Patent Grant
10654044
The present invention generally relates to systems and methods for emulsifying products. In particular, the present invention relates to a set of shear plates having a set of concave cutting edges for use on a colloid mill.
Industrial-grade mixing devices are generally divided into classes based upon their ability to mix fluids. Mixing is the process of reducing the size of particles or inhomogeneous species within the fluid. One metric for measuring the degree or “thoroughness” of mixing is the energy density per unit volume that a mixing device generates to disrupt the fluid particles. The classes are distinguished based on delivered energy densities. Three classes of industrial mixers have sufficient energy density to consistently produce mixtures or emulsions with particle sizes in a range from approximately 0 to approximately 50 microns.
Homogenization valve systems are typically classified as high energy devices. Fluid to be processed is pumped under high pressure through a narrow gap valve into a lower pressure environment. The pressure gradients across the valve and the resulting turbulence and cavitation act to break-up any particles in the fluid. These valve systems are most commonly used in milk homogenization and can yield average particle sizes in a range from approximately 0 to 1 micron.
In contrast, high shear mixer systems are classified as low energy devices. These systems typically utilize paddles or fluid rotors that turn at high speed in a reservoir of fluid to be processed, which, in many of the more common applications, is a food product. These systems are usually used when the acceptable average of particle sizes is greater than approximately 20 microns in the processed fluid.
Between high shear mixers and homogenization valve systems, in terms of the mixing energy density delivered to the fluid, are colloid mills, which are classified as intermediate energy devices. A colloid mill is a machine that is used to reduce the particle size of a solid in suspension in a liquid, or to reduce the droplet size of a liquid suspended in another liquid. This reduction is accomplished by applying high levels of hydraulic and mechanical shear via shear plates to the process liquid, thereby increasing the stability of suspensions and emulsions. Typically, colloid mills utilize a rotor shear plate and stator shear plate or cylinder. Many colloid mills with proper adjustment achieve average particle sizes of approximately 1 to approximately 25 microns in the processed fluid. These capabilities render colloid mills appropriate for a variety of applications including colloid and oil/water-based emulsion processing such as that required for everything from cosmetics, mayonnaise, or silicone/silver amalgam formation, to road and roofing-tar mixing.
However, colloid mills suffer from several problems, including low throughput and long cycle times. The prior art has attempted to solve these problems by making only minor variations with limited success.
Therefore, there is a need in the art to improve the process of modifying and emulsifying products including asphalt products, also known as bitumen products. Specifically, there is a need for a set of cyclonic shearing plates that modify and emulsify asphalt more efficiently than any shearing system of the prior art.
A cyclonic comminuting device includes a set of shearing plates that is adaptable to any colloid mill for improved efficiency and effectiveness in the production of all commodities including, but not limited to, asphalt or bitumen modification, tar, plastics, polymers, cosmetic processing and foods processing.
The set of shearing plates includes a set of concave cutting edges. The set of concave cutting edges is applied to radial teeth of a rotor plate and/or a stator plate of the set of shearing plates forming a cyclonic flow pattern of a commodity as the commodity is passed through the comminuting device. The resulting turbulence created by the intersecting concave cutting edges on the rotor plate and the stator plate increases the effective hydraulic shear generated by the rotor plate and the stator plate resulting in greater particle pulverization and resulting in higher quality emulsions with reduced cost of materials required for production.
The disclosed embodiments increase the efficiency of the emulsification process with the improved mechanical shear action created by the curved or concave cutting. The ultra-sharp intersecting edges will increase the effectiveness and efficiency of the rotor plate and the stator plate.
In the detailed description presented below, reference will be made to the following drawings.
Referring to
In a preferred embodiment, a motor is connected to shaft 107 to rotate shaft 107 and thereby rotor plate 108 about axis 112. Supply components enter through hole 105 of intake 104 and are processed between rotor plate 108 and stator plate 111. The rotation of rotor plate 108 about axis 112 generates shearing forces to emulsify and process the supply components entering through hole 105 of intake 104. The resulting processed components exit through outlet 106.
Any colloid mill known in the art may be employed as colloid mill 100. In one embodiment, stator plate 111 is optionally stationary with respect to rotor plate 108. In other embodiments, stator plate 111 is rotatably mounted to endcap 102 or a similar housing structure via a shaft. In these embodiments, a motor is connected to this shaft to rotate stator plate 111. In other embodiments, stator plate 111 is driven by a fluid between rotor plate 108 and stator plate 111.
Referring to
In a preferred embodiment, set of stator teeth 201 includes any number of singular teeth and any number of rings of teeth.
In a preferred embodiment, each of rings 204, 205, 206, and 207 is generally circular in shape. Other shapes may be employed.
In a preferred embodiment, each tooth of the set of teeth 201 includes a concave or a curved cutting edge as will be further described below.
In a preferred embodiment, stator plate 200 is made of a durable material such as a titanium, a stainless steel, or an alloy thereof. Other suitable durable materials known in the art may also be employed.
In one embodiment stator plate 200 is machined from a single piece of material. In another embodiment, stator plate 200 is cast in a mold from a molten material. Other suitable manufacturing means known in the art may be employed.
Referring to
In a preferred embodiment, each of rings 305, 306, 307, 308, and 309 is generally circular in shape. Other shapes may be employed.
In a preferred embodiment, set of rotor teeth 301 includes any number of singular teeth and any number of rings of teeth.
In a preferred embodiment, each tooth of set of rotor teeth 301 has a concave or a curved cutting edge as will be further described below.
In a preferred embodiment, rotor plate 300 is made of a durable material such as titanium, a stainless steel, or an alloy thereof. Other suitable materials known in the art may be employed.
In one embodiment, rotor plate 300 is machined from a single piece of material. In another embodiment, rotor plate 300 is cast in a mold from a molten material. Other suitable manufacturing means known in the art may be employed.
Referring to
In a preferred embodiment, angle α is approximately 30°. Other angles may be employed. Other arc lengths of each of teeth 402, 403, 404, 405, and 406 may be employed to suit any desired application.
Referring to
In a preferred embodiment, sides 504 and 505 and void 503 generate shear forces when a fluid engages with sides 504 and 505 when in use. For example, as teeth 501, 502, and 523 move in direction 524, a fluid will generally follow path 525. Path 525 will engage with edge 519 of side 520 of tooth 501. The curved surface of side 520 will redirect the fluid along path 525 to further engage with edge 522 and side 521 of tooth 523. As can be seen, sides 520 and 521 generate a generally cyclone-like shape of fluid path 525. As a result, the cyclonic shearing forces emulsify and process particles more efficiently than that found in the prior art.
Referring to
In a preferred embodiment, void 503 and circle 530 are concentrically aligned.
In a preferred embodiment, angle β is approximately 45°. Other angles may be employed.
In a preferred embodiment, angle γ is approximately 45°. Other angles may be employed.
In a preferred embodiment, angle λ approximately 135°. Other angles may be employed.
In a preferred embodiment, angle ϕ is approximately 135°. Other angles may be employed.
Referring to
Test 1
Referring to
Test 2
Referring to
Referring to
It will be appreciated by those skilled in the art that modifications can be made to the embodiments disclosed and remain within the inventive concept. Therefore, this invention is not limited to the specific embodiments disclosed, but is intended to cover changes within the scope and spirit of the claims.
This application claims priority to U.S. Provisional Application No. 62/219,535, filed Sep. 16, 2015. This patent application is incorporated herein by reference in its entirety to provide continuity of disclosure.
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