BRPI0716472B1 - Ultrasonic treatment system - Google Patents

Description

Field of the Invention This invention generally relates to systems for ultrasonically treating a substance, and more particularly to an ultrasonic treatment system for ultrasonically stirring a substance.

Background Agitation of liquid solutions finds numerous applications for enhancing the treatment of a liquid such as single component liquid, liquid-liquid mixture, liquid-gas mixture and liquid-particulate material mixture. For example, in the formulation of paints, paints and other viscous materials, two or more components (at least one being a liquid) are mixed to form the applicable solution. Other examples include the simultaneous introduction of various liquids and gases into the chamber to promote certain reactions. This would include the flow of water into the chamber with the introduction of gases such as air and / or oxygen and / or ozone, just to name a few. Also this chamber can be used to induce a variety of chemical reactions such as hydrogen peroxide decomposition, emulsion polymerization reactions and the creation of emulsions for emulsion polymerization mechanisms.

In other applications, this system can be used for particle deglomeration in a liquid stream. This would include the disintegration of nanoparticles such as pigments used in paint formulation. Plus the simultaneous formulation of an ink using these nanopigment particles. This system may also have simultaneous exposure to ultraviolet (UV) light to promote certain fluid or fluid / gas reactions or fluid / gas / solid systems in the ultrasonic chamber. Another application could be in the medical field where this mixing system is used in the preparation of pharmaceutical formulations which are composed of powders / liquids and dispensing liquids for use.

In particular, such agitation treatments lend themselves to continuous type flow treatment systems in which the liquid is treated while continuously moving through the system, usually through an elongated column or chamber. By shaking the liquid, the desired reaction (eg, mixing or other result) can be dispatched and thus capable of being achieved in a continuous flow operation.

Agitation of a liquid may be referred to as static agitation, wherein agitation is caused by the particular flow parameters (e.g., flow rate, pressure, etc.) of one or more liquid components through a column. Static agitation may also occur by directing a flow of liquid passed through stationary stirring members, such as a helical weather vane construction or other structures arranged in the flow column or chamber that rupture and thereby cause turbulence of the flow of liquid to be treated. . Dynamic agitation is caused by movement, for example, spinning, oscillating, vibrating, etc. One or more agitator members (e.g., weather vane, propeller blades, etc.) within the treatment chamber through which liquid flows.

A particularly useful type of dynamic agitation of the liquid results from ultrasonic cavitation, a more rigorous agitation, in the liquid. Ultrasonic cavitation refers to the formation, growth and implosive collapse of bubbles in the fluid due to its ultrasonic energization. Such cavitation results from pre-existing weaknesses in the liquid, such as gas-filled slits in the suspended particulate matter or transient microbubbles from previous cavitation events. As ultrasound passes through a liquid, expansion cycles exert negative pressure on the liquid, pulling molecules away from each other. Where ultrasonic energy is sufficiently intense, the expansion cycle creates cavities in the liquid when the negative pressure exceeds the local tensile strength of the liquid, which varies with the type and purity of the liquid.

Small gas bubbles formed by the initial cavities grow under additional absorption of ultrasonic energy. Under the appropriate conditions, these bubbles collapse violently, generating very high pressures and temperatures. In some fields, such as those known as sonochemistry, chemical reactions take advantage of these high pressures and temperatures taken through cavitation. However, the violent growth and collapse of the bubbles themselves provide desirably rigorous agitation of the liquid. Cavitation that occurs at the interface between the ultrasonically energized liquid and a solid surface is quite asymmetric and generates high velocity jets of the liquid, also shaking the liquid. This type of cavitation is particularly useful, for example, in facilitating a more complete mixing together of two or more components of a liquid solution.

Another example of an application in which the substances are agitated includes mixing solutions that have totally or partially separated into different components making up the liquid solution. The separation may be two or more liquids which separate at different stages where the denser liquid (s) will rest below the less dense liquid (s). Separation may also be where a particulate material lies below the liquid. It is common for the separated / partially separated liquid solution to be re-mixed before it can be used.

In yet another example, some substances deposit over time. That is, they solidify, partially solidify, or become gelatinous. Often these substances have to be prepared to flow (eg less viscous) before they can be used. Typically, these substances are heated using an external heater wherein a heating source is placed outside the container holding the substance. The heat source is then activated to heat the container and thus the substance. The substance, once heated, becomes more ready to flow. However, this type of heating process can be relatively slow and inefficient.

Summary In one aspect, an ultrasonic treatment system for ultrasonically treating a substance generally comprises an elongated ultrasonic horn that is positioned within the substance and excitable to vibrate ultrasonically to energize the substance. The horn has a longitudinal geometrical axis and an outer surface for contact with the substance. The system also comprises an agitator member arranged in the ultrasonic horn and pivotable about the longitudinal geometric axis of the horn during ultrasonic horn vibration to agitate the substance.

In another aspect, an ultrasonic method of treating a substance disposed within a container generally comprises positioning an ultrasonic horn within the container with at least a portion of the horn submerged in the substance. The horn is ultrasonically excited so as to ultrasonically energize the substance. A shaking member is rotated within the substance while the ultrasonic horn is excited to agitate the substance as the substance is ultrasonically energized.

Brief Description of the Drawings Fig. 1 is a schematic of a mixing system according to one embodiment of a system for ultrasonically treating an illustrated liquid in the form of an ink solution mixing system and incorporating an ultrasonic treatment chamber for ultrasonically treat a liquid;

Fig. 2 is a side elevation of an ultrasonic treatment chamber for ultrasonically treating a liquid;

Fig. 3 is a longitudinal (e.g., vertical) cross-section of the ultrasonic treatment chamber of Fig. 2;

Fig. 3A is an enlarged fragmentary view of a cross-sectional portion of Fig. 3;

Fig. 3B is a top plan view of a collar forming part of the housing of the ultrasonic treatment chamber of Fig. 2;

Fig. 4 is an exploded perspective view of a horn assembly and a deflector assembly of the ultrasonic treatment chamber of Fig. 2;

Fig. 5 is a front perspective view of an alternative embodiment of a horn assembly;

Fig. 6 is a fragmentary and enlarged longitudinal cross-section similar to Fig. 3A but illustrating an alternative embodiment of a baffle assembly;

Fig. 7 is a front perspective view of another alternative embodiment of a deflector assembly;

Fig. 8 is an exploded view thereof;

Fig. 9 is a longitudinal (e.g., vertical) cross section thereof;

Fig. 10 is a side elevation of an ultrasonic treatment device with parts thereof disintegrated to show the internal components, the ultrasonic treatment device being supported by a support structure; and Fig. 11 is a side elevation of an ultrasonic treatment device having another embodiment.

Corresponding reference characters indicate corresponding parts throughout the drawings.

Detailed Description With particular reference now to Fig. 1, in one embodiment, a system for ultrasonically treating a liquid generally comprises an ultrasonic treatment chamber, generally indicated at 21, which is operable for ultrasonically treating a liquid. The term "liquid" as used herein is intended to refer to a single component liquid, a solution comprised of two or more components, wherein at least one of the components is a liquid such as a liquid-liquid mixture, a mixture of liquid gas or a liquid in which the particulate matter is carried with it, or other viscous fluids. Ultrasonic treatment chamber 21 is illustrated schematically in Fig. 1 and also described herein with reference to using the treatment chamber in a mixing system, generally indicated at 23, used to form a liquid solution by mixing two or more components, in particular. that at least one of the components is a liquid, applying ultrasonic energy to the solution within the chamber, and more particularly to such a mixing system to form a liquid ink solution of two or more ink components. However, it is understood that the ultrasonic treatment chamber 21 illustrated and described herein can be used with mixing systems to form different liquid solutions than liquid paint solutions. It is also understood that the ultrasonic treatment chamber 21 may be used in different ultrasonic liquid treatment systems for mixing but where ultrasonic agitation of the liquid comprises at least in part the desired treatment of the liquid.

In particular, the ultrasonic treatment chamber 21 is suitable for use in liquid treatment systems where ultrasonic liquid agitation is desired in an in-line continuous flow process, for example, where fluid flows continuously through the chamber. . Examples of other contemplated uses of the ultrasonic treatment chamber include, without limitation, mixing solutions, paints and other viscous materials (e.g., other than paint solutions); food processing and processing; degassing solutions (eg dissolved gases extracting from liquid solutions such as oxygen, nitrogen, ammonia, etc.); and intensifying chemical reactions, for example, as is common in sonochemistry where excitation is given to a chemical reaction to dispatch the reaction. It is contemplated, however, that the treatment chamber 21 may be used in a liquid treatment system wherein the liquid is treated in accordance with a batch process rather than a continuous flow process and remains within the scope of this invention.

Additional examples of mixing uses contemplated for ultrasonic treatment chamber 21 include, without limitation, mixing resins and curing agents for the plastics industry; mixing pulp pulp with chemical additives such as bleaching agents, moisture resistance agents, starches, dyes, enzymes, fillers, antilode agents, silicone additives, etc .; mixing compounds used in the paper and fabric industries such as clay coatings, polymeric additives such as moisture resistant resins, starch suspensions, silicone compounds, lotions, filler suspensions, etc .; mixing resins and dyes, fillers, and other compounds; mixture of immiscible phases for preparing emulsions, such as food emulsions (eg for sunscreen products, hand lotions, lipstick compounds, etc.), cosmetics, cleaning agents (including oil and water nanoemulsions), pharmaceutical compounds, etc; and mixing dyes and other compounds to form cosmetics such as hair dyes.

Other contemplated uses of the ultrasonic treatment chamber 21 include, without limitation, degassing a mixture to simplify subsequent treatment and reduce vacuum formation; ink removal from recycled papermaking fibers, where ultrasonic energy can assist in the removal of inks (particularly in the presence of enzymes, detergents, or other chemicals); hydrogenation of oils, cheese, or other food products, in which gas and pastes or liquids must be mixed; homogenization of milk and other compounds; incorporation into bioreactors and fermentation units, where delicate cells must be mixed with nutrients and other compounds without intense mechanical shear, which could damage the cells; wastewater treatment and / or fertilizer, wherein a variety of additives and air bubbles may need to be mixed with a paste; manufacture of petrochemicals such as lubricant blends, gasoline blends, wax blends, etc., and petrochemical derived compounds; pulp processing (for example, mixing combinations of agents to be added to flour or processing the pulp itself, which may result in improved gluten decomposition etc.). Ultrasonic treatment chamber 21 may also be used in chemical reactors involving single or multiple phases, including pastes.

In other contemplated uses, the ultrasonic treatment chamber 21 may be used to remove captured gas bubbles from coating solutions that are used for embossing, Meyer bar coating or any other coating application where it is desirable to remove air bubbles from a solution.

In the embodiment illustrated in Fig. 1, the ultrasonic treatment chamber 21 is generally elongated and has a general inlet end 25 (a lower end in the orientation of the illustrated embodiment) and a general outlet end 27 (an upper end in the orientation of the embodiment shown). illustrated mode). The system 23 is configured so that fluid enters the treatment chamber 21 generally at the inlet end 25 thereof, generally flows longitudinally into the chamber (e.g. upwards in the orientation of the illustrated embodiment) and exits the chamber in at the exit end of the camera.

The terms "upper" and "lower" are used herein in accordance with the vertical orientation of the ultrasonic treatment chamber 21 illustrated in the various drawings and are not intended to describe a necessary orientation of the chamber in use. That is, although chamber 21 is more suitably oriented vertically, with the outlet end 27 of the chamber above the inlet end 25, as illustrated in the various drawings, it is understood that the chamber may be oriented with the inlet end above of the exit end, or may be oriented differently than in a vertical orientation and remains within the scope of this invention.

The terms axial and longitudinal refer directly here to the longitudinal direction of chamber 21 (e.g., end-to-end, such as the vertical direction in the illustrated embodiments). The terms transverse, lateral and radial refer here to a direction normal to the axial (e.g. longitudinal) direction. The terms internal and external are also used in reference to a direction transverse to the axial direction of the ultrasonic treatment chamber 21, with the term internal referring to a direction to the interior of the chamber (for example, to the longitudinal axis of the chamber) and the external term referring to an outward direction of the chamber (e.g., away from the longitudinal axis of the chamber). The inlet end 25 of the ultrasonic treatment chamber 21 is in fluid communication with a suitable release system, generally indicated at 29, which is operable to direct one or more liquid components to and more suitably through chamber 21. For example In the liquid ink solution mixing system 23 shown in Fig. 1, the delivery system 29 comprises a plurality of pumps 31 (such as a pump for each ink component to be mixed) operable to pump the respective components of a corresponding source (shown schematically in Fig. 1 as reference numeral 32 thereof) to the inlet end 25 of chamber 21 by means of suitable conduits (shown schematically in Fig. 1 as reference numeral 33). As an example, four such pumps 31, component sources and corresponding conduits 33 are shown in Fig. 1 to release a combination of ink components including, for example, components used to form a pigmented ink solution such as, without limitation, a dispersion of pigment, water, glycerine, a binder, a surfactant and / or a biocide, or components to form a reactive ink solution such as, without limitation, a tincture or lake, water, glycerine, a surfactant, a biocide and a binder, or components to form other liquid paint solutions.

It is understood that the delivery system 29 may be configured to release less than four (including one) or more than four components to the treatment chamber 21 without departing from the scope of this invention. It is also contemplated that delivery systems other than those illustrated in Fig. 1 and described herein may be used to release one or more components to the inlet end 25 of the ultrasonic treatment chamber 21 without departing from the scope of this invention. The ink mixing system 23 of the illustrated embodiment also comprises a postprocessing system, generally indicated at 35, in fluid communication with the outlet end 27 of the ultrasonic treatment chamber 21 for processing liquid solution (e.g., the solution after the liquid solution leaves the chamber. The illustrated mixing system 23 comprises one or more 37 pressure gauges (two are illustrated in Fig. 1) for monitoring the liquid pressure in the mixing system. One or more filter units 39a, 39b may also be arranged downstream along the liquid solution flow path of the treatment chamber 21 to filter particulate material such as dirt, debris or other contaminants that may be present in the liquid solution. (for example, to initially be present in one or more of the components released into the chamber) of the liquid solution. For example, in the embodiment illustrated, a first filter unit 39a is constructed to filter downstream particles larger than about 0.5 microns and a second filter unit 39b of the first filter unit is constructed to also filter particle size. greater than about 0.2 microns. However, it is understood that only one or more than two filter units 39a, 39b may be used, or that the filter units may be omitted completely without departing from the scope of this invention.

Still referring to Fig. 1, the postprocessing system 35 may also comprise a degassing and bubble removal unit 41 which is operable to remove gas bubbles from the liquid solution (e.g., the ink solution) after ultrasonic treatment. in the treatment chamber 21. In a particularly suitable embodiment, the degassing and bubble removal unit 41 comprises a conventional membrane contactor. The construction and operation of the membrane contactors are well known to those skilled in the art and are not described, therefore in further detail herein. An example of a suitable membrane contactor is that available from Membrane of Charlotte, North Carolina, U.S.A under the tradename SuperPhobic. One or more sensor units 43 may also be provided to monitor various characteristics of the liquid solution (e.g., the ink solution) such as, without limitation, pH, conductivity, viscosity, temperature, color, surface tension and other characteristics.

Following postprocessing, the liquid treated by the ultrasonic treatment chamber 21 may be directed to a storage container or operating device (either of which is schematically indicated by simple reference numeral 45) having any of several applications. For example, the liquid ink solution mixing system 23 of Fig. 1 may release ink solution directly into an inkjet head for continuous release of ink solution onto substrates, or pumped directly into a liner such as a slot matrix, engraving, silk screen, Meyer bar, laminator, spray or other coater suitable for use in coating substrates with paint solution. Examples of other applications include, without limitation, releasing the treated liquid to an atomizing spray nozzle, or releasing the treated liquid to an injection molding or reactive injection molding. Any system (not shown) used to release treated liquid to an applicator may be disposed downstream of the postprocessing system (such as postprocessing system 35), or the postprocessing system may be omitted and a system (not shown) may communicate directly with outlet port 65 of chamber 21 to release treated liquid to a subsequent applicator.

Referring now to Fig. 2, the ultrasonic treatment chamber 21 of the liquid treatment system 23 comprises a housing 51 that defines an interior space 53 of the chamber through that liquid released to the chamber flows from the inlet end 25 to the flow end. output 27 thereof. The housing 51 suitably comprises an elongate tube 55 generally defining at least in part a sidewall 57 of chamber 21. The tube 55 may have one or more inlet ports (such an inlet port being illustrated in Fig. 2 and 59) formed by which one or more components to be treated within the chamber 21 are released into the interior space 53 thereof. In the illustrated embodiment, housing 51 also comprises an inlet collar 61 which is attached and mounted to one end of tube 55 to also define (together with inlet port 59) the inlet end 25 of chamber 21. Housing 51 also comprises a closure 63 connected and substantially closing the longitudinally opposite end of the sidewall 57, and having at least one outlet port 65 therein for generally defining the outlet end 27 of the treatment chamber 21. The sidewall 57 (e.g. defined by the elongate tube 55) of chamber 21 has an inner surface 67 which together with collar 61 and closure 63 defines the interior space 53 of the chamber. In the illustrated embodiment, the tube 55 is generally cylindrical such that the sidewall of the chamber 57 is generally annular in cross section. However, it is contemplated that the cross-section of the sidewall of the chamber 57 may be non-annular, such as polygonal or other suitable shape, and remains within the scope of this invention. The chamber sidewall 57 of the illustrated chamber 21 is suitably constructed of a transparent material, although it is understood that any suitable material may be used as long as the material is compatible with the liquid components that are treated in the chamber, the pressure at which the chamber is intended to operate, and other environmental conditions within the chamber such as temperature.

With particular reference to Fig. 3B, the inlet collar 61 at the inlet end 25 of chamber 21 is generally annular and has at least one, and more suitably a plurality of inlet ports 69a, 69b formed therein to receive the components. of the liquid solution in the interior space 53 of chamber 21. At least one inlet port 69a is generally tangentially oriented with respect to the annular collar 61 such that the liquid flows into the interior space 53 of chamber 21 generally tangentially to the it is to give the liquid a rotating action as it enters the chamber. More suitably, in the embodiment illustrated, a pair of inlet ports 69a, 69b are arranged in parallel alignment with each other and generally extend tangentially with respect to annular collar 61, with a port 69a being designated herein as the outer inlet port. and the other port 69b which is designated the internal entrance port.

This dual tangential inlet port arrangement 69a, 69b is particularly useful for initiating mixing of two or more components before the liquid solution is also subjected to ultrasonic treatment within chamber 21. In a particularly suitable use of this arrangement where the liquid to be treated in chamber 21 comprises two or more liquids, the liquid having the lowest viscosity is directed to flow into the chamber through external inlet port 69a while liquid having the highest viscosity is directed to flow into the chamber by middle of internal entrance door 69b. The flow of lower viscosity ingredient through external inlet port 69a has a tendency to pull the higher viscosity ingredient into the interior space 53 of chamber 21 to accelerate the rate at which the higher viscosity ingredient is introduced into the chamber.

This action, combined with the rotation action resulting from the tangential direction in which the liquid components are directed to chamber 21, to facilitate an initial mixing of these two components before the liquid solution also flows through the chamber for ultrasonic treatment. If additional components are to be added to the mixture, such components may be released into the interior space 53 of chamber 21 via the inlet port 59 formed in the sidewall of chamber 57. In the illustrated embodiment, collar 61 also has an additional tangential group of inlet ports and a pair of generally vertically oriented inlet ports 71. However, it is understood that none of the doors 69a, 69b need to be oriented tangentially with respect to collar 61 to remain within the scope of this invention. It is also contemplated that the collar 61 may be omitted completely so that all components to be mixed are released to the inlet port 59 formed in the side wall of the chamber 57.

An ultrasonic waveguide assembly, generally indicated at 101, extends longitudinally at least in part within the interior space 53 of chamber 21 to ultrasonically energize the liquid (and any other component of the liquid solution) flowing through the space. inside 53 of the camera. In particular, the ultrasonic waveguide assembly 101 of the illustrated embodiment extends longitudinally from the lower or inlet end 25 of chamber 21 upwardly into the interior space 53 thereof to a terminal end 103 of the disposed waveguide assembly intermediate to the upper inlet port (for example, inlet port 59 where inlet is present, or otherwise inlet ports 69a, 69b). More suitably, the waveguide assembly 101 is mounted directly or indirectly to the chamber housing 51 as will be described hereinafter. The ultrasonic waveguide assembly 101 suitably comprises an elongate horn assembly, generally indicated at 105, disposed completely with the interior space 53 of the intermediate housing 51 to the upper inlet port and the outlet port for complete submersion within the liquid being treated within chamber 21, and more suitably is aligned coaxially with the sidewall of chamber 57. Horn assembly 105 has an outer surface 107 which along with the inner surface 67 of sidewall 57 a flow path defines within the interior space 53 of chamber 21 along which liquid and other components flow beyond the horn assembly within the chamber (this portion of the flow path being widely referred to herein as the ultrasonic treatment zone). Horn assembly 105 has an upper end 109 which defines a terminal end of the horn assembly (and thus the terminal end 103 of the waveguide assembly) and a longitudinally opposite lower end 111. The waveguide assembly 101 of the illustrated embodiment also comprises a coaxially aligned enhancer 113 connected to an upper end thereof to the lower end 111 of the horn assembly 105. However, it is understood that the waveguide assembly 101 may comprise only horn assembly 105 and remains within the scope of this invention. It is also contemplated that enhancer 113 may be disposed completely outside the chamber housing 51, with the horn assembly 105 mounted on the chamber housing 51 without departing from the scope of this invention. The ultrasonic waveguide assembly 101, and more particularly the intensifier 113 in the embodiment illustrated in Fig. 3, is suitably mounted in the chamber housing 51, for example, in the tube 55 defining the side wall of the chamber 57 at the end. superiority thereof by a mounting member 115 which is configured to vibratively isolate the waveguide assembly (which vibrates ultrasonically during operation thereof) from the ultrasonic treatment chamber housing. That is, the mounting member 115 inhibits the transfer of longitudinal and transverse mechanical vibration from the waveguide assembly 101 to the chamber housing 51 while maintaining the desired transverse position of the waveguide assembly (and in particular the horn assembly 105 ) within the interior space 53 of the chamber housing and allowing longitudinal and transverse displacement of the horn assembly within the chamber housing. In the illustrated embodiment, mounting member 115 also at least in part (e.g., together with enhancer 113) closes inlet end 25 of chamber 21.

As an example, the mounting member 115 of the illustrated embodiment generally comprises an annular outer segment 117 extending transverse to the waveguide assembly 101 in transversely spaced relationship therewith, and a flange member 119 that interconnects the outer segment to the waveguide set. Although flange member 119 and transverse outer segment 117 of mounting member 115 extend continuously around the circumference of the waveguide assembly 101, it is understood that one or more of these elements may be discontinuous around the guiding assembly. wave radius, without departing from the scope of this invention. The outer segment 117 of mounting member 115 is particularly configured to seat against a shoulder 121 formed by inlet collar 61.

As best seen in Fig. 6, the inner cross-sectional dimension (e.g., inner diameter) of collar 61 is scaled outward as the collar extends longitudinally downwardly away from the sidewall of chamber 57 to accommodate the flange member. 119. In a particularly suitable embodiment, collar 61 is sufficiently sized to be transversely spaced from flange member 119 to define a generally annular gap 123 therebetween wherein liquid is released to chamber 21 via inlet ports 69a, 69b of the paste enters the interior space 53 of the chamber. This annular gap 123 also facilitates the action of rotating liquid upon entry into chamber 21 via the collar entry ports 69a, 69b. Mounting member 115 is suitably dimensioned in cross section so that at least one outer edge margin of the outer segment 117, and more suitably a substantial transverse portion of the outer segment is seated on shoulder 121 formed on collar 61. A fastening system A suitable fit (not shown), such as a plurality of corresponding screws and nuts (not shown), attach the outer segment 117 of the mounting member 115 to the shoulder 121 formed by the collar 61 to thereby connect the intensifier 113 (and more broadly the set of waveguide 101) to the chamber housing 51. Flange member 119 may suitably be constructed relatively thinner than outer segment 117 of mounting member 115 to facilitate bending and / or bending of flange member 119 in response to ultrasonic vibration. of the waveguide assembly 101. As an example, in one embodiment, the thickness of the flange member 119 may be in the range of about 0.2 mm to about 5 mm, and more suitably about 2.5 mm. The flange member 119 of the illustrated mounting member 115 has an inner transverse member 125 suitably connected to the waveguide assembly 101 and generally extending transversely thereof but into the outer segment 117 of the mounting member, and a axial or longitudinal member 127 interconnecting the transverse inner component with the outer segment of the mounting member and together with the transverse internal member generally forming a generally L-shaped transverse section of the flange member 119. However, it is contemplated that flange member 119 may otherwise have a generally U-shaped or other suitable cross-sectional shape such as an H shape, an I shape, an inverted U shape and the like and remains within the scope of this invention. Additional examples of suitable configurations of mounting member 115 are illustrated and described in U.S. Patent No. 6,676,003, the entire disclosure thereof is incorporated herein by reference as consistent with it. The longitudinal member 127 of the illustrated flange member 119 is suitably balanced to the transverse outer segment 117 and the internal transverse member 125 of the flange, while the internal member of the flange member is balanced to the waveguide assembly 101 Accordingly, the flange member 119 is capable of dynamically bending and / or bending relative to the outer segment 117 of the mounting member 115 in response to the vibratory displacement of the waveguide assembly 101 to thereby isolate the housing from the housing. chamber 51 of transverse and longitudinal displacement of the waveguide assembly.

Although in the illustrated embodiment the transverse outer segment 117 of the mounting member 115 and the transverse inner component 125 of the flange member 119 are generally disposed in longitudinally offset locations with respect to each other, it is understood that they may be generally disposed therewith. location (e.g. where the flange member is generally U-shaped in cross section) or at locations other than those illustrated in Fig. 3) without departing from the scope of this invention.

In a particularly suitable embodiment, the mounting member 115 is of single piece construction. Even more suitably, mounting member 115 may be integrally formed with enhancer 113 (and more broadly with waveguide assembly 101) as illustrated in Fig. 3. However, it is understood that mounting member 115 may be formed. It is constructed separately from the waveguide assembly 101 and remains within the scope of this invention. It is also understood that one or more components of mounting member 115 may be separately constructed and properly connected or otherwise mounted between them.

In a suitable embodiment, mounting member 115 is also constructed to be generally rigid (e.g., resistant to static shifting under load) to retain waveguide assembly 101 in proper alignment within interior space 53 of chamber 21. For example, rigid mounting member 115, in one embodiment, may be constructed of a non-elastomeric material, more suitably metal, and even more suitably the same metal as intensifier 113 (and more broadly the waveguide assembly). 101) is built. However, the term rigid is not intended to mean that mounting member 115 is incapable of dynamic bending and / or bending in response to ultrasonic vibration of waveguide assembly 101. In other embodiments, rigid mounting member 115 may be constructed of an elastomeric material that is sufficiently resistant to static displacement under load, but is otherwise capable of dynamic bending and / or bending in response to the ultrasonic vibration of the waveguide assembly 101. Although the mounting member 115 illustrated in Fig. 3 is constructed of a metal, and more suitably constructed of the same material as enhancer 113, it is contemplated that the mounting member may be constructed of other generally suitable rigid materials without departing from the scope of this invention.

A suitable ultrasonic drive system 131 (shown schematically in Fig. 1) including at least one exciter (not shown) and a power supply (not shown) is disposed outside chamber 21 and operatively connected to intensifier 113 (and more). to the waveguide assembly 101) to energize the waveguide assembly to mechanically vibrate ultrasonically. Examples of suitable ultrasonic drive systems 131 include a Model 20A3000 system available from Dukane Ultrasonics of St. Charles, Illinois, and a Model 2000CS system available from Herrmann Ultrasonics from Schaumberg, Illinois.

In one embodiment, the drive system 131 is capable of operating waveguide assembly 101 at a frequency in the range of about 15 kHz to about 10kHz, more suitably in the range of about 15 kHz to about 60 kHz, and even more suitably in the range of about 20 kHz to about 40 kHz. Such ultrasonic drive systems 131 are well known to those skilled in the art and need not also be described herein.

With particular reference to Fig. 3, horn assembly 105 comprises a generally cylindrical elongate horn 133 having an outer surface 135, and two or more (i.e. a plurality of) agitator members 137 connected to the horn and extending through the horn. least partly transversely outwardly from the outer surface of the horn with respect to the longitudinally spaced relation to each other. The 133 as is suitably sized to have a length of about half a resonant wavelength (otherwise commonly referred to as half the wavelength) of the horn. In a particular embodiment, horn 133 is configured to resonate in the previously recited suitable ultrasonic frequency ranges, and suitably at 20 kHz. For example, horn 133 may be suitably constructed of a titanium alloy (e.g. Ti6A14V) and sized to resonate at 20 kHz. Half the wavelength in horn 133 operating at such frequencies thus has a length (corresponding to half the wavelength) in the range of about 101.6 mm (4 inches) to about 152.4 mm (6 inches). ), more suitably in the range of about 114.3 mm (4.5 inches) to about 139.7 mm (5.5 inches), even more suitably in the range of about 127.0 mm (5.0 inches). inches) to about 139.7 mm (5.5 inches), and suitably a length of about 133.4 mm (5.25 inches). However, it is understood that the ultrasonic treatment chamber 21 may include a horn assembly 105 wherein horn 133 is sized to have any non-abandonment half-wavelength increment of the scope of this invention.

In the illustrated embodiment, the stirring members 137 comprise a series of six washer-shaped rings extending continuously around the circumference of the horn member 133 in longitudinally and transversely spaced relationship (e.g., radially in the illustrated embodiment) to outside the outer surface of the horn. In this way, the vibrational displacement of each stirring member 137 with respect to horn 133 is relatively uniform around the circumference of the horn. However, it is understood that the agitating members 137 need not each be continuous around the circumference of the horn 133. For example, the agitating members 137 may be otherwise in the form of spokes, blades, aihetas or other distinct structural members that are extend transversely outwardly from outer surface 135 of horn 133.

To provide a dimensional example, for horn 133 of the embodiment illustrated in Fig. 3 having a length of about 133.4 mm (5.25 inches), one of the rings 137 is suitably disposed adjacent the terminal end of horn 133 (e.g. consequently of the waveguide assembly 101), and more suitably is longitudinally spaced about 1.6 mm (0.063 inch) from the terminal end of the horn member. In other embodiments, the upper ring 137 may be disposed at the terminal end of the horn and remain within the scope of this invention. The rings 137 are each about 3.2 mm (0.125 inch) in thickness and are longitudinally spaced apart (between the ring coating surfaces) at a distance of about 22.2 mm (0.875 inch). It is understood that the number of agitating members 137 (e.g., the rings in the illustrated embodiment) may be less than or more than six without departing from the scope of this invention. It is also understood that the longitudinal spacing between the stirring members 137 may be different as illustrated in Fig. 3 and described above (for example, or closer or more spaced from each other). Although the rings 137 shown in Fig. 3 are equally longitudinally spaced from each other, it is alternatively contemplated that where more than two agitator members are present the spacing between longitudinally successive agitator members need not be uniform to remain within the scope of this invention. .

In particular, the locations of the stirring members 137 are at least in part a function of the intended vibratory displacement of the vibrating stirring members of horn 133. For example, in the illustrated embodiment, horn 133 has a generally longitudinally located nodal region. centrally of the horn (for example, between the third and fourth rings). As used herein, the "nodal region" of horn 133 refers to a longitudinal region or segment of the horn member along which small (or none) longitudinal displacement occurs during ultrasonic horn vibration and transverse displacement (e.g., in the illustrated embodiment) of the horn is generally maximized. Horn transverse displacement 133 suitably comprises horn transverse expansion but may also include horn transverse movement (e.g. curvature).

In the illustrated embodiment, the configuration of the half-wavelength horn 133 is such that the nodal region is particularly defined in a nodal plane (i.e., a plane transverse to the horn member to which no longitudinal displacement occurs while transverse displacement is generally maximized) is present. This plane is also sometimes referred to as a nodal point. Accordingly, agitator members 137 (e.g., in the illustrated embodiment, the rings) which are longitudinally disposed also of the nodal region of horn 133 will experience primarily longitudinal displacement while agitator members that are longitudinally closer to the nodal region will experience an increased amount of displacement. and a decreased amount of longitudinal displacement with respect to longitudinally distal agitator members. It is understood that horn 133 may be configured such that the nodal region is different from centrally located longitudinally in the non-abandoning horn member of the scope of this invention. It is also understood that one or more of the stirring members 137 may be located longitudinally in the horn to experience longitudinal and transverse displacement relative to the horn under ultrasonic vibration of horn assembly 105.

Still referring to Fig. 3, the stirring members 137 are sufficiently constructed (e.g., in material and / or dimension such as thickness and transverse length, which is the distance that the stirring member extends transversely off the surface). horn 135) to facilitate dynamic movement, and in particular dynamic flexing / bending of the stirring limbs in response to ultrasonic vibration of the horn limb. In a particularly suitable embodiment, for a frequency of ultrasound mode given waveguide assembly 101 will be operated in the ultrasonic chamber (otherwise referred to herein as the predetermined frequency of the waveguide assembly) and a particular liquid to be treated within the chamber. 21, the stirring members 137 and horn 133 are suitably constructed and arranged to operate the stirring members wherein it is referred to herein as an ultrasonic cavitation mode at the predetermined frequency.

As used herein, the ultrasonic cavitation mode of the agitating limbs refers to the vibrational displacement of the agitating limbs sufficient to result in cavitation (i.e. the formation, growth, and implosive collapse of the bubbles in a liquid) of the fluid being treated at the frequency. predetermined ultrasound. For example, where the liquid flowing into the chamber comprises an aqueous solution, and more particularly water, and the ultrasonic frequency at which waveguide assembly 101 is to be operated (i.e., the predetermined frequency) is about 20 ° C. In one or more of the agitation members 137 are suitably constructed to provide a vibrational displacement of at least 1.75 mils (i.e. 0.044 mm, or 0.00175 inch) to establish a cavitation mode of the agitating members. It is understood that the waveguide assembly 101 may be configured differently (e.g., in material, size, etc.) to achieve a desired cavitation mode associated with the particular liquid being treated. For example, as the viscosity of the liquid being treated changes, the cavitation mode of the stirring members may need to be changed.

In particularly suitable embodiments, the agitation mode of the agitator limbs corresponds to a resonant mode of the agitator limbs whereby vibrational displacement of the agitator limbs is amplified with respect to horn displacement. However, it is understood that cavitation can occur without the agitating limbs operating in their resonant mode, or even at a vibrational displacement that is greater than the horn displacement, without abandoning the scope of this invention.

In a suitable dimensional example, a ratio of the transverse length of at least one and most suitably all stirring members 137 to the thickness of the stirring member is in the range of about 2: 1 to about 6: 1. As another example, the rings 137 shown in Fig. 3 each extend transversely outwardly from the outer surface 135 of the horn 133 to a length of about 12.7 mm (0.5 inch) and the thickness of each ring is about 3.2 mm (0.125 inch), so that the aspect ratio will change to thickness per annum and about **: i. However, the thickness and / or transverse length of the stirring members 137 may differ from those of the rings illustrated in Fig. 3 without departing from the scope of this invention. Also, while stirring members 137 (rings) of the illustrated embodiment each have the same transverse length and thickness, it is understood that the agitator members may have different thicknesses and / or transverse lengths.

In the illustrated embodiment, the transverse length of the stirring member 137 also at least partly defines the size (and at least partly the direction) of the flow path along which liquid or other flowable components in the interior space 53 of chamber 21 flow beyond horn assembly 105. For example, horn 133 illustrated in Fig. 3 has a radius of about 22.2 mm (0.875 inch) and the transverse length of each ring 137 is, as discussed above, about 12 inches. .7 mm (0.5 inch). The radius of the inner surface 67 of the housing sidewall 57 is about 44.5 mm (1.75 inch) so that the transverse spacing between each ring and the inner surface of the housing sidewall is about 9.5 mm. (0.375 inch). It is contemplated that the spacing between the outer surface of horn 135 and the inner surface 67 of the chamber side wall 57 and / or between the stirring members 137 and the inner surface of the chamber side wall may be larger or smaller than described above without abandoning the scope of this invention.

In general, horn 133 may be constructed of a metal having suitable acoustic and mechanical properties. Examples of metals suitable for horn construction 133 include, without limitation, aluminum, monel, titanium, stainless steel, and some alloy steels. It is also contemplated that all or part of horn 133 may be coated with another metal such as silver, platinum and copper to name a few. In a particularly suitable embodiment, the stirring members 137 are constructed of the same material as horn 133, and are more properly formed integrally with horn. In other embodiments, one or more of the stirring members 137 may be otherwise formed apart from the horn 133 and connected thereto to form the horn assembly 105.

Although the stirring members 137 (e.g. the rings) shown in Fig. 3 are relatively flat, that is, relatively rectangular in cross section, it is understood that the rings may have a cross-section that is different from rectangular without leaving the scope. of this invention. The term cross section is used in this circumstance to refer to a cross section taken in a transverse direction (e.g., radially in the illustrated embodiment) with respect to the outer surface of horn 135). Additionally, while the stirring members 137 (e.g. the rings) shown in Fig. 3 are constructed to have only one transverse component, it is contemplated that one or more of the stirring members may have at least one longitudinal component (e.g. , axial) to take advantage of the transverse vibrational displacement of the horn (for example, in and near the nodal region of the horn illustrated in Fig. 3) during the ultrasonic vibration of the waveguide assembly 101.

For example, Fig. 5 illustrates an alternative embodiment of a horn assembly 205 having five agitator members 237 transversely extending outwardly from the outer surface 235 of horn 233. While each agitator member 237 has a transverse component, for example, In the form of a ring similar to that of Fig. 3, the most central agitator member 237 also has an annular longitudinal member 241 attached to the transverse member. In particular, the most central agitating member 237 is longitudinally disposed generally in the nodal region, and more particularly in the nodal plane of horn 233 in the illustrated embodiment of Fig. 5, where the transverse displacement of horn 233 is generally maximized during ultrasonic energization of the horn. even while longitudinal displacement is generally minimized. The longitudinal component 241 is thus capable of dynamic movement (e.g. flexion / curvature) in a transverse direction in response to transverse displacement of horn 233 under ultrasonic horn energization. It is contemplated that the longitudinal component 241 need not extend completely longitudinally, i.e. parallel to the outer surface of horn 233, provided that the longitudinal component has some longitudinal vector therefor. Also, while in the embodiment illustrated the agitator member 237 having longitudinal member 241 is generally T-shaped in cross section, it is understood that other configurations of such an agitator member are suitable, such as an L-shaped cross-section ( with the upwardly or downwardly extending longitudinal member), a plus-sign cross-section, or other suitable cross-section. It is also contemplated that one or more orifices may be formed in the most central agitator member 237, such as the transverse member and / or the longitudinal members 241 to allow fluid to flow freely both horizontally and vertically through this member.

As best illustrated in Fig. 3, the terminal end 103 of the waveguide assembly 101 (e.g. of horn 133 in the illustrated embodiment) is substantially longitudinally spaced from the outlet port 65 at the outlet end 27 of chamber 21 to provide what is referred to herein as a buffer zone (i.e., the interior space portion 53 of the chamber housing 51 longitudinally beyond the terminal end 103 of the waveguide assembly 101) to allow more uniform mixing of the downstream components as liquid flows from the terminal end 103 of the waveguide assembly 101 to the outlet end 27 of the chamber. For example, in a suitable embodiment, the buffer zone has a null volume (ie, the volume of that portion of open space 53 within the chamber housing 51 within the buffer zone) where the ratio of this buffer zone null volume for the void volume of the remainder of the chamber housing the interior space upstream of the terminal end of the waveguide assembly is suitably in the range of about 0.01: 1 to about 5.0: 1, and more suitably about 1 : 1 ■ Providing the illustrated buffer zone is particularly suitable where chamber 21 is used to mix the components to form a liquid solution such as in the ink mixing system solution 23 of Fig. 1. That is, the longitudinal spacing between the terminal end 103 of the waveguide assembly 101 and the outlet port 65 of chamber 21 provides sufficient space for the agitated flow of the mixed liquid solution to generally stand before the liquid solution exits the chamber for several minutes. from the exit door. This is particularly useful where, as in the illustrated embodiment, one of the stirring members 137 is disposed or adjacent to the terminal end of horn 133. While such an arrangement leads to beneficial remixing of the liquid as it flows beyond the terminal end of horn 133, It is desirable for this agitated flow to rest at least in part before leaving the chamber. However, it is understood that the terminal end 103 of the waveguide assembly 101 within the interior space 53 of the chamber 21 may be disposed longitudinally closer to the exit port 65 at the exit end 27 of the chamber, or that the buffer zone may be omitted even substantially completely without departing from the scope of this invention. For example, the proximal opposite end of horn assembly 105 is spaced longitudinally spaced from collar 61 to define what is referred to herein as a liquid delivery zone in which the initial rotation of the liquid within the interior space. 53 of the chamber housing 51 occurs upstream of the horn assembly 105. This input zone is particularly useful where the treatment chamber 21 is used to mix two or more components whereby the initial mixing is facilitated by the rotating action on the housing. port as the components to be mixed enter chamber housing 51. It is understood, however, that the proximal end of horn assembly 105 may be closer to collar 61 as shown in Fig. 3, and may be substantially adjacent to the collar to generally omit the input zone, without departing from the scope of this invention.

Still referring to Fig. 3, a deflector assembly generally indicated at 145 is disposed within the inner space 53 of the chamber 21, and in particular generally transversely adjacent to the inner surface 67 of the sidewall 57 and generally transversely opposed to it. to a horn assembly 105. In a suitable embodiment, the deflector assembly 145 comprises one or more deflector members 147 disposed adjacent the inner surface 67 of the side wall of the housing 57 and extending at least in part transversely into the inner surface of the deflector. More preferably, the one or more deflecting members 147 extend transversely longitudinally into the side wall of the inner surface of the housing 67 to an interstitial position with the stirring members 137 extending. extend outwardly from the outer surface 135 of the horn member 133. The term "longitudinally interstitial" is the which is used to mean that a longitudinal line parallel to the longitudinal geometric axis of horn 133 passes through the agitation members 137 and the deflecting members 147. As an example, in the illustrated embodiment, the deflector assembly 145 comprises five generally annular deflecting members 147 (i.e., extending continuously around horn 133) longitudinally interstitial with the six rings 137 of horn assembly 105.

As a more particular example, the five annular deflecting members 147 shown in Fig. 3 are of the same thickness as the rings of horn assembly 137 (i.e. 3.2 mm (0.125 inch)) and are longitudinally spaced apart ( for example, between opposite faces of successive deflecting members) equal to the longitudinal spacing between the rings (ie 22.2 mm (0.875 inch)). Each of the annular deflecting members 147 has a transverse length (e.g., into the inner surface 67 of the housing side wall 57) of about 12.7 mm (0.5 inch) so that the innermost edges of the members baffles extend transversely inwardly beyond the outermost edges of the agitation members 137 (e.g., the rings). However, it is understood that the deflecting members 147 need not extend transversely inwardly beyond the outermost edges of the agitation members 137 of the horn assembly 105 to remain within the scope of this invention.

It will be appreciated that the deflecting members 147 thus extend into the flow path of the liquid flowing into the interior space 53 of the chamber 21 beyond the horn assembly 105 (e.g., within the ultrasonic treatment zone). As such, the deflecting members 147 inhibit the liquid from flowing along the inner surface 67 of the sidewall of the chamber 57 beyond the horn assembly 105, and more appropriately the deflecting members facilitate the flow of the fluid transversely inward toward the assembly. horn to flow into the agitator members of the horn assembly to thereby facilitate ultrasonic energization (i.e. agitation) of the liquid.

To inhibit bubbling against stagnation or otherwise accumulation along the inner surface 67 of the sidewall 57 and along the underside of each deflecting member 147, for example, as a result of agitation of the liquid, a series of notches 149 (openings large) is formed at the outer edge of each of the baffle members to facilitate gas flow (e.g., gas bubbles) between the outer edges of the baffle members and the inner surface of the sidewall of the chamber. For example, in embodiment four illustrated, such notches are formed at the outer edge of each of the deflecting members 147 in relation to equally spaced apart. It is understood that openings may be formed in the deflecting members 147 other than the outer edges where the deflecting members touch the housing, and remain within the scope of this invention. It is also understood that these notches 149 may otherwise be omitted. It is also contemplated that deflecting members 147 need not be annular or otherwise continually extending around horn 133. For example, deflecting members 147 may discontinuously extend around horn 133, such as in the form of rays, pumps, segments or other distinct structural formations extending transversely into the adjacent inner surface 67 of the housing sidewall 57. The term "continuously" in reference to the deflecting members 147 extending continuously around the horn does not exclude deflecting members as two or more arcuate segments arranged in end-to-end touch relationship, that is, as long as no significant gap is formed between such segments.

For example, as best illustrated in Fig. 4, the baffle members 147 are formed suitably separate from tube 55 and are mounted on the support bar assemblies 151 (four such bar assemblies are used in the illustrated embodiment). The carrier bar assemblies 151 are sized in length to extend from the outlet end 27 of the chamber (and more suitably the closure 63) below through each of the deflecting members. Support bar assemblies 151 are secured (such as being threadably secured) to closure 63 to generally secure the deflector assembly 145 in place within the interior space 53 of chamber 21.

More particularly, each of the annular deflecting members 147 of the illustrated embodiment is of two-piece construction (each piece being semi-annular) for ease of assembling the deflector assembly around the horn assembly 105. For example, an assembly of the member pieces deflector 147 is mounted on one pair of the support bar assemblies 151 and a set of the corresponding deflector member pieces is mounted on the other pair of the support bar assemblies so that when all the support bar assemblies are in place within the interior space 53 of chamber 21 the annular shape of each deflecting member is formed.

In the illustrated embodiment, each support bar assembly 151 comprises a plurality of distinct bar segments, for example, with a bar segment extending between and threadably connected to the pieces of the deflecting member 147. However, it is contemplated that each bar assembly 151 may comprise a single bar and the integrally formed or separate formed deflecting members 147 connected to such a single bar. It is also understood that the deflecting members 147 may be of single piece construction, or constructed of more than two pieces, without departing from the scope of this invention. It is also contemplated that the deflecting members 147 may be adequately supported in the interior space 53 of the chamber 21 other than the support bar assemblies 151 of the illustrated embodiment and remain within the scope of this invention. In other suitable embodiments, for example, the baffle members 147 may be otherwise formed integrally with the tube 55 of the chamber housing 51, or formed separate from the tube and attached to the inner surface 67 of the side wall of the housing 57.

Also, although the deflecting members 147 illustrated in Figs. 3 and 4 are each generally flat, for example having a generally thin rectangular cross-section, it is contemplated that one or more of the deflecting members may each be different from the generally flat or rectangular cross-section to also facilitate the flow of bubbles. gas along the interior space 53 of chamber 21. The term cross section is used in this circumstance to refer to a cross section taken in a transverse direction (e.g., radially in the illustrated embodiment) with respect to the outer surface of horn 135.

For example, Fig. 6 illustrates an alternative embodiment of a deflector assembly 345 comprised of a plurality of distinct annular deflecting members 347 in longitudinally spaced relation to each other. Each of the deflecting members 347 has opposite faces 353, 355 and has a non-uniform thickness, and in particular the thickness decreases as the deflecting member extends inwardly away from the sidewall of the chamber 57. In the illustrated embodiment, the Deflecting members 347 are generally triangular in cross section. More suitably, each baffle member 347 is constructed such that the lower face 353 of the baffle member extends differently in the transverse direction and in particular the lower face is angled with respect to the sidewall of the chamber 57 to extend in part longitudinally to the end. It is also contemplated that both lower and upper faces 353,355 may be angled with respect to the side wall of chamber 57 and extend in part longitudinally to the exit end of chamber 21 without departing from the scope thereof. invention.

Figures 7-9 illustrate another alternative embodiment of a useful deflector assembly 545 facilitating the flow of gas bubbles throughout the interior space of the chamber. In this embodiment, there are a plurality of distinct deflecting segments 546, each having a longitudinal outer wall 548 for touching against the sidewall of the chamber, and a pair of deflecting members 547 in the form of arcuate segments that are attached to the outer wall to extend circumferentially in part around the horn (not shown but similar to horn 133 of the embodiment of Fig. 3). As best seen in Fig. 9, the longitudinal position of each of the arcuate deflecting members 547 gradually varies as the segment extends in a circumferential direction. The baffle segments 546 are each mounted on suitable support bar assemblies 551 as previously described.

In operation, according to one embodiment of the ink mixing system solution 23 illustrated in Fig. 1, the one or more ink components 32 (with at least one of the components being a liquid) to be mixed are released ( for example, by pumps 31 in the illustrated embodiment) via conduits 33 to inlet ports 69a, 69b formed in the collar 61 of the treatment chamber housing 51. As these components enter the interior space 53 of chamber 21 via the Inlet ports 69a, 69b, the orientation of the inlet ports induces a relatively pivotal action to initiate mixing of these components upstream of the horn assembly 105, such as in the fluid delivery zone of the chamber interior space.

According to one embodiment of a process for treating liquid such as the ink solution, while the liquid solution continues to flow upwardly into the chamber 21, the waveguide assembly 101, and more particularly the horn assembly 105, is directed. by the drive system 131 to vibrate at a predetermined ultrasonic frequency. In response to the ultrasonic horn excitation 133, the stirring members 137 dynamically extending outwardly from the outer surface 135 of the horn 133 flex / bend relative to the horn, or move transversely (depending on the longitudinal position of the horn). agitating member with respect to the nodal region of the horn). When using a horn assembly 205 such as that shown in Fig. 5 with one of the agitator members 237 disposed in the nodal region of the horn and having a transversely spaced longitudinal component 241 of the horn, the longitudinal component of the agitator member dynamically flexes / bends crosswise with respect to the horn.

Liquid solution continuously flows longitudinally along the flow path between horn assembly 105 and inner surface 67 of housing sidewall 57 so that ultrasonic vibration of stirring members 137 induces mixing together of the various components being mixed. In particularly suitable embodiments, the dynamic movement of the stirring members causes cavitation in the liquid to also facilitate agitation, and in particular mixing in the system 23 of Fig. 1, of the liquid solution. The deflecting members 147 disrupt the longitudinal flow of the liquid along the inner surface 67 of the housing sidewall 57 and repeatedly direct the flow transversely inwardly to flow into the vibratory stirring members 137. As the mixed liquid solution flows longitudinally downstream In addition to the terminal end 103 of the waveguide assembly 101 for the buffer zone, an initial remixing of the liquid solution also occurs as a result of the dynamic movement of the stirring member 137 at or adjacent to the terminal end of the horn 133. Also the flow to Downstream of the liquid solution, for example within the buffer zone, results in the stirred solution providing a more even mixture of components before leaving the treatment chamber 21 via the outlet port 65 for subsequent post-processing by the system. post processing 35.

Figure 10 illustrates one embodiment of a system, generally indicated at 220, for ultrasonically treating a substance. The term substance is used herein to refer to a liquid, solid, semi-solid or gelatinous substance. The system of Fig. 10 comprises an ultrasonic treatment device, generally indicated at 221, supported by a suitable support structure, generally indicated at 222, for particular use in a batch type process wherein a solid, semi-solid or gelatinous substance it is contained within a container C and ultrasonically treated (for example, in a batch type treatment process) by the ultrasonic treatment device yielding the most ready-to-flow substance. However, it is understood that the ultrasonic treatment device of this embodiment may be used for mixing liquids or any of the other uses set forth above with respect to the above embodiments.

Additionally, although the ultrasonic treatment device 221 is illustrated in Fig. 10 as being used with a generally open container C to treat a substance within it in a batch type process, it is understood that this device may be used with the process. closed flow, continuous and treatment chamber of the above embodiments without departing from the scope of this invention. The illustrated support structure 222 generally comprises a base 230, a column 232 extending above the base, and a support arm 224 extending from the general column at the upper end thereof and having a mounting portion 226 in a distal end of the arm for mounting the ultrasonic treatment device 221 on the support structure. The support frame 222 also comprises a housing 228 to cover an upper extension of the ultrasonic treatment device 221 when the device is mounted to the support structure. The base 230 of the illustrated support structure 222 generally defines a platform on which the container C is located for treating the substance within the container. As an example, in the illustrated embodiment container C is a drum or cylinder, and more particularly a 55 gallon drum. However, it is understood that container C may be smaller or larger than a 55 gallon drum, and may be different than in drum or cylinder form without abandoning the scope of this invention. It is also contemplated that base 230 need not define a platform on which container C is located, so that the container simply rests on the floor or other surface on which the support structure was, or located on a platform (not shown). ) or other structure (not shown) that is separate from the support structure 222.

In a particularly suitable embodiment, the arm 224 is bent or otherwise pivoted to the column 232, so that the arm and thus the ultrasonic treatment device 221 may be pivoted or otherwise moved relative to the column, base 230 and container C to position the device at a desired transverse location, depth (i.e. diminished and elevated) and angle within the container. In another suitable embodiment, the column 230 may be adjustable in length (i.e., height in the illustrated embodiment) such that support structure 222 may accommodate containers C of various heights. It is understood that the support structure 222 may have different configurations and modes of operation than those illustrated in Fig. 10 and described above without departing from the scope of this invention. The ultrasonic treatment device 221 comprises an ultrasonic waveguide assembly, generally indicated at 301, operable at a predetermined ultrasonic frequency to energize the substance within container C. The illustrated ultrasonic waveguide assembly 301 suitably comprises an elongated ultrasonic horn 305 having an outer surface 333 and an end end 303, and also having a longitudinal geometry axis which, in the embodiment of Fig. 10, defines a longitudinal geometry axis of the entire waveguide assembly. The illustrated elongate horn 305 is sized to have a length of about six half-wavelengths of the horn. However, it is understood that the horn length may be greater or less than about six half-wavelengths without abandoning the scope of this invention. Horn 305 thus has multiple nodal regions generally located longitudinally along the horn. As used herein, a "nodal region" of horn 305 refers to a longitudinal region or segment of the horn along which small (or none) longitudinal displacement occurs during ultrasonic horn vibration and transverse displacement (for example, radial in the horn). illustrated mode) of the horn is generally maximized. The transverse displacement of the 305 suitably comprises transverse horn expansion but may also include transverse movement (e.g. curvature) of the horn. In the illustrated embodiment, the configuration of the ultrasonic horn 305 is such that the nodal regions are particularly defined by nodal planes (i.e., a plane transverse to the horn where no longitudinal displacement occurs while transverse displacement is generally maximized) is present. . This plane is also sometimes referred to as a nodal point. For the illustrated ultrasonic horn 305, the terminal end 303 of horn 305 defines an antinodal region, and more particularly an antidonal plane or point of the horn at which longitudinal horn displacement is generally maximized during ultrasonic horn vibration while dislocation. cross-sectional is generally minimized. However, it is understood that horn 305 may be configured such that a nodal region or plane is disposed at terminal end 303 of 305 without departing from the scope of this invention. The illustrated waveguide assembly 301 also comprises a coaxially aligned intensifier 313 connected to the ultrasonic horn 305 at an upper end of the horn. A suitable ultrasonic drive system 331 for ultrasonically driving the waveguide assembly 301 comprises at least one exciter (not shown) and a power supply (not shown) operatively connected to the intensifier 313 (and more broadly to the array). 301) to energize the waveguide assembly to mechanically vibrate horn 305 at an ultrasonic frequency. Examples of suitable ultrasonic drive systems 331 include a Model 20A3000 system available from Dukane Ultrasonics of St. Charles, Illinois, and a Model 2000CS system available from Herrmann Ultrasonics of Schaumberg, Illinois. Enhancer 313 may be operatively connected to the exciter employing any conventional technique or device. For example, electrical power may be directed with electrical conductors suitable for a conventional slip ring assembly 314, and the slip ring assembly may be operatively employed to direct electrical power to the exciter. The exciter may use electrical power to generate the desired ultrasonic energy, and direct the ultrasonic energy to horn 305. The ultrasonic treatment device 221 is properly mounted on the distal end of the support arm to allow rotation of the ultrasonic horn 305 around its longitudinal geometry axis, and more particularly, in the embodiment illustrated, to allow rotation of the entire waveguide assembly 301 about the longitudinal geometry axis of the as. As an example, in the embodiment of Fig. 10 the waveguide assembly 301 is mounted on the support arm 224 at least in part by a suitable bearing 354 such that the entire waveguide assembly is pivotable with respect to the support structure. support 222 and container C around the longitudinal geometric axis of the ultrasonic horn.

A suitable drive system, generally indicated at 342, is also mounted to the support frame 222 (for example, in the illustrated embodiment is mounted to the support arm 224) is triggering the connection to the waveguide assembly 221 to drive the rotation of the waveguide assembly, and hence the ultrasonic horn 305. The illustrated drive system 342 comprises a drive motor 344, a first motor-driven pulley 346, a second pulley 352 connected to the waveguide assembly 221 and a drive belt 350 operably connecting the second pulley to the first pulley. Consequently, operation of motor 344 to rotate the first pulley drives rotation of the waveguide assembly 221 by means of belt 352 and second pulley 352. It is understood that alternative drive systems may be used to rotate the ultrasonic horn without scope abandonment. of this invention. In a particularly suitable embodiment, the drive system 342 is controllable to vary the rotational speed of the waveguide assembly 301. That is, the rotational speed of the ultrasonic horn 305 may be selectively accelerated or reduced.

Referring also to Fig. 10, the ultrasonic waveguide assembly 301 also comprises at least one agitator member, generally indicated at 337, supported and more suitably mounted on horn 305 for rotation together with the horn around it. longitudinal geometrical axis and extending at least in part transversely outwardly from the outer surface of the horn. In the illustrated embodiment, the agitator member 337 suitably comprises a propeller having a center 340 and a plurality of blades 338 (two blades being shown in the helix of Fig. 10) extending outward from the center. Each of the blades 338 is suitably braided or chamfered along a portion of its length to facilitate movement of the substance by the blades rotating the blades within the substance. It is understood that the propeller may have any number of blades and that the blades may have a different configuration than shown in Fig. 10 without departing from the scope of this invention. Stirring member 337 of the illustrated embodiment is suitably mounted on horn 305 in a horn region or nodal plane to minimize exposure of the stirring member for longitudinal horn vibration. More suitably, the agitator member 337 is mounted on horn 305 at least in part by a suitable insulating member 360 which isolates the agitator member 337 from transverse shifting of the horn during its ultrasonic vibration. Thus, exposure of the agitator member 337 to both longitudinal and transverse displacement of horn 305 during ultrasonic vibration is reduced. As an example, the insulating member 360 of the illustrated embodiment comprises a suitable resilient glove surrounding the general ultrasonic horn in the nodal region in which the agitating member 337 is located. The center 340 of the agitator member fits into the resilient glove and clamps the glove between the center and the outer surface of the ultrasonic horn 305. It is understood, however, that in other embodiments the agitator member 337 may be located longitudinally in the horn 305 different from in a nodal region of the horn. In such an embodiment, the suitable insulating structure may be used to isolate the agitating member 337 from the longitudinal vibration of the horn. In other such embodiments, the agitator member 337 may be mounted to horn 305 without being vibratorically isolated therefrom such that the agitator member blades 338 are ultrasonically excited together with the horn, as in the same manner as the rings described in the embodiments. front, although the blades are being rotated.

In the embodiment illustrated in Fig. 10, the agitator member 337 is suitably located in the nodal region closest to the terminal end 303 of the ultrasonic horn 305 so that the agitator member will be disposed as deep as possible into the substance within container C when the dispensing device is present. ultrasonic treatment 221 is positioned within the container. However, it is understood that the agitator member 337 may be located differently from near the terminal end 303 of horn 305, as substantially anywhere along the horn including at the terminal end thereof without departing from the scope of this invention. It is also contemplated that more than one agitator member 337 may be mounted on horn 305 for rotation therebetween.

For example, Fig. 11 illustrates one embodiment of a system 221 'wherein the ultrasonic treatment device 221' has four agitator members 337 'mounted on the horn in longitudinal, coaxial relationship between them. The longitudinal spacing between the stirring members 337 'may differ from as illustrated in Fig. 11 (for example, or closer or more spaced from each other). Although stirring members 337 'illustrated in Fig. 11 are equally spaced along horn 305, it is alternatively contemplated that where more than two mixing members are present the spacing between longitudinally successive stirring members need not be uniform to remain within scope. of this invention.

Although in the illustrated embodiment of Fig. 11 the agitating members 337 are each propellers, it is understood that at least one of the agitating members may be configured differently from the other agitating members. For example, one or more of the agitating members 337 may comprise one of the rings used as agitating members in the above embodiments. Also, in the illustrated embodiments of Figs. 10 and 11, the agitator members 337 (the propellers) are mounted on the horn for rotation together with the horn. However, in other embodiments, it is contemplated that the horn may be stationary while the agitating members are mounted on the horn for rotation relative to the horn around the longitudinal geometric axis of the horn. In such an embodiment, drive system 342 would be operatively connected to agitator member (s) 337 instead of the entire waveguide assembly.

In operation, according to one embodiment of a process for treating a substance, the container C containing the substance to be treated is placed at the base 230 of the support structure 222, or otherwise below the ultrasonic treatment device 221, with the top of open container. The waveguide assembly 221 is shortened so that at least the portion of the ultrasonic horn 305 in which the stirring member 337 (or limbs) is submerged in the substance to be treated. The ultrasonic horn 305 is ultrasonically driven (via the exciter and intensifier) to ultrasonically excite the horn so as to ultrasonically energize the substance within container C. Simultaneously, the drive system 342 is operated to rotate the horn 305, and consequently the blades 338 of the stirring member 337, to also agitate or mix the substance while it is ultrasonically energized. The waveguide assembly 301 may be moved around and within the substance, such as changing the angle of the assembly relative to the container, raising and lowering the assembly within the container and / or transversely moving the assembly within the container to facilitate a more complete agitation through the substance. As a particular example, where the substance is a solid, semi-solid or gelatinous substance, such as lard or wax, ultrasonically energizing the substance using the ultrasonic horn while substantially rotating the stirring member within the substance increases the rate at which the substance increases. It is made more easily flowable for further processing of the substance.

By introducing elements of the present invention or preferred embodiments thereof, the articles "one", "one", "the", and "dit (a)" are intended to mean that there are one or more of the elements. The terms "comprising", "including", and "having" are intended to be inclusive.

By introducing elements of the present invention or preferred embodiments thereof, the articles "one", "one", "the", and "said" are intended to mean that there are one or more of the elements. The terms "comprising", "including", and "having" are intended to be inclusive and means that there may be additional elements different from those listed.

As various changes could be made to the above constructions and methods without departing from the scope of the invention, it is intended that the entire subject matter contained in the above description and shown in the accompanying drawings should be construed as illustrative and not in a limiting sense.

Claims (15)

1. Ultrasonic treatment system for ultrasonically treating a substance, characterized by the fact that said ultrasonic treatment system comprises an elongated ultrasonic horn positioned within the substance and excitable to vibrate to ultrasonically energize the substance, said ultrasonic treatment system. having a longitudinal geometrical axis and an external surface for contact with the substance, said system further comprising a stirring member disposed on the ultrasonic horn and rotatable about the longitudinal geometrical axis of the horn during ultrasonic vibration of said horn to agitate the substance, the agitating member being mounted on the ultrasonic horn by an insulating member to at least in part isolate the agitating member from vibration of the ultrasonic horn. Ultrasonic treatment system according to claim 1, characterized in that said system comprises support structure for supporting the ultrasonic horn within the substance, the horn being rotatable with respect to the support structure around the geometric axis. longitudinal axis of the horn, the agitator member being mounted on the horn for rotation together with the horn around the longitudinal geometric axis of said horn. Ultrasonic treatment system according to claim 1, characterized in that the insulating member is the agitating member of at least one of the longitudinal displacement and transverse displacement of the horn. Ultrasonic treatment system according to claim 1, characterized in that the agitating member comprises a center surrounding the outer surface of the horn, the insulating member comprising a glove constructed of a resilient material, said glove being disposed. between the center and the outer surface of the horn. Ultrasonic treatment system according to claim 1, characterized in that the ultrasonic horn has at least one nodal region, the agitating member being disposed in the general horn in said nodal region, Ultrasonic treatment system according to claim 1, characterized in that the agitating member comprises a propeller having a plurality of blades arranged to extend transversely outwardly with respect to the outer surface of the horn; Ultrasonic treatment system according to claim 6, characterized in that each of the plurality of blades is braided along a portion of their length; Ultrasonic treatment system according to claim 2, characterized in that it further comprises a drive system for driving the rotation of the ultrasonic horn, said drive system comprising a motor, a first pulley driven by the motor. , a second pulley operably connected to the horn, and a actionably belt connecting the first and second pulleys. Ultrasonic treatment system according to claim 8, characterized by the fact that the drive system is a variable speed drive system. Ultrasonic treatment system according to claim 1, characterized in that the ultrasonic horn has a terminal end, the agitating member being disposed in the horn generally adjacent to the terminal end of the horn. Ultrasonic treatment system according to claim 1, characterized in that the ultrasonic horn has a length greater than one wavelength. Ultrasonic treatment system according to claim 1, characterized in that the system comprises a plurality of agitator members disposed in said horn in longitudinal relation to each other, at least one of the agitator members being rotatable around them. of the longitudinal geometric axis of the horn. Ultrasonic treatment system according to claim 12, characterized in that each of the stirring members is rotatable about the longitudinal geometric axis of the horn. Ultrasonic treatment system according to claim 12, characterized in that the ultrasonic horn has a plurality of nodal regions, each of the agitating members being disposed in the horn in one of the nodal regions. 15. Ultrasonic treatment system for ultrasonically treating a substance, characterized by the fact that said ultrasonic treatment system comprises an elongated ultrasonic horn positioned within the substance and excitable to vibrate to ultrasonically energize the substance, said ultrasonic treatment system. having a longitudinal geometrical axis and an external surface for contact with the substance, said system further comprising a plurality of stirring members disposed in the ultrasonic horn and longitudinally in relation to one another, at least one of the stirring members being pivotal about the geometrical axis. horn longitudinally during ultrasonic vibration of said horn to agitate the substance, at least one of the stirring members being mounted on the ultrasonic horn by an insulating member to at least partially isolate the stirring member from the mechanical vibration of the horn.