Multicomponent powder mixing process and compositions produced thereby
First Claim
1. A method for controlling chemical distribution of dry substances, the method comprising the steps of:
- (a) dry mixing particles of a first powder and a triggerable granule facilitator to form first microcapsules, the first microcapsules each having a core of one of the particles and a coating of the facilitator;
(b) further dry mixing at a speed sufficient to cause increased frictional interaction between the microcapsules, thereby triggering the facilitator while dry mixing the microcapsules to form granules of the microcapsules by an aggregation process; and
(c) ceasing the dry mixing while maintaining the granules of the microcapsules in a dry phase.
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Abstract
A method for controlling chemical distribution of substances in a solid state (and products produced thereby), the method comprising the steps of mixing particles of a first powder and a triggerable granule facilitator to form first microcapsules, the first microcapsules each having a core of one of the particles and a cladding of the facilitator; and triggering the facilitator while dry mixing the microcapsules to form substantially spherical granules of the microcapsules, the granules each having a controlled chemical distribution.
The method also includes the steps of mixing particles of a second powder with the facilitator to form second microcapsules, the second microcapsules each having a core of one of the particles of the second powder and a cladding of the facilitator; and then mixing the first and the second microcapsules prior to said triggering step.
The method further includes the step of the triggering, mixing the first microcapsules and a second triggerable granule facilitator to form a second cladding on the first microcapsules. To any of the foregoing, there can be the further step of pyrolyzing the microcapsules to remove a portion of the facilitator but leave a resulting pyrolysis product, forming a distribution of the pyrolysis product and the particles. Thereafter, if desired, there follows the step of heating the distribution of the pyrolysis product and the particles to induce a solid state reaction between the pyrolysis product and the particles of the first powder.
69 Citations
35 Claims
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1. A method for controlling chemical distribution of dry substances, the method comprising the steps of:
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(a) dry mixing particles of a first powder and a triggerable granule facilitator to form first microcapsules, the first microcapsules each having a core of one of the particles and a coating of the facilitator; (b) further dry mixing at a speed sufficient to cause increased frictional interaction between the microcapsules, thereby triggering the facilitator while dry mixing the microcapsules to form granules of the microcapsules by an aggregation process; and (c) ceasing the dry mixing while maintaining the granules of the microcapsules in a dry phase. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A method for controlling chemical distribution of substances, the method comprising the steps of:
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coating particles of a first powder to form microcapsules; pyrolyzing the microcapsules in a solid state to leave a resulting pyrolysis product, forming a distribution of the pyrolysis product and the particles; and heating the distribution of the pyrolysis product and the particles to induce mass transport chemical distribution in a solid state. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32, 33, 34)
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35. A method for controlling chemical distribution of substances, the method comprising the steps of:
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coating particles of a first powder to form microcapsules; pyrolyzing the microcapsules to leave a resulting pyrolysis product, forming a distribution of the pyrolysis product and the particles; and heating the distribution of the pyrolysis product and the particles to induce mass transport chemical distribution in a solid state, wherein the coating includes a triggerable granule facilitator which is finer than 325 mesh.
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Specification