The present disclosure relates to production systems for fabricating material particles, and methods for producing a plurality of material particles.
BACKGROUND
This section provides background information related to the present disclosure which is not necessarily prior art.
Production of small material particles may entail processes for forming individual particles separately from the base material, through additive manufacturing or other direct deposition processes. While attempts have been made using various processes to produce small material particles, such attempts are costly and limited in their capability. Therefore, it would be advantageous to have a system and method for producing material particles that takes into account at least some of the issues discussed above as well as possibly other issues.
SUMMARY
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
According to the present disclosure, exemplary embodiments of a system are provided for system for producing a plurality of material particles. In one example, a system for system for producing a plurality of material particles comprises a plated polymer sheet that includes a polymer sheet having a layer of material deposited thereon by electroless plating. The system further comprises a pair of meshing rollers through which the plated polymer sheet is fed, the meshing rollers having a plurality of gear teeth sized and configured to impart a bend of a predetermined radius R in the plated polymer sheet to cause fracturing of the layer of material plated on the polymer sheet. The system further comprises a fluid spray applicator configured to direct fluid flow impinging the plated polymer sheet exiting the meshing rollers to cause separation of the fractured layer of material from the polymer sheet to yield a plurality of material particles that are less than a predetermined size.
In another aspect of the present disclosure, exemplary embodiments of a method are provided for producing a plurality of material particles. In one example, a method for producing a plurality of material particles comprises the steps of comprising the steps of dispensing a plated polymer sheet that is plated with a layer of material by electroless plating, and feeding the plated polymer sheet into a pair of meshing rollers through which the plated polymer sheet is drawn. The method further comprises imparting a bend of a predetermined radius R in the plated polymer sheet via the meshing rollers having a plurality of gear teeth through which the plated polymer sheet is drawn, and fracturing of the layer of material plated on the polymer sheet by forming cracks in the layer of polymer material via the imparted bend, to yield a fractured layer of material on the polymer sheet. The method further comprises directing a fluid flow impinging the plated polymer sheet, via a fluid spray applicator, to cause separation of the fractured layer of material from the polymer sheet to produce a plurality of material particles less than a predetermined size.
Further areas of applicability will become apparent from the description herein. The description and specific examples in the summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is an illustration of an exemplary embodiment of a system for producing a plurality of material particles, according to the present disclosure;
FIG. 2 is an illustration of a pair of meshing rollers of the system shown in FIG. 1;
FIG. 3 is an illustration of a plated polymer sheet processed by the system shown in FIG's 1 and 2, and
FIG. 4 is an illustration of a method for producing a plurality of material particles, according to the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
Example embodiments will now be described more fully with reference to the accompanying drawings. According to various aspects of the present disclosure, embodiments are described of an apparatus for attenuating a select radar signal. The features, functions and advantages discussed in the preceding section can be achieved independently in various embodiments or may be combined in yet other embodiments. Further aspects of the present disclosure can be seen with reference to the drawings and following described exemplary embodiments.
Referring to FIG. 1, one example of a system 100 for fabricating or producing a plurality of material particles 102 is provided that comprises a plated polymer sheet 110, which is comprised of a polymer sheet 112 having a layer of material 114 deposited thereon by electroless plating. The polymer sheet 112 is comprised of a pliable, resilient polymer material. The polymer sheet 112 has a thickness that is less than 0.09375 inches, and preferably has a thickness between 6 microns (25 gage sheet) and 0.09375 inches. The polymer sheet is made of a plastic or polymer material, which may be a polyethylene or polypropylene, for example. The polymer sheet 112 is plated with a layer of material 114 having a thickness that is not more than 0.020 inches, where the polymer sheet 112 is preferably plated with a layer of material 114 having a thickness that is between 0.1 micron and 0.020 inches. The layer of material 114 that is plated onto the polymer sheet may be one of a number of chemical elements that are able to be deposited by electroless plating, or that of a compound comprising one or more elements that are able to be deposited through electroless plating, including but not limited to elements of the first transition series and compounds thereof. The system 100 for producing the plurality of material particles 102 preferably includes roll of the plated polymer sheet 110, where the roll of plated polymer sheet 110 is positioned on a roller and unwound to enable feeding a supply of the plated polymer sheet 110 to an apparatus of the system 100 for generating the plurality of material particles. The system 100 may further include a guide roller 104, across which the supply of the plated polymer sheet 110 (which is unwound from a wound roll of the plated polymer sheet) is directed, for guiding the plated polymer sheet 110 towards a pair of meshing rollers 120A, 120B.
Referring to FIG. 2, the system includes a pair of meshing rollers 120A, 120B through which the plated polymer sheet 110 is drawn or fed. The pair of meshing rollers 120A, 120B have a plurality of teeth 122 sized and configured to impart a bend of a predetermined radius R in the plated polymer sheet 110 to cause fracturing of the layer of material 114 plated on the polymer sheet 112. The pair of meshing rollers 120A, 120B may comprise a grooved roller with an outer surface having a plurality of lateral grooves extending parallel to the axis of rotation of the roller, which grooves define a plurality of gear teeth 122 (or ribs) projecting radially outward from the roller and extending parallel to the axis of rotation of the roller. Alternatively, the pair of meshing rollers 120A, 120B may comprise a pair of meshing spur gear shafts, where the spur gear shafts have a plurality of laterally extending gear teeth 122 that are aligned parallel to the axis of rotation of the spur gear shaft (or roller). The laterally extending gear teeth 122 project radially outward from the spur gear shaft (or roller) and may have a profile in the form of an involute curve. The meshing rollers 120A, 120B have gear teeth 122 having a height (or depth between adjacent teeth) of at least 0.375 inches and a predetermined clearance, such that the meshing rollers 120A, 120B are configured to receive the plated polymer sheet 110 between opposing teeth of the meshing rollers and to impart a bend of a predetermined radius R in the plated polymer sheet 110 as shown in FIG. 2. Preferably, the pair of meshing rollers 120A, 120B have gear teeth 122 that are sized and configured to impart a bend of a predetermined radius R that is not more than 0.500 inches, wherein the radius R is more preferably between 0.1875 inches and 0.375 inches. The opposing gear teeth 122 of the meshing rollers 120A, 120B are sized and configured to impart an arcuate bend or arc contour in the plated polymer sheet 110, where the arc has a radius R with an angle A subtended by the arc that is at least 70 degrees, as shown in FIG. 2. The bend of a predetermined radius R that is not more than 0.500 inches is effective to cause fracturing of the layer of material 114 plated on the polymer sheet 112 so as to form cracks in the layer of polymer material 114, to yield a layer of fractured material 114A on the polymer sheet 112 as shown in FIG. 3. The polymer sheet 112 has a modulus of elasticity that is greater than that of the layer of material 114 that is plated on the polymer sheet 112, such that imparting the bend in the plated polymer sheet 110 causes greater bending deflection in the polymer sheet 112 portion (of the plated polymer sheet 110) than the bending deflection of the layer of material 114 that is plated on the polymer sheet, to thereby facilitate fracturing or cracking of the layer of material 114 that is plated on the polymer sheet 112. Similarly, the layer of material 114 that is plated onto the polymer sheet 112 has a stiffness that is greater than that of the polymer sheet 112, such that when a load is applied to the polymer sheet 112 that is plated with the layer of material 114 the bending deflection of the layer of material 114 is less than the bending deflection of the polymer sheet 112, to facilitate fracturing or cracking of the layer of material 114 that is plated on the polymer sheet 112. The system 100 may further include a rotary drive mechanism such as a motor, coupled to the meshing rollers 120A, 120B, for rotating the meshing rollers 120A, 120B in counter-rotating directions, to facility forming of cracks in the layer of material 114 plated on the polymer film 112.
The system 100 includes a fluid spray applicator 130 configured to direct fluid flow impinging the plated polymer sheet 110 exiting the meshing rollers 120A, 120B, to cause separation of the fractured layer of material 114A from the polymer sheet 112 to produce a plurality of material particles 102 less than a predetermined size. As shown in FIG. 2, the fluid spray applicator 130 may comprise two or more applicators, such as a fluid spray applicator 130 positioned above the plated polymer sheet 110 and a fluid spray applicator 130 positioned below the plated polymer sheet 110, but may alternatively comprise a single fluid spray applicator 130 configured to spray opposing sides of the plated polymer sheet 110. It should be noted that the polymer sheet 112 may be plated with a layer of material by electroless plating on both sides of the polymer sheet 112, or alternatively the polymer sheet 112 may be plated only on a singled side of the polymer sheet 112 such that the fluid spray applicator 130 is positioned and directed at only the single plated side of the plated polymer sheet 110. The fluid spray applicator 130 preferably includes fluid supply conduit line in fluid communication with a plurality of spaced-apart spray nozzles that are oriented to direct fluid flow towards the plate polymer sheet 110. The fluid spray applicator 130 is positioned and oriented to direct fluid flow under pressure at a predetermined angle relative to the plated polymer sheet, where the predetermined angle of the fluid flow relative to the plated polymer sheet is generally between 15 degrees and 60 degrees. More preferably, the fluid spray applicator 130 is oriented to direct fluid flow under pressure at a predetermined angle relative to the plated polymer sheet of between 35 and 45 degrees. The fluid spray applicator 130 is coupled to a fluid flow source, where the fluid is preferably water supplied at a pressure of between 45 and 80 pounds per square inch. The predetermined angle at which the fluid spray applicator is oriented, and the resulting predetermined angle of the fluid flow relative to the plated polymer sheet, is effective to cause separation of the layer of fractured material 114 from the polymer sheet 112 to produce a plurality of material particles 102 plurality of particles absent the presence of polymer (or containing only trace amounts of polymer, of less than 0.5 percent by weight). As shown in FIG. 2, the system 100 may further include a guide roller 132, across which the plated polymer sheet 110 is directed towards a winding roll for collecting the polymer sheet 112. The system 100 further includes a collection bin 140 positioned below the fluid spray applicator 130 to collect the plurality of material particles 102 produced from the fractured layer of material 114 separated from the polymer sheet via the fluid spray applicator 130. The pair of meshing rollers 120A, 120B having gear teeth 122 that are sized and configured to impart a bend of a predetermined radius R cause fracturing of the layer of material 114 plated on the polymer sheet 112 to enable separation of the layer of fractured material 114 from the polymer sheet 112 (by the fluid spray applicator 130) in a manner that results in producing a plurality of material particles 102 of a predetermined size. In at least 90 percent of the resulting plurality of material particles 102, the plurality of material particles 102 are less than a predetermined size of up to 2 inches. Preferably, the plurality of material particles 102 produced by the system 100 have a size in the range of between 0.001 inches and 2 inches, and more preferably at least 50 percent of the material particles may have a size of between 0.001 inches and 0.500 inches. While a small percentage of outlier material particles may have a length greater than 2 inches, in at least 90 percent of the resulting plurality of particles 102 the plurality of material particles 102 produced by the system 100 may be of a size in which the maximum dimension across the particle is a length of up to 2 inches, and the minimum dimension (or width) across the particle is at least 0.001 inches. The system 100 may further comprise a grinder (not shown) for grinding the plurality of material particles 102 collected via the collection bin 140, where the grinder is configured to grind the plurality of material particles 102 to a smaller, more uniform size.
Referring to FIG. 4, an illustration of a flowchart is shown, depicting an example of a method 200 for producing a plurality of material particles. The method comprises, at step 210, dispensing (or unwinding from a roll) a plated polymer sheet that is plated with a layer of material by electroless plating. The method may optionally include an initial step of plating a layer of material onto a polymer sheet, where the polymer sheet has a thickness that is less than 0.125 inches and the polymer sheet is plated with a layer of material having a thickness that is equal to or less than 0.020 inches. More preferably, the method includes an initial step of plating a layer of material polymer sheet with a layer of material having a thickness that is between 0.1 micron and 0.020 inches. The method includes, at step 212, feeding the plated polymer sheet into a pair of meshing rollers through which the plated polymer sheet is drawn. The method includes, at step 214, imparting a bend of a predetermined radius R in the plated polymer sheet via the meshing rollers having a plurality of gear teeth through which the plated polymer sheet is drawn. The method includes, at step 216, fracturing of the layer of material plated on the polymer sheet by forming cracks in the layer of polymer material via the imparted bend, to yield a layer of fractured material on the polymer sheet. The method of imparting a bend of a predetermined radius R may comprise providing meshing rollers having a plurality of gear teeth sized and configured to receive the plated polymer material between opposing gear teeth that impart a bend of a predetermined radius R that is effective to cause fracturing of the layer of material plated on the polymer sheet. The method further includes, at step 218, directing via a fluid spray applicator a fluid flow impinging the plated polymer sheet to cause separation of the fractured layer of material from the polymer sheet to produce a plurality of material particles less than a predetermined size. The method further comprises at step 220 collecting, via a collection bin positioned below the fluid spray applicator, the plurality of material particles produced from the fractured layer of material separated from the polymer sheet via the fluid spray applicator. The method may further comprise grinding the plurality of material particles collected via the collection bin, where the grinder is configured to grind the plurality of material particles to a smaller, more uniform size. The method may further include the step of rotating, via a rotary drive mechanism, the meshing rollers in counter-rotating directions, to facility forming of cracks in the layer of material plated on the polymer film.
The examples are provided to convey aspects of the apparatus and method to those skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods. It will be apparent to those skilled in the art that the examples may be embodied and/or modified in many different forms and should not be construed to limit the scope of the disclosure. In some examples, well-known processes, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.
Patent Application
20250041938
