The disclosure of the present patent application relates to making solid-in-liquid suspensions, and particularly to an automated system for preparing suspensions.
Suspensions are formed from a base fluid and a non-dissolved quantity of solid particles, typically having nano or microscale sizes. Although a wide variety of suspensions exist, common base fluids include water, ethylene glycol, etc., and typical solid nano or micro particles include copper, aluminum oxide, titanium oxide, etc. The preparation of suspensions can be performed in a number of different ways. The two-step method is the most widely used method for preparing suspensions. In this method, nano or microparticles are produced as dry powders by chemical or physical techniques. Then, the fabricated powder is dispersed into a fluid in the second processing step with the help of intensive magnetic force agitation, ultrasonic agitation, high-shear mixing, homogenizing, and/or ball milling. The two-step method is the most economic method to produce suspensions in large quantities because nano or microparticle synthesis techniques have already been scaled up to fulfill industrial production levels.
Due to the high surface area and surface activity, these particles have a tendency to aggregate. Thus, the use of surfactants is of great importance in producing physically stabilized suspensions. Due to the difficulty in preparing stable suspensions by the two-step method, several advanced techniques have been developed to produce suspensions in a one-step method. The one-step process consists of simultaneously making and dispersing the particles in the fluid. In this method, the processes of drying, storage, transportation, and dispersion of particles are avoided, so the agglomeration of particles is minimized, and the stability of suspension is increased. The one-step processes can prepare uniformly dispersed particles, and the particles can be stably suspended in the base fluid.
The vacuum submerged arc nanoparticle synthesis system (SANSS) is another efficient method to prepare suspensions using different dielectric liquids and can result in particles of several shapes. The particles prepared exhibit needle-like, polygonal, square, and circular morphological shapes. The method avoids the problem of undesired particle aggregation fairly well.
Other methods exist than those discussed above, however, no matter which method is used to prepare a suspension, the preparation of a suspension can be extremely difficult to control, particularly either by hand or on a very large scale. The preparation of suspensions is extremely sensitive to variations in mass/volume of the components, temperature, humidity, and other environmental factors. In any method of preparing suspensions, each parameter involved must be very carefully controlled, which can be extremely difficult to do, particularly when preparing suspensions in a laboratory or in a large-scale industrial process. Thus, a system for making suspensions solving the aforementioned problems is desired.
The system for making suspensions is an automated system for the controlled preparation of solid-in-liquid suspensions. The system for making suspensions includes a housing which has a base, an upper wall, at least one sidewall and an open front. A platform is mounted within the housing, and a translating table is slidably mounted on the platform for removably supporting a receptacle. The translating table may be, or may include, a temperature-controlling plate for controlling a temperature of the receptacle from the receptacle’s bottom end. An additional temperature-controlling jacket may be wrapped around the remainder, or a selected portion, of the receptacle. A base fluid tank is provided for storing a base fluid, and a solid particle container is provided for storing solid particles.
A rotating dispenser system is mounted within the housing, above the platform and the receptacle. The rotating dispenser includes a base fluid dispenser for selectively dispensing a controlled mass of the base fluid into the receptacle, and a solid particle dispenser for selectively dispensing a controlled mass of the solid particles into the receptacle. The base fluid dispenser is in fluid communication with the base fluid tank, and the solid particle dispenser is in communication with the solid particle container. A mixer is provided for selectively and controllably mixing the controlled mass of the base fluid and the controlled mass of the solid particles in the receptacle to form the suspension.
These and other features of the present subject matter will become readily apparent upon further review of the following specification.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
The system for making suspensions 10 is an automated system for the controlled preparation of solid-in-liquid suspensions. As shown in
A rotating dispenser system 40 is mounted within the housing 12, above the platform 24 and the receptacle 26. As will be described in greater detail below, the rotating dispenser system 40 receives at least a base fluid and a quantity of solid particles for making the solid-in-liquid suspensions, which are mixed in receptacle 26. As best shown in
The rotating dispenser system 40 includes a rotating plate 52 having a plurality of openings 50 formed therethrough. Each of the base fluid dispenser 84 and the solid particle dispenser 115 includes a nozzle assembly slidably received within a corresponding one of the openings 50. A lower end 112 of the base fluid dispenser 84 projects through the corresponding opening 50. Similarly, the lower end 116 of the solid particle dispenser also projects through its corresponding opening 50. A lower end 56 of an axle 54 is secured to the rotating plate 52. As further seen in
First and second stepper motors 118, 120 are mounted on the rotating plate 52 respectively adjacent to the base fluid dispenser 84 and the solid particle dispenser 115. First and second threaded rods 159, 134 are respectively driven to rotate by the first and second stepper motors 118, 120. First and second nozzle assembly holders 126, 130 are respectively secured to the respective upper ends 110, 114 of the base fluid dispenser 84 and the solid particle dispenser 115. The first nozzle assembly holder 126 has a threaded opening 128 formed therethrough for receiving a portion of the first threaded rod 159. Similarly, the second nozzle assembly holder 130 has a threaded opening 132 formed therethrough for receiving a portion of the second threaded rod 134. Thus, as the first and second threaded rods 159, 134, respectively, are driven to rotate by their respective stepper motors 118, 120, the base fluid dispenser 84 and the solid particle dispener 115 can be moved up and down, in a controlled manner, through their corresponding openings 50. This vertical movement can be used to initiate or cease dispensing, as well as bringing the desired dispenser in closer proximity to the receptacle 26. The particular dispenser being used at any given time is positioned above the receptacle 26 through operation of the motor 72, which rotates the rotating plate 52. As shown in
The rotating dispenser system 40 may also include a liquid surfactant dispenser 79 in fluid communication with a liquid surfactant tank 74 for selectively dispensing a controlled mass of the liquid surfactant into the receptacle 26, and a solid surfactant dispenser 141 in communication with a solid surfactant container for selectively dispensing a controlled mass of a solid surfactant into the receptacle 26, as will be discussed in greater detail below. Similar to the base fluid dispenser 84 and the solid particle dispenser 115, each of the liquid surfactant dispenser 79 and the solid surfactant dispenser 141 includes a nozzle assembly slidably received within a corresponding one of the openings 50 formed through the rotating plate 52.
Third and fourth stepper motors 144, 146, are mounted on the rotating plate 52 respectively adjacent to the liquid surfactant dispenser 79 and the solid surfactant dispenser 141, and third and fourth threaded rods 148, 158 are respectively driven to rotate by the third and fourth stepper motors 144, 146. Third and fourth nozzle assembly holders 152, 150 are respectively secured to the respective upper ends 78, 140 of the liquid surfactant dispenser 79 and the solid surfactant dispenser 141. Each of the third and fourth nozzle assembly holders 152, 150 has a respective threaded opening 154, 151 formed therethrough for respectively receiving a portion of the third and fourth threaded rods 148, 158. Thus, the liquid surfactant dispenser 79 and the solid surfactant dispenser 141 may be moved and controlled in a manner similar to the base fluid dispenser 84 and the solid particle dispenser 115.
The mixer may include both a sonicator 86 and a homogenizer 88. As shown in
As best seen in
For metering the base fluid, a base fluid receptacle 94 may be in fluid communication with the base fluid tank 36. As shown in
As best seen in
Returning to
Similarly, for metering the solid particles, a solid particle scale 102 may be provided for measuring a mass of the solid particles in a solid particle container 100. As shown in
In order to control the delivery of the solid particles, a cap 200 may be provided for covering an open lower end 210 of the solid particle container 100, where the cap has a first opening 202 formed therethrough. A rotating disc 204 is mounted beneath the cap 200, and the rotating disc 204 has a second opening 206 formed therethrough. In order to dispense the solid particles from the solid particle container 100, the rotating disc 204 is rotated such that the second opening 206 aligns with the first opening 202 formed through the cap 200. To control this dispensing, the rotating disc 204 has teeth 508 peripherally formed thereon for engaging a gear 214, which is selectively and controllably driven to rotate by a stepper motor 212. As shown, the stepper motor 212 may be held in place by passing the body thereof through opening 504 of holder 500, and receiving a lower end 218 thereof within a recess 216 formed in solid particle scale 102.
In use, the initial weight of the solid particle container 100 (along with the attached cap 200, rotating disc 204, and funnel 222) is measured by solid particle scale 102. The dispensing of the solid particles is initiated through the driven alignment of first opening 202 with second opening 206. The mass of solid particles dispensed into the solid particle receiver 512 is determined by constant real-time monitoring of the weight of solid particle container 100 (along with the attached cap 200, rotating disc 204, and funnel 222). Once a desired mass of solid particles has been received by solid particle receiver 512, the dispensing of the solid particles is halted. An identical system 410 for delivering the solid surfactant to the solid surfactant dispenser 141 may also be used. As shown in
In use, the user enters the desired mass or volume of each component of the suspension into the user interface 300. As each component has a known density, the controller 400 can calculate the desired mass to be dispensed based on any volume which may be entered. It should be understood that any suitable additional environmental or utility equipment may also be mounted to or within the housing 12. As non-limiting examples, a dehumidifer 310 and a cleaning system 404 may be mounted on the housing 12, as shown in
It is to be understood that the system for making suspensions is not limited to the specific embodiments described above, but encompasses any and all embodiments within the scope of the generic language of the following claims enabled by the embodiments described herein, or otherwise shown in the drawings or described above in terms sufficient to enable one of ordinary skill in the art to make and use the claimed subject matter.