Patent Application
20230286046
The present disclosure relates to manufacturing equipment and more particularly to systems and equipment for the manufacture of undercooled metallic core-shell particles including micro/nano particles.
Undercooling of metals (also known as supercooling) refers to the cooling of a liquid metal or alloy below its melting/freezing point without it becoming solid. Due to the metastable nature of undercooled metals, the production of undercooled metal in practical yields and at any size scale is a particular challenge, especially where large undercooling values are desired. One method for producing undercooled metal particles uses a container-less drop tube technique, where one particle is undercooled at a time during free fall. Another method using droplet emulsion allows for the production of more than one particle at once if the carrier liquid can maintain a thin, inert surface coating inhibiting crystallization, however, stability is still a major concern.
Thus, it is a primary object of the disclosure to provide a system for manufacture of undercooled metallic core-shell particles, including micro/nano particles, that improves upon the state of the art.
Another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that reduces manufacturing time.
Yet another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that increases yields.
Another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles from materials having higher melting temperatures.
Yet another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that reduces power requirements.
Another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that increases throughput.
Yet another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that is easy to use.
Another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that improves functionality.
Yet another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that is relatively inexpensive.
Another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that is adaptable for manufacture of different products.
Yet another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that can control temperature while processing materials.
Another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that can control pressure while processing materials.
Yet another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that can control flow of materials while processing the materials.
Another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that can control and adjust atmosphere and reagents while processing materials.
Yet another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that produces a relatively inexpensive product.
Another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that has a minimum number of parts.
Yet another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that is durable.
Another object of the disclosure is to provide a system for manufacture of undercooled metallic core-shell particles that has a long useful life.
These and other objects, features, or advantages of the present disclosure will become apparent from the specification, claims and drawings.
In one or more arrangements, an enclosure system is presented for producing metallic core-shell particles. The enclosure system includes the housing having a front, a back, a top, a bottom, and opposing sides. The front, back, top, bottom, and opposing sides form a hollow interior of the housing. The housing includes a first opening in the top of the housing. An upper door assembly is connected to the housing. The upper door assembly is configured to provide access to the hollow interior through the first opening when open and cover and seal the first opening when closed. The housing includes a second opening in the bottom of the housing. A lower door assembly is connected to the housing. The lower door assembly is configured to provide access to the hollow interior through the second opening when open and cover and seal second opening when closed. A shearing assembly is positioned within the hollow interior of the housing. The shearing assembly is configured to, when a molten metal input, a carrier fluid, and one or more reagents are held within hollow interior and sealed within housing, shear the molten metal input into particles of an effective size so that a shell created on a surface of the particles via reaction with the one or more reagents prevents a core of the particles from solidifying when the particles are cooled to a temperature below a freezing temperature of the molten metal input.
In the following detailed description of the embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the disclosure may be practiced. The embodiments of the present disclosure described below are not intended to be exhaustive or to limit the disclosure to the precise forms in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present disclosure. It will be understood by those skilled in the art that various changes in form and details may be made without departing from the principles and scope of the disclosure. It is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures. For instance, although aspects and features may be illustrated in or described with reference to certain figures or embodiments, it will be appreciated that features from one figure or embodiment may be combined with features of another figure or embodiment even though the combination is not explicitly shown or explicitly described as a combination. In the depicted embodiments, like reference numbers refer to like elements throughout the various drawings.
It should be understood that any advantages and/or improvements discussed herein may not be provided by various disclosed embodiments, or implementations thereof. The contemplated embodiments are not so limited and should not be interpreted as being restricted to embodiments which provide such advantages or improvements. Similarly, it should be understood that various embodiments may not address all or any objects of the disclosure or objects of the disclosure that may be described herein. The contemplated embodiments are not so limited and should not be interpreted as being restricted to embodiments which address such objects of the disclosure. Furthermore, although some disclosed embodiments may be described relative to specific materials, embodiments are not limited to the specific materials or apparatuses but only to their specific characteristics and capabilities and other materials and apparatuses can be substituted as is well understood by those skilled in the art in view of the present disclosure.
It is to be understood that the terms such as “left, right, top, bottom, front, back, side, height, length, width, upper, lower, interior, exterior, inner, outer, and the like as may be used herein, merely describe points of reference and do not limit the present disclosure to any particular orientation or configuration.
As used herein, “and/or” includes all combinations of one or more of the associated listed items, such that “A and/or B” includes “A but not B,” “B but not A,” and “A as well as B,” unless it is clearly indicated that only a single item, subgroup of items, or all items are present.
The use of “etc.” is defined as “et cetera” and indicates the inclusion of all other elements belonging to the same group of the preceding items, in any “and/or” combination(s).
As used herein, the singular forms “a,” “an,” and “the” are intended to include both the singular and plural forms, unless the language explicitly indicates otherwise. Indefinite articles like “a” and “an” introduce or refer to any modified term, both previously-introduced and not, while definite articles like “the” refer to a same previously-introduced term; as such, it is understood that “a” or “an” modify items that are permitted to be previously-introduced or new, while definite articles modify an item that is the same as immediately previously presented. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including,” when used herein, specify the presence of stated features, characteristics, steps, operations, elements, and/or components, but do not themselves preclude the presence or addition of one or more other features, characteristics, steps, operations, elements, components, and/or groups thereof, unless expressly indicated otherwise. For example, if an embodiment of a system is described at comprising an article, it is understood the system is not limited to a single instance of the article unless expressly indicated otherwise, even if elsewhere another embodiment of the system is described as comprising a plurality of articles.
It will be understood that when an element is referred to as being “connected,” “coupled,” “mated,” “attached,” “fixed,” etc. to another element, it can be directly connected to the other element, and/or intervening elements may be present. In contrast, when an element is referred to as being “directly connected,” “directly coupled,” “directly engaged” etc. to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” “engaged” versus “directly engaged,” etc.). Similarly, a term such as “operatively”, such as when used as “operatively connected” or “operatively engaged” is to be interpreted as connected or engaged, respectively, in any manner that facilitates operation, which may include being directly connected, indirectly connected, electronically connected, wirelessly connected or connected by any other manner, method or means that facilitates desired operation. Similarly, a term such as “communicatively connected” includes all variations of information exchange and routing between two electronic devices, including intermediary devices, networks, etc., connected wirelessly or not. Similarly, “connected” or other similar language particularly for electronic components is intended to mean connected by any means, either directly or indirectly, wired and/or wirelessly, such that electricity and/or information may be transmitted between the components.
It will be understood that, although the ordinal terms “first,” “second,” etc. may be used herein to describe various elements, these elements should not be limited to any order by these terms unless specifically stated as such. These terms are used only to distinguish one element from another; where there are “second” or higher ordinals, there merely must be a number of elements, without necessarily any difference or other relationship. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments or methods.
Similarly, the structures and operations discussed herein may occur out of the order described and/or noted in the figures. For example, two operations and/or figures shown in succession may in fact be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved. Similarly, individual operations within example methods described below may be executed repetitively, individually or sequentially, to provide looping or other series of operations aside from single operations described below. It should be presumed that any embodiment or method having features and functionality described below, in any workable combination, falls within the scope of example embodiments.
As used herein, various disclosed embodiments may be primarily described in the context of manufacturing undercooled metallic core-shell particles. However, the embodiments are not so limited. It is appreciated that the embodiments may be adapted for use in other applications and/or for manufacture of other items, which may be improved by the disclosed structures, arrangements and/or methods. The system is merely shown and described as being used in the context of manufacturing undercooled metallic core-shell particles for ease of description and as one of countless examples.
With reference to the figures, a system for manufacture of undercooled metallic core-shell particles (system 10) is presented. System 10 is formed of components of any suitable size, shape, design, technology, and in any arrangement or configuration to facilitate manufacture of undercooled metallic core-shell particles 12. In an arrangement shown, as one example, system 10 includes an enclosure 20 configured to: contain a molten metal input 28, carrier fluid 30, and reagent inputs 32 (collectively “material inputs”); separate the molten metal input 28 into particles of a desired size; and form a coating 16 on the particles to facilitate undercooling of a metal core 14 of the particles when ejected from the enclosure 20 and cooled to form the undercooled metallic core-shell particles 12. The undercooled metallic core-shell particles 12 are preserved metastable form of the molten metal input 28. Metastable materials are form of materials that under the right conditions (pressure, temperature, or stimuli) or over time, will transform into a different, lower energy and more stable form of the same material. In the context of this application, one or more arrangements may be used to produce materials having a metastable form, which may include undercooled liquid, glass, higher energy crystal structure(s), semi-crystallinity, short range or long range order, a combination of ordered and disordered regions, or preferential distribution on the surface of the particle i.e. directed spinodal decomposition.
In one or more arrangements, the system further includes input tanks 22 for holding the molten metal input 28, carrier fluid 30 and/or one or more reagents 32, a transfer mechanism 24 connected to the input tanks 22 and enclosure 20, and a cooling tank 26 configured to receive processed materials when ejected from enclosure 20.
Enclosure 20 is formed of components of any suitable size, shape, and design and is configured to contain a molten metal input 28, a carrier fluid 30, and reagent 32; separate the molten metal into particles of a desired size; and form a coating on the particles to facilitate undercooling of a metal core of the particles when ejected from the enclosure 20 and cooled. In the arrangement shown, as one example, enclosure 20 includes a housing 34 having a hollow interior 50, an upper door assembly 36 positioned in a top 58 of the housing 34, a lower door assembly 38 positioned in a bottom 60 of the housing 34, a shearing assembly 40 positioned within the hollow interior 50, and a motor 42 connected to the shearing assembly 40, and a process control system 44, among other components.
Housing 34:
Housing 34 is formed of any suitable size, shape, design and is configured to provide a hollow interior 50 to house shearing assembly 40 and receive and hold molten metal input 28, carrier fluid 30, and reagents 32 for processing. In the arrangement shown, as one example, housing 34 has a front 52, a back 54, sides 56, a top 58, a bottom 60, which form hollow interior 50. In this example arrangement, top 58 has an opening 62, at which upper door assembly 36 is positioned. In this example arrangement, bottom 60 has an opening 64, to which upper door assembly 36 is attached. In this example arrangement, housing 34 has openings 66 in sides 56 through which shearing assembly 40 is installed and positioned.
In one or more arrangements, housing 34 is formed of a corrosive resistant material or corrosion resistant material. The material forming housing 34 may be any material which has a melting temperature that is higher that the melting temperature of the molten metal input 28 and which is resistant to corrosion by the carrier fluid 30 and reagent inputs 32. In some various arrangements, material forming housing 34 may include but is not limited to, for example, stainless steel (e.g., 302, 304, and/or 316), bronze, Durimet, Monel, Hasterloy B, Hastelor C, titanium, cobalt base alloy 6, aluminum, galvanized steel, and/or any other metal or corrosive and heat resistant material. Alternatively, housing 34 may be formed of a ceramic, such as glass or any other ceramic material. Alternatively, housing 34 may have a coating, such as a ceramic coating, a Teflon coating, a plastic coating, etc. on the surface of hollow interior 50 that prevents corrosion. Any other manner of preventing or reducing the corrosion of housing 34 is hereby contemplated for use.
Openings 90:
In the example shown, as one example, housing 34 also includes a set of openings 90 in top 58 for insertion and/or removal of material (e.g., gases and/or fluids) while enclosure 20 is sealed for example to add molten metal input 28, carrier fluids 30, and/or reagent 32, and/or adjust pressure within enclosure 20. In one or more arrangements, valves, fittings, and/or other connectors are attached to openings to facilitate connection of hoses or pipes or other components to openings 90.
In one or more arrangements, one or more of the set of openings 90 are configured to facilitate sampling of material inputs during processing within enclosure to facilitate tracking status and/or progress of the processes and/or reactions. In one or more arrangements, such opening 90 (a “sample opening 90”) may be any suitable size, shape, and design and is configured to facilitate extraction of samples from within enclosure 20 while is operation. In some arrangements, as one example, sample opening 90 may be positioned to transfer samples to a sample valve that can be opened to permit samples to drain out. In some arrangements, sample opening 90 may be configured to extract samples from enclosure that are located proximate to opening. Additionally or alternatively, in some arrangements, opening may be connected to a dip tube (not shown) configure to transfer samples from a target location within enclosure 20 out through sample opening 90. Additionally or alternatively, in some arrangements, sample opening 90 may be configured to permit a sample tool (e.g., pipette, siphon tube, fluidic pump, and/or any other suitable sampler) to be inserted through sample opening 90 into enclosure 20.
Holes 92 & Heating Elements 96:
In the arrangement shown, as one example, housing 34 also includes a set of holes 92 for insertion of heating elements 96 (not shown), which may also be referred to as a temperature control assembly or a temperature control system or similar language that is configured to control the temperature of the housing 34 and/or the temperature of hollow interior 50 of the housing 34. Heating elements 96 are formed of any suitable size, shape, and design and are configured to heat housing 34 and/or hollow interior 50 to a desired temperature during operation. In one or more arrangements, heating elements 96 are electric heating elements (such as block heating elements, electric coils, electric filaments, or the like). However, embodiments are not so limited. Rather, it is contemplated that in one or more arrangements enclosure 20 may be heated using any type of heating system. Furthermore, it is contemplated that in one or more embodiments, enclosure may additionally or alternatively include cooling elements to facilitate cooling of housing 34.
Upper Door Assembly 36:
Upper door assembly 36 is formed of any suitable size, shape, and design and is configured to provide access to hollow interior 50 through opening 62 when open and cover and seal opening 62 when closed. In the arrangement shown, as one example, upper door assembly 36 includes a door 70, hinge members 72 connecting the door 70 to the top 58 of housing 34, a seal 76 positioned between the door 70 and the top 58, and latch mechanisms 74, among other components.
Door 70:
Door 70 is formed of any suitable size, shape, and design and is configured to cover and seal the opening 62 when the upper door assembly 36 is closed. In the arrangement shown, door 70 is generally rectangular shaped and is configured to seat within a corresponding rectangular shaped recess in top 58. However, it is contemplated that in various embodiments door 70 may be any shape. In the arrangement shown, door 70 includes a window 82 positioned at an opening 78 in door 70 for visual inspection of hollow interior 50. In the arrangement shown, door 70 includes a circular flange 80 positioned around opening 78 and extending upward from door 70. In this arrangement, flange 80 has an inner diameter that is slightly larger than a diameter of opening 62. In this arrangement, window 82 is configured to fit snuggly within flange 80 and over door 70. The window 82 is held in place within flange 80 by a threaded cover 86, which is configured to engage threads of flange 80 and clamp window 82 between threaded cover 86 and door 70 when screwed tight. Seals 84 are positioned between door 70 and window 82 and between window 82 and threaded cover 86.
Seals 76 and 84:
Seals 76 and 84 are formed of any suitable any suitable size, shape, design, and materials and are configured to provide an airtight seal when upper door assembly 36 is closed so enclosure 20 may be pressurized. In some various arrangements, seals may be formed of any compressible material that is capable of forming an airtight or nearly airtight seal between components such as rubber, foam, plastic, composite, nylon, neoprene, a poly, or any other compressible material and/or combination thereof.
Hinge Member 72:
In the arrangement shown, hinge members 72 are attached to an upper surface of top 58 of housing 34 and door 70. Hinge members 72 are formed of any suitable size, shape and design and are configured to facilitate hinged attachment of door 70 to top 58. In an arrangement shown, as one example, hinge members 72 are attached to a forward edge of door 70 on opposing sides of opening 78. Alternatively, in one or more arrangements hinge members 72 may be omitted and door 70 may be held in place by latch mechanisms 74 or another means for connecting door to top 58 including but not limited to rivets, pins, clamps, bolts, screws, adhesives, chemical bonding, and/or any other process or means that results in a permanent or semi-permanent connection.
Latch Mechanism(s) 74:
Latch mechanism(s) 74 are formed of any suitable size, shape, and design and are configured to hold door 70 in a closed position, at which an airtight or nearly airtight seal of opening 62 is provided, when latched and release door 70 from the closed position when unlatched. In various embodiments, latch mechanism(s) 74 may be implemented using various mechanisms including but not limited to, for example, cam latches, compression latches, toggle latches, clamp latches, slam latches, draw latches, sliding latches, over center latches, snaps, clips, hooks, hasps, catches, and/or other type of fastener. In the arrangement shown, latch mechanism(s) 74 are clamp latches configured to press door 70 downward against top 58 to compress seal 76 between door 70 and top 58 to provide an airtight or nearly airtight seal of opening 62.
Lower Door Assembly 38:
Lower door assembly 38 is formed of any suitable size, shape, and design and is configured to provide access to hollow interior 50 through opening 64 when open and cover and seal opening 64 when closed. In the arrangement shown, as one example, lower door assembly 38 includes a door 100 and latch assembly 104, among other components.
Door 100:
Door 100 is formed of any suitable size, shape, and design and is configured to cover and seal the opening 64 when the lower door assembly 38 is closed. In the arrangement shown, door 100 has a generally rectangular planar shape extending between a forward edge 110, a rearward edge 112, and opposition side edges 114. In this example arrangement, door 100 has a flange 116 extending upward from the forward edge 110, rearward edge 112, and side edges 114. In this example arrangement, the bottom 60 of housing 34 is configured to fit within flange 116 when door 100 is raised to a closed position.
In the arrangement shows, door 100 includes a plug 120 extending upward from a center of door 100. Plug 120 is formed of any suitable size, shape, and design and is positioned and configured to be inserted into and mate with opening 64 when door 100 is raised to the closed position, thereby plugging opening 64. In the arrangement shown, as one example, plug has a conical shaped side 122 and a top 124 that is configured to be flush with a lower interior surface of the hollow interior 50 of housing 34 when door 100 is raised to the closed position.
In the arrangement shown, door 100 has a seal 126 positioned on an upper surface of door around plug 120. Seal 126 is formed of any suitable any suitable size, shape, design, and materials and is configured to provide an airtight or nearly airtight seal between door 100 and bottom 60 of housing 34 when door 100 is raised to the closed position. In some various arrangements, seal 126 may be formed of any compressible material that is capable of forming an airtight or nearly airtight seal such as rubber, foam, plastic, composite, nylon, neoprene, a poly, or any other compressible material and/or combination thereof.
In the arrangement shown, door 100 includes a set of drain holes 128. Drain holes 128 are formed of any suitable size, shape, and design and are configured to facilitate passage of fluid exiting enclosure 20 from opening 64 through drain holes 128. In the arrangement shown, door 100 includes four arc shaped drain holes 128 positioned around plug 120. However, embodiments are not so limited. Rather, it is contemplated that door 100 may have any number of drain holes 128 with any type of shape.
In the arrangement shown, door 100 includes upper flange portions 132 extending upward from flange 116 at forward edge 110 and rearward edge 112 of door 100. Upper flange portions 132 are formed of any suitable size, shape, and design and are configured to facilitate connection of door 100 to latch assembly 104.
Latch Assembly 104:
Latch assembly 104 is formed of any suitable size, shape, and design and is configured to facilitate latching and unlatching of door 100 to and from the closed position and raising and lowing of door 100 between the closed position to the open position. In the arrangement shown, as one example, latch assembly 104 includes mounting blocks 136, latch mechanisms 138, and slide assemblies 140.
Mounting Blocks 136:
In the arrangement shown, mounting blocks 136 attached to the front 52 and back 54 of housing 34. Mounting blocks 136 are formed of any suitable size, shape, and design and are configured to facilitate attachment of latch mechanisms 138 and slide assemblies 140 to housing 34. In the arrangement shown, as one example, mounting blocks 136 are have a generally rectangular planar shape and are aligned with upper flange portions 132 of door 100. In various arrangements, mounting blocks 136 may be attached to housing 34, latch mechanisms 138, and/or slide assemblies 140 using various processes and means including, for example, welding, rivets, pins, clamps, bolts, screws, adhesives, chemical bonding, and/or any other process or means that results in a permanent or semi-permanent connection.
Latch Mechanisms 138:
Latch mechanisms 138 are formed of any suitable size, shape, and design and are configured to hold door 100 in the closed position when latched and release door from the closed position when unlatched. In various embodiments, latch mechanism(s) 138 may be implemented using various mechanisms including but not limited to, for example, cam latches, compression latches, toggle latches, clamp latches, slam latches, draw latches, sliding latches, over center latches, snaps, clips, hooks, hasps, catches, and/or other type of fastener. In the arrangement shown, latch mechanisms 138 are clamp latches, similar to latch mechanisms 74, and are configured to pull door 100 upward against bottom 60 to compress seal 126 between door 100 and bottom 60 to provide an airtight seal of opening 64.
Slide Assemblies 140:
Slide Assemblies 140 are formed of any suitable size, shape, and design and are configured to provide a sliding connection between door 100 and housing 34 that permits door 100 to slide between the open and closed positions. In the arrangement shown, as one example, slide assemblies 140 include slide brackets 144, slide bolts 146, and nuts 148. Slide brackets 144 are formed of any suitable size, shape, and design and are configured to providing sliding connection between slide bolts and upper flange 132 and mounting blocks 136. In the arrangement shown, as one example, slide bracket 144 has a body 152, a slide hole 154 extending vertically through body 152, and flanges 156 extending outward from the sides of a rearward end of body 152. In this example arrangement, flanges 156 have holes 158 to facilitate attachment of slide bracket 144 to mounting blocks 136 and/or upper flange portions 132 of door 100, for example, by bolts or screws. However, embodiments are not so limited. Rather, it is contemplated that slide bracket 144 may be attached to mounting blocks 136 and/or upper flange portions 132 of door 100 using various processes and means including, for example, welding, rivets, pins, clamps, bolts, screws, adhesives, chemical bonding, and/or any other process or means that results in a permanent or semi-permanent connection.
In this example arrangement, each slide assemblies 140 includes an upper slide bracket 144 attached to mounting block 136, a lower slide bracket 144 attached to upper flange portion 132 of door 100, and a slide bolt 146 extending though the slide holes 154 of the upper and lower slide brackets. Nuts 148 are threaded onto ends of slide bolts 146 to hold slide bolt 146 in slide holes 154 while permitting door 100 to slide up and down between the open and closed positions.
Although arrangements are primarily described with reference to enclosure 20 having upper door assembly 36 positioned in top 58 and lower door assembly 38 positioned in bottom 60, the embodiments are not so limited. Rather, it is contemplated that enclosure may have door assemblies positioned at any location of enclosure to provide access to hollow interior 50 for insertion and/or removal of materials (e.g., molten metal input 28, carrier fluid 30, and/or reagent(s) 32). Additionally or alternatively, it is contemplated that in one or more arrangements, door assemblies (e.g., 36 and 38) may be omitted and materials (e.g., molten metal input 28, carrier fluid 30, and/or reagent(s) 32) inserted and/or removed from hollow interior 50 of enclosure 20 via one or more openings 90 and/or valves, fittings, and/or other connectors are attached thereto.
Shearing Assembly 40:
In the arrangement shown, enclosure 20 includes shearing assembly 40 positioned within housing 34. Shearing assembly 40 is formed of any suitable size, shape, and design and is configured to separate the molten metal input 28 in contents of enclosure into smaller particles of a desired size. In the arrangement shown, as one example, shearing assembly 40 rotatable shaft 168, a set of impellers 164 attached to the rotatable shaft 168, a stator 166 in proximate position to the impellers, and a bearing and seal assembly 170. When the shaft 168 and impellers 164 are rotated, the impellers 164 and stator 166 interact with contents 28/30/32 of enclosure 20 to shear particles of molten metal input 28, suspended in carrier fluid 30 and reagent 32, into particles of the desired size.
In the arrangement shown, as one example, shearing assembly 40 is positioned at a lower end of hollow interior 50 of housing 34. In this position, shearing assembly 40 is able to contact contents 28/30/32 of enclosure 20 when smaller batches are processed. In this position, interactions between the interior surface and shearing assembly 40 may also assist in shearing of metal input 28 to the desire size.
In various arrangements, system may be used to process batches of various sizes. In the arrangement shown in
Stator 166:
Stator 166 is formed of any suitable size, shape, and design and is configured to direct the flow of contents inside of enclosure 20 when impellers 164 are rotated to facilitate shearing of motel metal input 28. In the arrangement shown, as one example, stator 166 has the general shape of an elongated cylindrical tube extending between opposing ends 174. In this example arrangement, stator 166 has a diameter sufficient to permit impellers 164 and shaft 168 to be positioned within stator 166. In this example arrangement, stator 166 has a circular flange 176 extending outward at one of the ends 174. The circular flange 176 is configured to facilitate attachment of stator 166 to housing 34. In various arrangements, circular flange 176 of stator 166 may be attached to housing 34 using various processes and means including, for example, welding, rivets, pins, clamps, bolts, screws, adhesives, chemical bonding, and/or any other process or means that results in a permanent or semi-permanent connection. In the arrangement shown, stator 166 has slots 178 positioned around the circumference of the stator 166. In this example arrangement, slots 178 extend along the length of the stator 166. Slots 178 permit fluids to move into and out of stator 166 when impellers 164 are rotated and facilitate shearing of molten metal input 28. In the arrangement shown, as one example, stator 166 remains stationary while impellers 164 are rotated to facilitate shearing of molten metal input 28. However, the arrangements are not so limited. Rather, it is contemplated that in one or more arrangements, shearing assembly 40 may be configured to rotate stator 166 in one direction while impellers 164 are rotated in the opposite direction.
Impellers 164:
Impellers 164 are formed of any suitable size, shape, and design and are configured to induce flow of contents 28/30/32 of enclosure 20 when rotated and to shear particles of molten metal input 28, suspended in carrier fluid 30 and reagent 32, into particles of the desired size. Various different arrangements may use various different types of impellers 164 including but not limited to, for example, open impellers, semi-closed impellers, closed or shrouded impellers, flexible impellers, and/or any other type of impeller. Such impellers 164 may be configured for axial flow, radial flow, right hand rotation, left hand rotation, and/or any combination of these and other configurations of impellers 164.
Baffles 172:
In one or more arrangements, one or more baffles 172 may be positioned inside of enclosure 20. Baffles 172 are formed of any suitable size, shape, and design and is configured to direct the flow of contents inside of enclosure 20 when impellers 164 are rotated. Baffles may be configured, for example, to direct contents away from openings 90 and holes 92 of enclosure during operation. In the arrangement shown, as one example, baffles have generally planar rectangular shaped extending inward from an interior wall of enclosure. In this example arrangement, baffles 172 includes holes 173 to permit limited flow of contents through baffles 172. However, it is contemplated that, in some various arrangements, baffles 172 may have any other shape and may be positioned differently than shown herein. Moreover, it is contemplated that, in some various arrangements, enclosure 20 may include more or fewer baffles 172, or baffles 172 may be omitted. In some arrangements, baffles 172 are removable. Such arrangement permits a user to customize flow of contents during operation as needed with little adjustment to enclosure 20.
Bearing and Seal Assembly 170:
Bearing and seal assembly 170 is formed of any suitable size, shape, and design and is configured to connect with and hold shaft 168 and impellers 164 in the hollow interior 50 of housing 34 with shaft extending outward from opening 66 in a side 56 of housing, while permitting smooth rotation of shaft 168 and also sealing openings 66 to provide an airtight or nearly airtight seal. In the arrangement shown, as one example, bearing and seal assembly 170 includes, for each opening 66 of housing 34, a seal centering member 184, a positioning brace member 186, a seal 188, a bearing centering lid 190, bearings 192, a shim 194, a washer 196, a nut 198, and a cover 200, among other components.
Seal Centering Member 184:
Seal centering member 184 is formed of any suitable size, shape, and design and is configured to fit in opening 66 and connect with housing 43 and facilitate positioning of seal 188. In the arrangement shown, as one example, seal centering member 184 as a cylindrical tube shape with an exterior end having a flange 204 that extends outward from the center. Circular flange 204 is configured to facilitate connection with outer surface of housing 34. In various arrangements, circular flange 204 of seal centering member 184 may be attached to housing 34 using various processes and means including, for example, welding, rivets, pins, clamps, bolts, screws, adhesives, chemical bonding, and/or any other process or means that results in a permanent or semi-permanent connection. In this example arrangement, seal centering member 184 has an inside diameter configured to receive and hold seal 188.
Positioning Brace Member 186:
Positioning brace member 186 is formed of any suitable size, shape, and design and is configured to attach to seal centering member 184 and contain seal 188 therein. In the arrangement shown, as one example, positioning brace member 186 has cylindrical tube shape having one end connected to circular flange 204 of seal centering member. In various arrangements, positioning brace member 186 may be attached to seal centering member 184 using various processes and means including, for example, welding, rivets, pins, clamps, bolts, screws, adhesives, chemical bonding, and/or any other process or means that results in a permanent or semi-permanent connection. In this example arrangement, positioning brace member 186 has a set of openings 206 to facilitate connection of nitrogen gas inlet outlet system 208 to bearing 192. In the arrangement shown, positioning brace member 186 has four openings 206. However, embodiments are not so limited. Rather it is contemplated that in one or more arrangements, positioning brace member 186 may have a greater or fewer number of openings 206.
Seal 188:
Seal 188 is formed of any suitable size, shape, and design and is configured to providing a seal between seal centering member 184 and shaft 168 in opening 66. In various different arrangements, seal 188 may be implanted using various different types of seals including but not limited to, for example, packing seals, lip seals mechanical seals, single seals, double seals, tandem seals, cartridge seals, gas seals, and/or any other type of seal. In the arrangement shown, seal 188 is a gas seal. Gas seals arc non-contacting seals with faces designed to be pressurized using an inert gas as a barrier instead of traditional lubricating liquid. Seal faces are separated or held in loose contact during operation by adjusting the gas pressure. In one or more arrangements, seal 188 is supplied with nitrogen gas during operation by nitrogen gas inlet outlet system 208.
Bearing Centering Lid 190:
Bearing centering lid 190 is formed of any suitable size, shape, and design and is configured to attached to positioning brace member 186, hold seal 188 in seal centering member 184, and hold bearings 192 in proper position. In the arrangement shown, as one example bearing centering lid 190 generally has a circular disc shaped body 212 with a cylindrical hole 214 in the center and a circular flange 216 extending outward from a peripheral edge of the body 212. Flange 216 is configured to facilitate attachment to positioning brace member 186. In various arrangements, flange 216 of bearing centering lid 190 may be attached to positioning brace member 186 using various processes and means including, for example, welding, rivets, pins, clamps, bolts, screws, adhesives, chemical bonding, and/or any other process or means that results in a permanent or semi-permanent connection.
Bearings 192
Bearings 192 are positioned and held within cylindrical hole 214 of bearing centering lid 190. Bearings 192 are formed of any suitable size, shape, and design and are configured to hold and center shaft 168 and while facilitating smooth rotation of shaft 168. In various different arrangements, bearings 192 may be implemented using various different types of bearings including but not limited to, for example, rolling element bearings such as ball bearings or roller bearings, plane bearings, fluid bearings, gas bearings, hydrostatic bearings, magnetic bearings, and/or any other type of bearing.
In the arrangement shown, each bearing 192 is held within cylindrical hole 214 of bearing centering lid 190 by a shim 194, a washer, and a nut 198 threaded onto shaft 168. With a nut 198 threaded onto each end of shaft 168, shaft 168 is held in place during operation. However, embodiments are not so limited. Rather, it is contemplated that one or more arrangements may utilize various alternative connectors to bearings 192 is held within cylindrical hole 214 and hold shaft 168 in place including but not limited to, for example, linchpins, cotter pins, wire lock pins, other types locking pins, screws, bolts, clamps, and/or any other means or method to facilitate connection to shaft 168. In this example arrangement, cover 200 is fitted over shim 194, a washer, and a nut 198.
Motor 42:
In the arrangement shown, a motor 42 is connected to a portion of shaft 168 that extends through bearings 192 and cover 200 of one side of enclosure 20. Motor 42 is formed of any suitable size, shape and design and is configured to generate mechanical movement. In the arrangement shown, as one example, motor 42 is an electric motor (e.g., a DC motor or an AC motor) configured to convert electric power into rotational motion. However, embodiments are not so limited. For example, in some arrangements, motor 42 may be an internal combustion engine, a fluid driven engine (e.g., steam, water, and/or air driven), or any other type of motor or engine. In the arrangement shown, a drive shaft of motor 42 is operatively connected to and is configured to rotate shaft 168 when operated. In one or more arrangements, speed of motor 42 is adjustable to facilitate adjustment of the speed at which impellers 164 are rotated during operation, for example to adjust the size of the particles 12 that are produced. In one or more various arrangements, speed of motor 42 may be adjusted to facilitate production of undercooled metallic particles of various sizes ranging from the millimeter scale down to nanometer scale. In one or more arrangements are thought to be particularly useful for efficient production of undercooled metallic particles in the range of 50 nanometers to 500 micrometers. Additionally or alternatively, in one or more arrangements, system 10 may be adjusted to control particle size distribution, and shape (e.g., spherical or ellipsoidal).
Pressure Control Assembly:
In the example shown, housing 34 also includes a pressure control assembly or pressure control system (not shown) for controlling the pressure (or vacuum) within hollow interior 50 of housing 34. In one arrangement, pressure control assembly is configured to inject gasses into hollow interior 50 of housing 34 (or conversely to suck gasses out of hollow interior 50 of housing 34) thereby controlling the pressure within hollow interior 50 of housing 34. Pressure control assembly may inject atmospheric air or a specific gas or mixture of gasses (such as oxygen, carbon dioxide, nitrogen, inert gasses, reactive gasses, or any other gas or mixture thereof to accomplish the optimum performance of the system 10). In one arrangement, pressure control system is a controllable source of pressurized air that is pumped into hollow interior 50 of housing 34. In one arrangement, pressure control system may control the pressure within hollow interior 50 of housing 34 to ambient pressure.
Processing Control System 44:
In one or more arrangements, system 10 includes a processing control system 44. Processing control system 44 is formed of any suitable any suitable size, shape and design and is configured to control one or more environmental factors within enclosure 20. In one example arrangement shown, as one example, processing control system 44 includes a control circuit 220, user interface 222, and/or sensors 224, among other components.
In various different arrangements, processing control system 44 may be configured to control various different environmental factors, which may include but are not limited to, for example, temperature, pressure, rotational speed of impellers, rotational direction of impellers, processing times/schedules, and/or input or release of gaseous, liquid, and/or solid matter to or from enclosure 20, schedule and/or rate of input of such matter to enclosure 20, schedule and/or rate of release of such matter from enclosure 20. For example, in one or more arrangements, processing control system 44 is configured to provide adjustment of pressure in enclosure 20 from atmospheric pressure up to 1000 PSI. As another example, in one or more arrangements, processing control system 44 is configured to provide adjustment of temperature within enclosure 20 between 0° C.-350° C. For example, in one or more arrangements, processing control system 44 may be configured to adjust temperature at different stages of the process to improve sheering and/or reactions. For example, in one or more arrangement, at a lower temperature molten metal input 28 has a greater viscosity and is easier to shear with shearing assembly 40.
In some arrangements, processing control system 44 may be configured to control various system 10 components to adjust environmental factors of system 10 according to a static programmed schedule. Additionally or alternatively, in one or more arrangements, processing control system 44 may be configured to monitor various conditions within enclosure 20 and control various system 10 components to dynamically adjust one or more environmental factors in response to the monitored conditions.
For example, in one or more arrangements, processing control system 44 may be configured to monitor progress of shearing and/or reactions within enclosure 20. In some various arrangements, processing control system 44 may be configured to progress of shearing and/or reactions using various means and/or methods including but not limited to, for example, chemical sensors, temperature sensors, pressure sensors, optical sensors, ph sensors, high performance liquid chromatography system (HPLC), and/or any other suitable method or means for monitoring shearing and/or reactions.
As one illustrative example, in some arrangements, processing control system 44 is configured to determine the size of particles 14 created be shearing by using an optical sensor to measure settling rate of the particles 14. For instance, in one or more arrangements, system 10 may include a laser positioned to direct a laser through contents of hollow interior 50 of housing 34 to an optical sensor. In this example, intensity of laser light detected by the sensor is correlated with the density of particles 14 in the path of the laser. As particles 14 settle, particle density should decrease, and the intensity of laser light detected by the sensor should increase. Using readings of the optical sensor over a period of time, the processing control system 44 can determine the rate at which the particles 14 are settling as well as the size of the particles 14.
In one or more arrangements, processing control system 44 may be configured to periodically pause operation of shearing assembly 40 and use optical sensor to observe settling rate and determine the size of particles 14. If the size of particles 14 is too large, processing control system 44 may prompt shearing assembly 40 to resume operation and continue shearing. In this manner, processing control system 44 may monitor the process of shearing to know when particles 14 are an effective size for formation of undercooled metallic core shell particles 12.
Additionally or alternatively, in one or more arrangements, processing control system 44 may be configured to monitor reactions to determine progress of shell 16 on particles 14. For example, in one or more arrangements, progress of shell 16 formation may be determined by monitoring consumption of consumption of oxygen (and/or other reagents) and/or production of products of the chemical reactions. In some arrangements, concentrations of reagents and/or products may be determined directly, for example, using HPLC. Additionally or alternatively, in some arrangements, consumption of reagents and/or production of products may be monitored indirectly by measuring, for example, partial pressure gaseous reagents and/or products, ph concentration, exothermic/endothermic temperature changes, or any other measurement indicative of chemical reactions for shell 16 formation.
Control Circuit 220:
Control circuit 220 is formed of any suitable size, shape, design, technology, and in any arrangement and is configured to control operation of other components of processing control system 44 to facilitate triggering of user customized actions in response to signals of sensors 224.
Sensors may include but are not limited to, for example, pressure sensors, temperature sensors, chemical sensors (e.g., PH sensors), flow rate sensors, optical sensors, an HPLC system, and/or any other type of method or means for monitoring environmental factors, shearing, reactions, and/or any other data metric that may be relevant to operation of system 10. In the arrangement shown, as one example implementation, processing control system 44 control circuit 220 includes a processing circuit 228 and memory 230 having software code 236 or instructions that facilitates the computational operation of processing control system 44. Processing circuit 228 may be any computing device that receives and processes information and outputs commands according to software code 236 or instructions stored in memory 230.
Memory 230 may be any form of information storage such as flash memory, ram memory, dram memory, a hard drive, or any other form of memory. Processing circuit 228 and memory 230 may be formed of a single combined unit. Alternatively, processing circuit 228 and memory 230 may be formed of separate but electrically connected components. Alternatively, processing circuit 228 and memory 230 may each be formed of multiple separate but electrically connected components.
Software code 236 or instructions is any form of information or rules that direct processing circuit 228 how to receive, interpret and respond to information to operate as described herein. Software code 236 or instructions is stored in memory 230 and accessible to processing circuit 228. As an illustrative example, in one or more arrangements, software code or instructions may configure processing circuit 228 of processing control system 44 to control motor 42 and/or heating elements 96 in holes 92 of enclosure 20 in response to user input received via user interface 222 and/or data received from sensors 224.
Communication Circuit 232:
Communication circuit 232 is formed of any suitable size, shape, design, technology, and in any arrangement and is configured to facilitate communication with devices to be controlled, monitored, and/or alerted by processing control system 44. In one or more arrangements, as one example, communication circuit 232 is a includes a transmitter (for one way communication) or transceiver (for two way communication). In various arrangements, communication circuit 232 may be configured to communicate with various components of system 10 using various wired and/or wireless communication technologies and protocols over various networks and/or mediums including but not limited to, for example, Serial Data Interface 12 (SDI-12), UART, Serial Peripheral Interface, PCI/PCIe, Serial ATA, ARM Advanced Microcontroller Bus Architecture (AMBA), USB, Firewire, RFID, Near Field Communication (NFC), infrared and optical communication, 802.3/Ethernet, 802.11/WIFI. Wi-Max, Bluetooth. Bluetooth low energy, UltraWideband (UWB), 802.15.4/ZigBee, ZWave, GSM/EDGE, UMTS/HSPA+/HSDPA, CDMA, LTE, FM/VHF/UHF networks, and/or any other communication protocol, technology or network.
User Interface 222:
User Interface is formed of any suitable size, shape, design, technology, and in any arrangement and is configured to facilitate user control and/or adjustment of various components of system 10. In one or more arrangements, as one example, user interface 222 includes a set of inputs 240. Inputs 240 are formed of any suitable size, shape and design and are configured to facilitate user input of data and/or control commands. In various different arrangements, inputs 240 may include various types of controls including but not limited to, for example, buttons, switches, dials, knobs, a keyboard, a mouse, a touch pad, a touchscreen, a joystick, a roller ball, or any other form of user input. Optionally, in one or more arrangements, user interface includes a display 242 (not shown). Display 242 is formed of any suitable size, shape, design, technology, and in any arrangement and is configured to facilitate display information of settings, sensor readings, time elapsed, and/or other information pertaining to processing of materials in enclosure 20. In one or more arrangements, display 242 may include, for example, LED lights, meters, gauges, screen or monitor of a computing device, tablet, and/or smartphone. Additionally or alternatively, in one or more arrangements, the inputs 240 and/or display may be implemented on a separate device that is communicatively connected to processing control system 44. For example, in one or more arrangements, operation of processing control system 44 may customized using a smartphone or other computing device that is communicatively connected to the processing control system 44 (e.g., via Bluetooth. WIFI, and/or the internet).
In Operation:
In one example application, system 10 may be used for manufacture of undercooled metallic core-shell particles 12.
At process block 254, metal input 28, carrier fluid 30, and reagents 32 are transferred into enclosure 20. In various different arrangements, metal input 28, carrier fluid 30, and/or reagents 32 may be transferred to enclosure 20 through upper door assembly 36, openings 90 in top 58 of enclosure 20 or any other opening in enclosure 20. In various different arrangements, metal input 28, carrier fluid 30, and/or reagents 32 may be transferred to enclosure 20 manually by hand (e.g., via pouring) or using a transfer mechanism 24.
At process block 256, enclosure 20 is sealed. In one or more arrangements, enclosure 20 and/or bearings may be pressurized by gases at process block 256.
At process block 258, impellers 164 are rotated to shear the molten metal input 28 into particles of target size and place the particles in contact with reagents 32 to form a coating 16 on the particles, for example as illustrated in
At block 260, contents of the enclosure 20 are ejected from enclosure 20, e.g., by lowering lower door assembly 38. When lower door assembly 38 is lowered, plug 120 is removed from opening 64 permitting contents of enclosure to flow through opening 64, through drain holes 128 in lower door assembly 38 into a cooling tank 26. As the coated particles of metal input 28 in the contents are cooled below melting/freezing temperature, coating 16 causes core 14 formed of the metal input 28 to remain in a molten state, thereby forming undercooled metallic core-shell particles 12.
It is recognized that the temperatures, pressures, and processing times, depend on the metal input, reagents, used to produce core-shell particles and the target particle size. Processes and components of some example metallic core-shell particles are described in U.S. Pat. No. 10,266,925 titled “STABLE UNDERCOOLED METALLIC PARTICLES FOR ENGINEERING AT AMBIENT CONDITIONS”, which is hereby fully incorporated by reference herein.
BiSn Cores, Melting Point 139° C.
As one illustrative example, in one or more embodiments, metallic core-shell particles 12 are created using bismuth-tin (BiSn) for metal input 28 and a carrier fluid 30 (e.g., diethylene glycol) containing a 10% excess of reagents 32 (e.g., polyacrylic acid and oxygen). However, the embodiments are not so limited. Rather, it is contemplated that the prosses may adapted facilitate undercooling of any type of metal. Similarly, it is contemplated that in various arrangements, the process may use adapted to use various alternative or additional reagents (e.g., acids, bases, and/or gases) to facilitate formation of coating 16 over particles.
In an example process, for this BiSn example, a liter of carrier fluid 30 and reagents 32 is introduced into the enclosure 20 of the equipment and is slowly heated to 160° C. In this example, an ingot of eutectic bismuth tin solder weighing 1 kg total is added to the hot liquid in enclosure 20 and equilibrated for 10 minutes.
In one or more arrangements, bearings 192 and/or seal 188 are pressurized to 50 psi with nitrogen, the enclosure 20 is sealed, and the enclosure 20 is pressurized to 48 psi with an appropriate gas (e.g., air for a 20% O2 environment, or a mixture of O2 and an inert carrier where a different partial pressure is needed). The pressure differential leads to a flow of gas out of the enclosure 20 and into a vented system.
In one or more arrangement, the shearing assembly 40 is turned on to 20,000 RPM and the molten metal BiSn is sheared into microcapsules. In this example, the BiSn metal input 28 is sheared for approximately 90 seconds to shear the BiSn metal input 28 into particles. During this processing, the polyacrylic acid and oxygen react with BiSn particles 14 to form a polyacrylic acid metal oxide coating 16 thereon in situ. After this time, in this example, the air pressure to the enclosure 20 is decreased followed by reduction of the nitrogen pressure to the until they are both off. In this example, the upper door assembly 36 on top of enclosure 20 is then opened to air. In this example, the lower door assembly 38 is then opened to release and drop the suspension of coated molten BiSn particles into cooling tank 26 (or other collection vessel) and allowed to cool. In this example, the cooled suspension is then filtered (e.g., by separation system 270) to recover the clean supercooled liquid metal microcapsules.
As another illustrative example, in one or more embodiments, metallic core-shell particles 12 are created using SAC305 (a lead-free alloy that contains 96.5% tin, 3% silver, and 0.5% copper) for metal input 28 and a carrier fluid 30 (e.g., polyethylene glycol dimethyl ether 2000) containing a reagents 32 for formation of shell coating 16. In one or more arrangements, a liter of polyethylene glycol dimethyl ether 2000 carrier fluid 30 and a mass of 12 grams of the reagent 32 (e.g., an organic component for formation of the shell 16) is introduced into the enclosure 20 and are slowly heated to 260° C. In this example, the liquid is mixed under an air atmosphere until the reagent 32 is dissolved. In this example, a spool of SAC305 solder wire without a flux core weighing 1 kg total is added to the solution and heated for 15 minutes.
In one or more arrangements, bearings 192 and/or seal 188 are pressurized to 50 psi with nitrogen, the enclosure 20 is sealed, and the enclosure 20 is pressurized to 48 psi with air. The pressure differential leads to a flow of gas out of the enclosure 20 and into a vented system.
In this example, the shearing assembly 40 is operated at approximately 20,000 RPM and the molten metal SAC305 mass is sheared into microparticles 14. The metal is sheared for approximately 600 seconds. In this example, during this processing, the reagent 32 reacts with SAC 305 particles 14 to form a coating 16 thereon in situ.
After this time, the air pressure is decreased followed by the nitrogen pressure until they are both off. In this example, the upper door assembly 36 on top of enclosure 20 is then opened to air. In this example, the lower door assembly 38 is then opened to release and drop the suspension of coated molten SAC305 microcapsules into cooling tank 26 (or other collection vessel) with warm (80° C.) carrier fluid to quench the temperature of the hot carrier fluid suspension. In this example, the cooled suspension is then filtered warm to recover the clean supercooled liquid metal microcapsules.
As another illustrative example, in one or more embodiments, metallic core-shell particles 12 are created using Au80Sn20 for metal input 28 and a carrier fluid 30 containing a reagents 32 for formation of shell coating 16. In one or more arrangements, a liter of ionic liquid carrier fluid 30 is introduced into the enclosure 20 and slowly heated to 300° C. An ingot of Au80Sn20 metal input 28 weighing 200 g total is added to the enclosure 40 and heated with the carrier fluid 32 and reagent 32 for 15 minutes.
In one or more arrangements, the bearings 192 and/or seal 188 are pressurized to 50 psi with nitrogen, the enclosure 20 is sealed, and the enclosure 20 is pressurized to 48 psi with 5% oxygen in nitrogen. The pressure differential leads to a flow of gas out of the enclosure 20 and into a vented system.
In this example, the shearing assembly 40 is operated at approximately 25,000 RPM and the molten metal AuSn metal input 28 is sheared into microparticles 14. In this example, the metal is sheared for approximately 600 seconds. During this processing, the reagent 32 reacts with AuSn microparticles 14 to form a metal oxide coating 16 thereon in situ.
In this example, the shearing and heating are then stopped and the equipment is allowed to cool to 160° C. In this example, the 5% oxygen pressure is then decreased followed by the nitrogen pressure until they are both off. In this example, the upper door assembly 36 on top of enclosure 20 is then opened to air. In this example, the lower door assembly 38 is then opened to release and drop the suspension of coated molten AuSn particles 14 into cooling tank 26 (or other collection vessel) with room temperature triethylene glycol with organic shell previously dissolved within. The organic component bonds to the metal oxide on particles 14. This process quenches the temperature of the hot carrier fluid suspension. In one or more arrangements, the cooled suspension is then filtered to recover the clean solid metal core shell particles. In one or more arrangements, the supercooled liquid phase is recoverable to form undercooled mentality core shell particles 12 by heating the particles above the melting point of the alloy and then cooling back down to a temperature above the solidification temperature.
As yet another illustrative example, in one or more embodiments, metallic core-shell particles 12 are created using Au88Ge12 for metal input 28 and a carrier fluid 30 containing a reagents 32 for formation of shell coating 16. In one or more arrangements, a 200 g ingot of Au88Ge12 metal input 28 and carrier fluid 30 reagent 32 mixture (e.g., a high temperature liquid phase heat transfer fluid with excellent thermal stability, like BMIM PF6 ionic liquid) are added into the enclosure 20. The enclosure 20 is filled with argon and the fluid and metal are heated to 385° C.
In one or more arrangements, the bearings 192 and/or seal 188 are pressurized to 50 psi with nitrogen and the enclosure 20 is pressurized to 48 psi with 1% oxygen in argon. The pressure differential leads to a flow of gas out of the enclosure 20 and into a vented system. In this example, the shearing assembly 40 is operated at approximately 30,000 RPM and the molten metal Au88Ge12 mass is sheared into microparticles 14. In this example, the metal is sheared for approximately 1500 seconds. During this processing, the reagent 32 reacts with Au88Ge12 microparticles 14 to form a metal oxide coating 16 thereon in situ.
In this example, the shearing and heating are then stopped and the equipment is allowed to cool to approximately 160° C. In this example, the 1% oxygen pressure is then decreased followed by the nitrogen pressure until they are both off. In one or more arrangements, a flow of hot acetic acid vapor in air is then piped into the enclosure 20 and the microcapsules stirred at approximately 20 RPM for approximately 5 min using shearing assembly 40. In this example, the upper door assembly 36 on top of enclosure 20 is then opened to air. In this example, the lower door assembly 38 is then opened to release and drop the suspension of coated molten Au88Ge12 microcapsules into cooling tank 26 (or other collection vessel) with room temperature triethylene glycol. This quenches the temperature of the hot carrier fluid suspension. In this example, the cooled suspension is then filtered to recover the clean solid metallic core shell particles. In one or more arrangements, the supercooled liquid phase of the particles is then recoverable to form undercooled mentality core shell particles 12 by heating the microcapsules above the melting point of the alloy and then cooling back down to a temperature above the solidification temperature as determined by DSC.
In one or more arrangements, enclosure 20 is formed as part of a larger system further including input tanks 22 for holding the molten metal input 28, carrier fluid 30 and/or one or more reagents 32, a transfer mechanism 24 connected to the input tanks 22 and enclosure 20, and a cooling tank 26 configured to receive processed materials when ejected from enclosure 20.
Tanks 22:
Tanks 22 are formed of any suitable size, shape, and design and are configured to hold and heat material inputs (e.g., metal input 28, carrier fluid 30, and/or one or more reagents 32) before they are added to the enclosure 20. In an example arrangement, tanks 22 are formed of corrosive resistant material and include one or more valves to facilitate moving metal input 28, carrier fluid 30, and/or one or more reagents 32 into and out of the tanks 22. In one or more arrangements, one or more tanks 22 may include heating elements to facilitate heating of the metal input 28, carrier fluid 30 and/or one or more reagents 32.
Transfer Mechanism 24:
Transfer mechanism 24 is formed of any suitable size, shape, and design and is configured to transfer material inputs (e.g., metal input 28, carrier fluid 30, and/or one or more reagents 32) from tanks 22 to enclosure 20. In some various different arrangements, transfer mechanism may include but is not limited to tubes, pipes, hoses, values, pumps, and/or any other method or means for transferring matter.
Cooling Tank 26:
Cooling Tank 26 is formed of any suitable size, shape, and design and is configured to receive materials that are ejected from enclosure 20 through opening 64 in bottom 60 of the enclosure 20 and facilitate cooling of the contents. In an example arrangement, cooling tank 26 is formed of corrosive resistant material. In one or more arrangements, one or more tanks 22 may include a cooling system to facilitate rapid cooling of the content. Such a cooling system may include but is not limited to, for example, cooling coils, thermoelectric cooling elements, injection of cooled material (e.g., liquid nitrogen), and/or any other method or mechanism of cooling.
In one or more arrangements, cooling tank is used as a settling tank to facilitate separation of the manufactured undercooled metallic core-shell particles 12 from the carrier fluid 30 and reagents 32.
Additionally or alternatively, in some arrangements, system 10 may include a separation system 270. Separation system 270 is formed of any suitable size, shape, and design and is configured to receive undercooled metallic core-shell particles 12, carrier fluid 30 and reagents 32 from cooling tank 26 and separate the metallic core-shell particles 12 from the carrier fluid 30 and reagents 32 while maintaining cores 14 in the undercooled metastable state. I In some various arrangements, separation system 20 may be configured to separate carrier fluid 30 and/or reagents 32 from the undercooled metallic core-shell particles 12 using various different methods and means including but not limited to, for example, strainers, screens, filters, centrifuges, settling tanks, and/or any other method or means for separating solids from fluids. In one or more arrangements, the separation system 270 separation system 270 is configured to provide the separated carrier fluid 30 and reagents 32 back to enclosure 20 so it may be reused for processing of additional metallic core-shell particles 12.
In one or more arrangements, separation system 270 may be configured to clean metallic core-shell particles 12 to remove any residual carrier fluid 30 and reagents 32 from the undercooled metallic core-shell particles 12. Carrier fluid 30 and reagents 32 may be removed from the undercooled metallic core-shell particles 12 using various methods or means including but not limited to, for example, rinsing and/or washing, blowing, absorbent materials, mechanical removal, and/or any other methods of means for removal of residual materials,
In one or more arrangements, separation system 270 may additionally or alternatively be configured to neutralize residual reagents 32 remaining on the undercooled metallic core-shell particles 12 (e.g., by applying a neutralizing agent to the undercooled metallic core-shell particles 12).
In one or more arrangements, separation system 270 may include a cooling stage assembly 272. Cooling stage assembly 272 is formed of any suitable size, shape, and design and is configured to receive the heated metallic core-shell particles 12, carrier fluid 30, and/or reagents 32 from enclosure 20 and cool the metallic core-shell particles 12 carrier fluid 30, and/or reagents 32 to place the particles 12 into an undercooled liquid state. For example, in one or more arrangements, cooling stage assembly 272 may include one or more cooling elements (not shown) to facilitate cooling of the particles 12. In one or more arrangements, cooling elements are electric cooling elements (such as a Peltier cooling element). However, embodiments are not so limited. Rather, it is contemplated that in one or more arrangements particles 12 may be cooled using any type of cooling system including but not limited to thermoelectric cooling elements, liquid cooling elements, heat pumps, or any other means or method for cooling.
Although the arrangements are primarily discussed with reference to batch processing of inputs in enclosure 20 to form undercooled metallic core-shell particles 12, embodiments are not so limited. Rather, it is contemplated that in one or more arrangements, enclosure 20 may be configured for continuous flow processing.
In the arrangement shown in
In one or more arrangements, flow rate may be adjusted by adjusting the angle of enclosure. In other words, flow rate may be adjusted by adjusting the slope of the path that materials travel through enclosure. Additionally or alternatively, in one or more arrangements, system 10 may include a flow control assembly 264 (not shown) connected to opening 64 in bottom. Flow control assembly 264 is formed of any suitable size, shape, or design, and is configured to control the rate at which contents of enclosure exit enclosure through opening 64 in bottom. In one or more various arrangements, flow control assembly 264 may include but is not limited to, for example, valves, priority vales, deceleration valves, apertures, flow regulators, bypass flow regulators, demand-compensated flow controls, pressure-compensated flow regulators, and any other method or device for controlling flow rate of materials.
In one or more arrangements, enclosure 20 is configured to sort particles of the metal input 28 by size using centripetal force to facilitate output of undercooled metallic core-shell particles 12 from enclosure 20. In the arrangements shown in
In one or more arrangements, system 10 may be configured to manufacture undercooled metallic core-shell particles 12 as a continuous flow process. In contrast to batch processing, continuous flow processes are not limited in the amount of product that can be produced in a given production run. Rather, various material inputs (e.g., metal input 28, carrier fluid 30, and/or one or more reagents 32) may be added to the system 10 (e.g., added to enclosure 20) during the manufacturing process as required to maintain the manufacturing process chain. In some various arrangements and implementations of a continuous flow process, various material inputs may be added either continuously or intermittently, for example, as directed by processing control system 44. Similarly, in some various arrangements and implementations of a continuous flow process, metallic core-shell particles 12 and/or other semi-process materials may be output from enclosure 20 or moved between various process stages continuously or intermittently. As used herein, continuous flow process is used to refer to any process in which additional material inputs are added to the production system prior to completing processing of previously added material inputs or said another way is any process that is not restricted to a fixed amount of inputs material (e.g. as in batch processing). It is understood that in some arrangements and implementations inputs and outputs of a continuous flow process (or stages thereof) may be continuous, intermittent, and/or periodic.
In one or more arrangements, processing control system 44 may be configured to control various different environmental factors within enclosure 20 to facilitate a continuous flow type production of metallic core-shell particles 12. Such environmental factors may include but are not limited to, for example, temperature, pressure, rotational speed of impellers, rotational direction of impellers, processing times/schedules, and/or input or release of gaseous, liquid, and/or solid matter to or from enclosure 20, schedule and/or rate of input of such matter to enclosure 20, schedule and/or rate of release of such matter from enclosure 20, and/or any other factor relevant to production of metallic core-shell particles 12. As described with reference to the arrangements shown in
While some arrangement may be primarily described with reference to manufacture of undercooled metallic core-shell particles 12, the arrangements are not so limited. Rather, it is contemplated that in one or more arrangements, system 10 may be configured to facilitate transition cores 14 of metallic core-shell particles 12 into various different states after undercooling including but not limited to, for example, a crystalline metal state, an amorphous metal state (also known as bulk metallic glass, metallic glass, glassy metal, or shiny metal), or any other state. Atoms of most metals are arranged in a crystalline structure in their natural solid state. In contrast, amorphous metals are non-crystalline and have a glass like structure.
In one or more arrangements, cooling tank 26 is configured to transition cores 14 of metallic core-shell particles 12 into different states by controlling the degree to which cores 14 of metallic core-shell particles 12 are undercooled. In one or more arrangements, the degree of undercooling of metallic core shell particles 12 may be characterized as:
where Tm is the melting temperature of the metal of the cores 14 and Ts is the temperature that the core transition from an undercooled liquid state to a solid state. In one or more arrangements, cooling tank 26 can produce undercooled metallic core-shell particles 12 having cores 14 undercooled to a degree of undercooling as low as 0.4.
In some various different arrangements, system 10 may be configured to control the degree of undercooling via control of various environmental variables after formation of metallic core-shell particles 12. For example, in one or more arrangements, cooling tank 26 may control the degree of undercooling by controlling the temperature and/or cooling rate of metallic core-shell particles 12 after removal from enclosure 20.
Although cooling rates and temperatures thresholds vary for different metals and alloys, generally speaking, transition metals from a liquid state an amorphous solid state generally requires the metal to be cooled and solidified rapidly (e.g., by extremely rapid cooling). In one or more arrangements, cooling tank 26 can produce undercooled metallic core-shell particles 12 having core 14 that will solidify rapidly and transform into an amorphous metal state when shell 20 is damaged and/or dissolved by undercooling cores 14 of metallic core-shell particles 12 to a greater extent. Conversely, cores 14 of metallic core-shell particles 12 may be undercooled to a lesser extent to produce undercooled metallic core-shell particles 12 having core 14 that will solidify more slowing and transform into a crystalline metal state when shell 20 is broken.
With reference to
For more information describing the conditions and/or processes to place cores 14 of metallic core-shell particles 12 into undercooled and/or amorphous metal states, reference may be made to: U.S. Provisional Application No. 63/371,994, titled “METHODS AND APPARATUSES FOR SUPERCOOLED MICRO-CAPSULES”, and filed Aug. 19, 2022; U.S. Patent Publication 2022/0212250, titled, “SYSTEM AND METHOD FOR MANUFACTURE OF UNDERCOOLDED METALLIC CORE-SHELL PARTICLES”, and filed Dec. 29, 2021; PCT Patent Publication WO 2017011029 titled “STABLE UNDERCOOLED METALLIC PARTICLES FOR ENGINEERING AT AMBIENT CONDITIONS”; U.S. Pat. No. 10,266,925 titled “STABLE UNDERCOOLED METALLIC PARTICLES FOR ENGINEERING AT AMBIENT CONDITIONS”; and U.S. Patent Publication 2018/0354037 titled “DIRECT PRINTING AND WRITING USING UNDERCOOLED METALLIC CORE-SHELL PARTICLES”, all of which are hereby fully incorporated by reference herein.
From the above discussion it will be appreciated that system 10 presented herein improves upon the state of the art and provides a system: that improves upon the state of the art; that reduces manufacturing time; that increases yields; that can produce undercooled metallic core-shell particles from materials with higher melting temperatures; that reduces power requirements; that increases throughput; that is easy to use; that improves functionality; that is relatively inexpensive; that is adaptable for manufacture of different products; that can control temperature while processing materials; that can control pressure while processing materials; that can control flow of materials while processing the materials; that can control and adjust atmosphere and reagents while processing materials; that is relatively inexpensive; that has a minimum number of parts; that is durable; and/or that has a long useful life. These and other objects, features, or advantages of the present disclosure will become apparent from the specification and claims.
Although the present disclosure has been described with respect to certain illustrative embodiments, those skilled in the art will appreciate is not limited to these embodiments and that changes and modifications can be made therein within the scope of the disclosure as set forth in the appended claims.
This application is a continuation in part of U.S. patent application Ser. No. 17/564,325, titled “SYSTEM AND METHOD FOR MANUFACTURE OF UNDERCOOLED METALLIC CORE-SHELL PARTICLES”, filed on Dec. 29, 2021 and published as U.S. Pub No. 2022/0212250, which claims priority to U.S. Provisional Patent Application 63/133,537 filed on Jan. 4, 2021 and titled “SYSTEM FOR MANUFACTURE OF UNDERCOOLED METALLIC CORE-SHELL PARTICLES”, the entirety of which is hereby fully incorporated by reference herein. This application also claims priority to U.S. Provisional Application No. 63/371,994, titled “METHODS AND APPARATUSES FOR SUPERCOOLED MICRO-CAPSULES”, and filed Aug. 19, 2022, the entirety of which is hereby incorporated by reference herein. This application is related to PCT Patent Publication WO 2017011029 titled “STABLE UNDERCOOLED METALLIC PARTICLES FOR ENGINEERING AT AMBIENT CONDITIONS”; U.S. Pat. No. 10,266,925 titled “STABLE UNDERCOOLED METALLIC PARTICLES FOR ENGINEERING AT AMBIENT CONDITIONS”; and U.S. Patent Publication 2018/0354037 titled “DIRECT PRINTING AND WRITING USING UNDERCOOLED METALLIC CORE-SHELL PARTICLES”, all of which are hereby fully incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63133537 | Jan 2021 | US | |
| 63371994 | Aug 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17564325 | Dec 2021 | US |
| Child | 18193426 | US |
