooling system.

22. The atomizer system of claim 1 further comprising a liquefying system that subjects the material to be melted to elevated acceleration prior to liquefying.

23. The atomizer system of claim 22 wherein the operation of the liquefying system is non-continuous.

24. The atomizer system of claim 22 wherein the liquefying system applies radiant heating to the melt material to be atomized.

25. The atomizer system of claim 22 wherein the liquefying system applies induction heating to the melt material to be atomized.

26. The atomizer system of claim 22 wherein the liquefying system applies electric arc heating to the melt material to be atomized.

27. The atomizer system of claim 22 wherein the liquefying system applies lasers to the melt material to be atomized.

28. The atomizer system of claim 22 wherein the liquefying system applies hot atomizing fluid heating to the melt material to be atomized.

29. The atomizer system of claim 22 wherein the liquefying system applies chemical reaction heating to the melt material to be atomized.

30. The atomizer system of claim 22 wherein the liquefying system applies refractory containment heating to the melt material to be atomized.

31. The atomizer system of claim 22 wherein the liquefying system applies plasma arc heating to the melt material to be atomized.

32. A method of atomizing a material comprising the steps of:

a.) accelerating the environment of the material to be atomized such that the gravitational forces experienced by the material are elevated relative to Earth'"'"'s standard gravitational force; and

b.) flowing an atomizing fluid across an exposed surface of the material facilitating the establishment of liquid droplets which aerosolize and create fine particulates.

33. The atomizer method of claim 32 further comprises the step of introducing relative motion between the containment portion and the melt material.

34. The atomizer method of claim 33 further comprises the step of rotating the atomizer system on more than one axis.

35. The atomizer method of claim 33 further comprises the step of spinning the containment portion while introducing the liquid melt material into it.

36. The atomizer method of claim 33 further comprises the step of exposing the melt material to an acceleration that has both normal and perpendicular components to the retaining surface of the melt containment portion.

37. The atomizer method of claim 32 further comprises the step of accelerating the environment of the melt material in a centrifuge.

38. The atomizer method of claim 32 further comprises the step of introducing a source of vibration to facilitate disturbances within the melt material.

39. The atomizer method of claim 32 further comprises the step of controlling a non-continuous flow of atomization fluid.

40. The atomizer method of claim 32 further comprises the step of containing the melt material with a containment portion made of a solid form of the melt material itself.

41. The atomizer method of claim 32 further comprises the step of processing entrained (non-dissolved) fluid within the melt material to facilitate atomization for at least a portion of the overall atomization process.

42. The atomizer method of claim 32 wherein the atomizing fluid is a gas.

43. The atomizer method of claim 42 wherein the gas that is the atomizing fluid is inert.

44. The atomizer method of claim 42 wherein the gas that is the atomizing fluid is oxidizing.

45. The atomizer method of claim 42 wherein the gas that is the atomizing fluid is reducing.

46. The atomizer method of claim 32 wherein the atomizing fluid is a liquid.

47. The atomizer method of claim 46 wherein the liquid that is the atomizing fluid is inert.

48. The atomizer method of claim 46 wherein the liquid that is the atomizing fluid is oxidizing.

49. The atomizer method of claim 46 wherein the liquid that is the atomizing fluid is reducing.

50. The atomizer method of claim 32 wherein the atomizing fluid contains particulates therein.

51. The atomizer method of claim 32 further comprises the step of the user selecting the thermodynamic conditions, i.e. temperature, pressure, and density, as well as velocity (axial and angular) of the atomizing fluid.

52. The atomizer method of claim 32 further comprises the step of cooling at least one component of the atomizer.

53. The atomizing method of claim 32 further comprising the step of subjecting the material to be liquefied to the intended acceleration prior to being liquefied.

54. The atomizing method of claim 53 wherein the step of liquefying the melt material is non-continuous

55. The atomizing method of claim 53 wherein the liquefying step applies radiant heating to the melt material to be atomized.

56. The atomizing method of claim 53 wherein the liquefying step applies induction heating to the melt material to be atomized.

57. The atomizing method of claim 53 wherein the liquefying step applies electric arc heating to the melt material to be atomized.

58. The atomizing method of claim 53 wherein the liquefying step applies lasers to the melt material to be atomized.

59. The atomizing method of claim 53 wherein the liquefying step applies hot atomizing fluid heating to the melt material to be atomized.

60. The atomizing method of claim 53 wherein the liquefying step applies chemical reaction heating to the melt material to be atomized.

61. The atomizing method of claim 53 wherein the liquefying step applies refractory containment heating to the melt material to be atomized.

62. The atomizing method of claim 53 wherein the liquefying step applies plasma arc heating to the melt material to be atomized.