Method for producing granulated material

• US 6,210,625 B1
• Filed: 03/29/1999
• Issued: 04/03/2001
• Est. Priority Date: 02/20/1996
• Status: Expired due to Fees

• Current Assignee: Mikuni Corporation
• Original Assignee: Mikuni Corporation
• Inventors: Inamura, Shinpei, Matsushita, Mitsuhiro
• Primary Examiner(s): Fiorilla, Christopher A.
• Application Number:
  US09/147,152
• Time in Patent Office: 736 Days
• Field of Search: 264/610, 264/628, 264/635, 264/636, 264/109, 264/125, 264/232, 264/234, 426/514, 419/5, 419/61, 419/66
• US Class Current: 264/610
• CPC Class Codes: B01J 2/006 Coating of the granules without description of the process or the device by which the granules are obtained to prevent the granules sticking together B01J2/30
• CPC Class Codes: B28B 1/004 Devices for shaping artificial aggregates from ceramic mixtures or from mixtures containing hydraulic binder from slag C04B5/00; composition of artificial aggregates C04B18/02
• CPC Class Codes: B28B 1/30 by applying the material on to a core or other moulding surface to form a layer thereon to form a permanent layer B28B19/00
• CPC Class Codes: B28B 7/342 which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
• CPC Class Codes: C04B 35/00 Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C04B 38/009 Porous or hollow ceramic granular materials, e.g. microballoons C04B18/027, C04B20/002 take precedence
• CPC Class Codes: C04B 38/06 by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
• CPC Class Codes: C04B 38/067 Macromolecular compounds C04B38/062 takes precedence; polysaccharides C04B38/0645

Abstract

The invention is a method of making a novel spherical form of granulated products that can be effectively used in various product forms in drug, fertilizer, foodstuff, feed, agricultural chemical, catalyst, ceramics, powder metallurgy, detergent, plastic, and bio-material fields, for instance, as catalysts, lightweight materials, sound-insulating materials, microcapsules, and lightweight aggregates. To obtain a granulated product which is a spherical solid shell having a spherical space therein, a polymer having high water absorption properties is swollen by the absorption of water therein, and then brought in contact with a powder to form a powder layer all over the surface of the swollen polymer particle. This spherical particle is then dried and fired if necessary.

Claims

1. A method of making a granulated spherical solid shell having a spherical space therein, said method comprising:

allowing a polymer particle having high water absorption properties to be swollen by absorption of water therein, and

bringing the water-swollen polymer particle into contact with a powder to form a powder layer all over the surface of the water-swollen polymer particle resulting in the granulated spherical solid shell,

followed by drying the granulated spherical solid shell.

2. A granulated product-making method as recited in claim 1, wherein said powder is an organic material.

3. A granulated product-making method as recited in claim 1, wherein said powder is an inorganic material.

4. A granulated product-making method as recited in claim 3, wherein said inorganic material is a ceramic raw material.

5. A granulated product-making method as recited in claim 4, wherein said ceramic raw material or ceramic is at least one member selected from the group consisting of clay, a clay mineral, chamotte, silica sand, steatite, feldspar, alumina, magnesia, mullite, zirconia, silica, cordierite, ferrite, apatite, blast-furnace slag, shirasu, fly ash, silicon carbide, aluminum nitride, and silicon nitride.

6. A granulated product-making method as recited in claim 4, wherein said ceramic raw material or ceramic is a mixture of a binder and at least one member selected from the group consisting of clay, a clay mineral, chamotte, silica sand, steatite, feldspar, alumina, magnesia, mullite, zirconia, silica, cordierite, ferrite, apatite, blast-furnace slag, shirasu, fly ash, silicon carbide, aluminum nitride, and silicon nitride.

7. A granulated product-making method as recited in any one of claim 1, wherein said powder contains a binder.

8. A granulated product-making method as recited in claim 1, wherein said drying is carried out by dielectric heating in a high-frequency dielectric heating system.

9. A granulated product-making method, characterized in that the granulated product obtained by the method recited in claim 1 is immersed in a liquid to impregnate the shell of said granulated product with said liquid.

10. A granulated product-making method as recited in claim 9, wherein said liquid is a metal salt solution.

11. A granulated product-making method, characterized in that the granulated product obtained by the method recited in claim 1 is immersed in a suspension of finely divided solid powder, and dried to incorporate the finely divided solid powder into the shell of said granulated product.

12. A granulated product-making method, characterized in that the granulated product obtained by the method recited in claim 1 is immersed in a liquid to occlude said liquid in the spherical space in said granulated product.

13. A granulated product-making method, characterized in that the granulated product obtained by the method recited in claim 1 is placed in a gas to occlude said gas in the spherical space in said granulated product.

14. A granulated product-making method as recited in claim 1, wherein said polymer having high water absorption properties is a spherical powder having a particle size of 0.02 to 3.0 mm.

15. A granulated product-making method as recited in claim 1, wherein said polymer having high water absorption properties is a small sphere having a particle diameter of 0.2 to 60.0 mm.

16. A granulated product-making method as recited in claim 1, wherein a ratio of the polymer having high water absorption properties to the water is 1:

50 to 1;

500.

17. A granulated product-making method as recited in claim 1, wherein said powder is a pharmaceutical material.

18. A granulated product-making method as recited in claim 1, wherein said powder is a fertilizer material.

19. A granulated product-making method as recited in claim 1, wherein said powder is a foodstuff material.

20. A granulated product-making method as recited in claim 1, wherein said powder is a cement material.

21. A granulated product-making method as recited in claim 1, wherein said powder is a feed material.

22. A granulated product-making method as recited in claim 1, wherein said powder is a coloring material.

23. A granulated product-making method as recited in claim 1, wherein said powder is a material for agricultural chemicals.

24. A granulated product-making method as recited in claim 1, wherein said powder is a cosmetic material.

25. A granulated product-making method as recited in claim 1, wherein said powder is an enzyme-containing material.

26. A granulated product-making method as recited in claim 1, wherein said powder is a surfactant material.

27. A granulated product-making method as recited in claim 1, wherein said powder is a semiconductor material.

28. A granulated product-making method as recited in claim 1, wherein said powder is a metal material.

29. A granulated product-making method as recited in claim 1, wherein said powder is a multi-capsulated material.

30. A granulated product-making method as recited in claim 1, wherein said powder is a cermet material.

31. A granulated product-making method as recited in claim 1, wherein said powder is a paint coating material.

32. A granulated product-making method as recited in claim 1, wherein said powder is a filtering material.

33. A granulated product-making method as recited in claim 1, wherein said powder is a heat-insulating material.

34. A granulated product-making method as recited in claim 1, wherein said powder is a sound-absorbing material.

35. A granulated product-making method as recited in claim 1, wherein said powder is an electric wave-absorbing material.

36. A granulated product-making method as recited in claim 1, wherein said powder is a light-absorbing material.

37. A granulated product-making method as recited in claim 1, wherein said powder is a reflecting material.

38. A granulated product-making method as recited in claim 1, wherein said powder is a signposting material.

39. A granulated product-making method as recited in claim 1, wherein said powder is a ball bearing material.

40. A granulated product-making method as recited in claim 1, wherein said powder is a bio-reactor material.

41. A granulated product-making method as recited in claim 1, wherein said powder is a far infrared ray-radiating material.

42. A granulated product-making method as recited in claim 1, wherein said powder is an electric heating material.

43. A granulated product-making method as recited in claim 1, wherein said powder is a lightweight aggregate material.

44. A granulated product-making method as recited in claim 1, wherein said powder is a material for ball games.

45. A granulated product-making method as recited in claim 1, wherein said powder is a dehumidifying material.

46. A granulated product-making method as recited in claim 1, wherein said powder is a furnace material.

47. A granulated product-making method as recited in claim 1, wherein said powder is a material for engine room walls.

48. A granulated product-making method as recited in claim 1, wherein said powder is a material for gas turbine room walls.

49. A granulated product-making method as recited in claim 1, wherein said powder is a lining material.

50. A granulated product-making method as recited in claim 1, wherein said powder is a material for vent holes.

51. A granulated product-making method as recited in claim 1, wherein said powder is a soil material.

52. A granulated product-making method as recited in claim 1, wherein said powder is a bio-material or a bio-ceramic material.

53. A granulated product-making method as recited in claim 1, wherein said powder is a material for slopes.

54. A granulated product-making method as recited in claim 1, wherein said powder is an apatite material.

55. A granulated product-making method as recited in claim 1, wherein said powder is a material having delayed action.

56. A granulated product-making method as recited in claim 1, wherein said powder is a plastic material.

57. A granulated product-making method as recited in claim 1, wherein said powder is a photosensitive material.

58. A granulated product-making method as recited in claim 1, wherein said powder is a hydrogen occluding material.

59. A granulated product-making method as recited in claim 1, wherein said powder is a material for musical instruments.

60. A granulated product-making method as recited in claim 1, wherein said powder is an acoustic or speaker material.

61. A granulated product-making method as recited in claim 1, wherein said powder is an ozone-decomposing material.

62. A granulated product-making method as recited in claim 1, wherein said powder is a porcelain enamel material.

63. A granulated product-making method as recited in claim 1, wherein said powder is a glazing material.

64. A granulated product-making method as recited in claim 1, wherein said powder is an aerospace material.

65. A granulated product-making method as recited in claim 1, wherein said powder is a material for solar furnaces.

66. A granulated product-making method as recited in claim 1, wherein said powder is an artificial dental material.

67. A granulated product-making method as recited in claim 1, wherein said powder is a tile material.

68. A granulated product-making method as recited in claim 1, wherein said powder is a pigment material.

69. A granulated product-making method as recited in claim 1, wherein said powder is a filler material.

70. A granulated product-making method as recited in claim 1, wherein said powder is a main adhesive component material.

71. A granulated product-making method as recited in claim 1, wherein said powder is an ultrafine particle material.

72. A granulated product-making method as recited in claim 1, wherein said powder is a permanent magnet material.

73. A granulated product-making method as recited in claim 1, wherein said powder is a shape-memory material.

74. A method of making an agglomerate comprising a multiplicity of granulated products that are agglomerated and bound together, characterized in that a multiplicity of discrete granulated products obtained by the method recited in claim 1 are agglomerated and bound together into an agglomerate.

75. A method of making a sintered agglomerate, characterized in that a multiplicity of discrete granulated products obtained by the method recited in claim 1 are sintered into a sintered agglomerate.

76. A granulated product-making method as recited in claim 1, wherein a plurality of different layers are coated on a granulated product to obtain a granulated product comprising a spherical, multilayered solid shell.

77. An agglomerate-making method, characterized in that a multiplicity of discrete granulated products as recited in claim 76 are agglomerated and bound together into an agglomerate.

78. A sintered agglomerate-making method, characterized in that a multiplicity of discrete granulated products as recited in claim 76 are agglomerated and bound together into a sintered agglomerate.

79. A granulated product-making method as recited in claim 1, wherein said granulated product is at least one member selected from the group consisting of (1) a pharmaceutical substance, (2) a fertilizer, (3) foodstuff, (4) cement, (5) feed, (6) a coloring material, (7) agricultural chemicals, (8) a cosmetic material, (9) an enzyme-containing material, (10) a surfactant, (11) a semiconductor, (12) a metal, (13) a multi-capsulated structure, (14) cermet, (15) a paint coating material, (16) a filtering material, (17) a heat-insulating material, (18) a sound-absorbing material, (19) an electric wave-absorbing material, (20) a light-absorbing material, (21) a reflecting material, (22) a signposting material, (23) a ball bearing, (24) a bio-reactor, (25) a far infrared ray-radiating material, (26) an electric heating material, (27) a light-weight aggregate, (28) a material for ball games, (29) a dehumidifying material, (30) a furnace material, (31) a material for engine room walls, (32) a material for gas turbine room walls, (33) a lining material, (34) a material for vent holes, (35) a soil material, (36) a bio-material or bio-ceramics, (37) a material for slopes, (38) an apatite material, (39) a material having delayed action, (40) a plastic material, (41) a photosensitive material, (42) an hydrogen occluding material, (43) a material for musical instruments, (44) an acoustic material, (45) an ozone-decomposing material, (46) a porcelain enamel material, (47) a glazing material, (48) an aerospace material, (49) a solar furnace material, (50) an artificial dental material, (51) a tile material, (52) a pigment, (53) a filler material, (54) a main adhesive component material, (55) an ultrafine particle material, (56) a permanent magnet material, and (57) a shape-memory material.

80. A method of making a granulated product as recited in claim 1, characterized by allowing a polymer particle having high water absorption properties to be swollen by absorption of water therein, depositing a first powder layer on a surface of said polymer particle, depositing one or more powder layers on said first powder layer, and drying a multilayered structure to obtain a granulated spherical product of the multilayered structure having a spherical space therein.

81. A method of making a granulated product as recited in claim 1, characterized by allowing a polymer particle having high water absorption properties to be swollen by absorption of water therein, depositing a first powder layer on a surface of said polymer particle, depositing one or more powder layers on said first powder layer, and drying and firing a multilayered structure to obtain a granulated spherical product of the multilayered structure having a spherical space therein.

82. A granulated product-making method as recited in claim 1, characterized by depositing a powder mixture comprising two or more different powders on a surface of a polymer particle having high water absorption properties, said polymer particle being swollen by absorption of water therein, followed by drying, thereby obtaining a granulated product comprising a spherical solid shell that is formed by binding said different powders together and has a spherical space therein.

83. A granulated product-making method as recited in claim 1, characterized by depositing a powder mixture comprising two or more different powders on a surface of a polymer particle having high water absorption properties, said polymer particle being swollen by absorption of water therein, followed by drying and firing, thereby obtaining a granulated product comprising a spherical solid shell that is formed by binding said different powders together and has a spherical space therein.

84. A granulated product-making method as recited in claim 1, characterized by depositing a binder on a surface of a polymer particle having high water absorption properties, said polymer particle being swollen by absorption of water therein, and depositing a powder on a surface of said binder, followed by drying, thereby obtaining a granulated product comprising a spherical solid shell and having a spherical space therein.

85. A granulated product-making method as recited in claim 1, characterized by depositing a binder on a surface of a polymer particle having high water absorption properties, said polymer particle being swollen by absorption of water therein, and depositing a powder on a surface of said binder, followed by drying and firing, thereby obtaining a granulated product comprising a spherical solid shell and having a spherical space therein.

86. A method of making a granulated spherical ceramic shell having a spherical space therein, said method comprising:

allowing a polymer particle having high water absorption properties to be swollen by absorption of water therein, and

bringing the water-swollen polymer particle into contact with a ceramic raw material powder to form a ceramic raw material powder layer all over the surface of the water-swollen polymer particle resulting in the granulated spherical ceramic shell,

followed by drying and firing the granulated spherical ceramic shell.

87. A granulated ceramic product-making method as recited in claim 86, wherein said drying and said firing are carried out by dielectric heating in a high-frequency dielectric heating system.