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Apparatus And Method For Forming Ceramic Mini Media

Abstract: An apparatus (10) and method (52) for forming ceramic min-media is disclosed. A bottom plate (65) securely holds a reaction column (35) filled with a gel forming solution (50). The reaction column (35) is attached to a slurry chamber (25) that is guided with the four rods (80) in such a way to slide up and down. A slurry dosage control unit (15) is connected to the slurry chamber (25) via a screw rod (85) and a pressing disc (20) and a vibration motor (75) is connected to the slurry chamber (25). A plurality of nozzles (30) is being spaced at a predetermined distance attached to the slurry chamber (25) and to facilitate fluid flow into the reaction column (35), each nozzle (30) having a flat tipped needle (36) of similar height affixed to a nozzle fixing holder (37) with downward projection. The slurry dosage control unit (15) moves the screw rod (85) downwards and the vibration motor (75) creates vibration in the slurry chamber (25) in such a way to control dosage of the slurry (5) into the reaction column (35) through the nozzles (30). The slurry droplets (40) that pass through the gel forming solution (50) takes spherical shape under surface tension and solidifies upon ion- exchange reaction to form a plurality of spherical particles (45) of uniform shape. [FIGURE 3]

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Notices, Deadlines & Correspondence

Patent Information

Application #
Filing Date
19 March 2020
Publication Number
39/2021
Publication Type
INA
Invention Field
MECHANICAL ENGINEERING
Status
Email
patent@depenning.com
Parent Application
Patent Number
Legal Status
Grant Date
2024-01-04
Renewal Date

Applicants

Carborundum Universal Limited
Parry House, 43, Moore Street, Chennai

Inventors

1. Santanu Mandal
Carborundum Universal Limited, "Parry House", 43, Moore Street, Chennai - 600 001
2. Krishnan V
Carborundum Universal Limited, "Parry House", 43, Moore Street, Chennai - 600 001
3. Ritendu Ganguly
Carborundum Universal Limited, "Parry House", 43, Moore Street, Chennai - 600 001
4. Premanshu Jana
Carborundum Universal Limited, "Parry House", 43, Moore Street, Chennai - 600 001
5. Jabaseelan P
Carborundum Universal Limited, "Parry House", 43, Moore Street, Chennai - 600 001
6. Shyam S Rao
Carborundum Universal Limited, "Parry House", 43, Moore Street, Chennai - 600 001
7. Jayan P S
Carborundum Universal Limited, "Parry House", 43, Moore Street, Chennai - 600 001

Specification

We Claim:
1. An apparatus (10), comprising:
a bottom plate (65) securely holds a reaction column (35), the reaction column (35) filled with a gel forming solution (50) is attached to a slurry chamber (25) that is guided with the four rods (80) in such a way to slide up and down;
a slurry dosage control unit (15) connected to the slurry chamber (25) via a screw rod (85) and a pressing disc (20) and a vibration motor (75) connected to the slurry chamber (25) for vibrating the slurry chamber (25);
a plurality of nozzles (30) being spaced at a predetermined distance attached to the slurry chamber (25) and in fluid communication with the reaction column (35), each nozzle (30) having a flat tipped needle (36) of similar height affixed to a nozzle fixing holder (37) with downward projection,
wherein after filling the slurry chamber (25) with slurry (5) the slurry dosage control unit (15) moves the screw rod (85) downwards and the vibration motor (75) creates vibration in the slurry chamber (25) in such a way to control dosage of the slurry (5) into the reaction column (35) through the nozzles (30) to form slurry droplets (40) that pass through the gel forming solution (50) takes spherical shape under surface tension and solidifies upon ion-exchange reaction to form a plurality of spherical particles of uniform shape.
2. The apparatus (10) as claimed in claim 1, wherein the plurality of
spherical particles is composed of a plurality of ceramic mini-media (45).
3. The apparatus (10) as claimed in claim 1, wherein the apparatus comprising: a hand wheel (55) attached to the slurry dosage control unit (15) in such a way to control downward pressure to dose the slurry (5) through the nozzle (30) into the reaction column (35);

a second hand wheel (56) connected to the slurry chamber (25) to maintain distance between the nozzles (30) and the gel forming solution in the reaction column (35) to form the ceramic mini-media (45) of uniform shape.
4. The apparatus (10) as claimed in claim 1, further comprising:
a first scale (60) connected to the rods (80) to determine a distance between the nozzles (30) and the reaction column (35); and
a second scale (61) attached to the reaction column (35) to determine height of the reaction column (35).
5. The apparatus (10) as claimed in claim 1, wherein the slurry dosage
control unit (15) is composed of at least one of the following control unit:
an electrical control unit (12), a mechanical control unit (14) or a pneumatic control unit (16).
control unit (12) further comprises:
a stepper motor (70) connected to the slurry chamber (25) via the screw rod (85) and a drive unit (24) attached to the stepper motor (70) in such a way to control the speed of the hand wheel (56);
a timing belt and pulley (22) connected to the screw rod (85) and the stepper motor (70); and
a PLC module (26) connected to the stepper motor (70) to automatically control the apparatus (10),
wherein the vibration motor (75) and the stepper motor (70) moves the screw rod (85) downwards to control dosage of the slurry (5) from the slurry chamber (25) to the reaction column (35) based on signal given by the driveunit(24)andtograduallymovethedisc(20).

7. The apparatus (10) as claimed in claims 1 and 6, wherein the stepper motor (70) controls force and vibration of the bottom plate (65) and dosage of the slurry (5) to maintain uniform shape of the ceramic mini-media (45).
8. The apparatus (10) as claimed in claims 1 and 5, wherein the mechanical control unit (14) further comprises:
a gear motor (32) connected to the slurry chamber (25) via the screw rod (85) and the rotating handle (55) to rotate the screw rod (85) up and down axis;
a drive unit (24) attached to the gear motor (70) in such a way to control the speed of the hand wheel (56);
a baseplate (34) located at the end of screw rod (85) moves 90º vertically inside the slurry chamber (25),
wherein the vibration motor (75) and the gear motor (70) moves the screw rod (85) downward to apply continuous pressure on the slurry chamber (25) and the speed of the gear motor (32) is controlled to control frequency of applying the pressure and the droplet movement into the reaction column (35).
9. The apparatus (10) as claimed in claims 1 and 5, wherein the
pneumatic control unit (16) further comprises:
a pneumatic cylinder (42) connected to the disc (20) moves 90º vertically inside the slurry chamber (25);
a flow control valve (44) attached to the pneumatic cylinder (42) receives feedback from a slurry speed sensor (46) attached to the PLC module (26),
wherein signal from the PLC module (26) is given to the flow control valve (44) to work in closed loop system and to control the speed of slurry dosage with varying pressure.
10. The apparatus(10) as claimed in claim,wherein the nozzle fixing
holder (37) is made of polymeric or metallic material.

11. The apparatus (10) as claimed in claim 1, wherein the needle (36) interior is conical in shape (38) and is made of stainless steel or an anti-corrosive material.
12. The apparatus (10) as claimed in claim 1, wherein the reaction column (35) is made of polymeric or metallic material or a non-reacting substance.
13. The apparatus (10) as claimed in claim 1, further comprising a butterfly valve (95) at the beneath of the mesh located at the bottom of the reaction column (35) in such a way that the gel forming solution (50) is drain out upon completion of the process.
14. The apparatus (10) as claimed in claim 1, wherein the mini-media (45) collected at the bottom of the reaction column (35) is periodically removed onceitreachesastaticheightinordertomaintainitsshape.
15. The apparatus (10) as claimed in claim 1, wherein the spherical shaped ceramic mini-media (45) has a sphericity greater than 0.8.
16. A method (52) for forming ceramic mini-media (45), said method comprising the steps of: moving a screw rod (85) downwards after filling a slurry chamber (25) with slurry (5);
controllably dosing the slurry (5) from the slurry chamber (25) into a reaction column (35) via a plurality of nozzles (30) by a slurry dosage control unit (15);
passing slurry droplets (40) through the reaction column (35) having a gel forming solution (50) that takes spherical shape under surface tension and solidifies upon ion-exchange reaction to form fine droplets of uniform size; and forming a plurality of ceramic mini-media (45) of uniform shape.
draining out the gel forming solution (50) using a butterfly valve (95) at the

beneath of the mesh located at the bottom of the reaction column (35) upon completion of forming the ceramic mini-media (45); and
periodically removing the mini-media (45) collected at bottom of the reaction column (35) once it reaches a static height in order to maintain its shape wherein the collected mini-media (45) undergoes drying and sintering process.

Documents

Orders

Section Controller Decision Date

Application Documents

# Name Date
1 202041011845-IntimationOfGrant04-01-2024.pdf 2024-01-04
1 202041011845-STATEMENT OF UNDERTAKING (FORM 3) [19-03-2020(online)].pdf 2020-03-19
2 202041011845-PatentCertificate04-01-2024.pdf 2024-01-04
2 202041011845-REQUEST FOR EXAMINATION (FORM-18) [19-03-2020(online)].pdf 2020-03-19
3 202041011845-FORM 18 [19-03-2020(online)].pdf 2020-03-19
3 202041011845-2. Marked Copy under Rule 14(2) [02-01-2024(online)].pdf 2024-01-02
4 202041011845-PETITION UNDER RULE 137 [02-01-2024(online)].pdf 2024-01-02
4 202041011845-FORM 1 [19-03-2020(online)].pdf 2020-03-19
5 202041011845-Retyped Pages under Rule 14(1) [02-01-2024(online)].pdf 2024-01-02
5 202041011845-FIGURE OF ABSTRACT [19-03-2020(online)].jpg 2020-03-19
6 202041011845-Written submissions and relevant documents [02-01-2024(online)].pdf 2024-01-02
6 202041011845-DRAWINGS [19-03-2020(online)].pdf 2020-03-19
7 202041011845-Correspondence to notify the Controller [18-12-2023(online)].pdf 2023-12-18
7 202041011845-COMPLETE SPECIFICATION [19-03-2020(online)].pdf 2020-03-19
8 202041011845-US(14)-HearingNotice-(HearingDate-21-12-2023).pdf 2023-12-08
8 202041011845-Proof of Right [17-09-2020(online)].pdf 2020-09-17
9 202041011845-Correspondence And Form-1_02-11-2021.pdf 2021-11-02
9 202041011845-Correspondence_General Power of Attorney_28-09-2022.pdf 2022-09-28
10 202041011845-ABSTRACT [12-07-2022(online)].pdf 2022-07-12
10 202041011845-FER.pdf 2022-01-31
11 202041011845-CLAIMS [12-07-2022(online)].pdf 2022-07-12
11 202041011845-OTHERS [12-07-2022(online)].pdf 2022-07-12
12 202041011845-COMPLETE SPECIFICATION [12-07-2022(online)].pdf 2022-07-12
12 202041011845-FORM-26 [12-07-2022(online)].pdf 2022-07-12
13 202041011845-DRAWING [12-07-2022(online)].pdf 2022-07-12
13 202041011845-FER_SER_REPLY [12-07-2022(online)].pdf 2022-07-12
14 202041011845-DRAWING [12-07-2022(online)].pdf 2022-07-12
14 202041011845-FER_SER_REPLY [12-07-2022(online)].pdf 2022-07-12
15 202041011845-COMPLETE SPECIFICATION [12-07-2022(online)].pdf 2022-07-12
15 202041011845-FORM-26 [12-07-2022(online)].pdf 2022-07-12
16 202041011845-CLAIMS [12-07-2022(online)].pdf 2022-07-12
16 202041011845-OTHERS [12-07-2022(online)].pdf 2022-07-12
17 202041011845-FER.pdf 2022-01-31
17 202041011845-ABSTRACT [12-07-2022(online)].pdf 2022-07-12
18 202041011845-Correspondence And Form-1_02-11-2021.pdf 2021-11-02
18 202041011845-Correspondence_General Power of Attorney_28-09-2022.pdf 2022-09-28
19 202041011845-Proof of Right [17-09-2020(online)].pdf 2020-09-17
19 202041011845-US(14)-HearingNotice-(HearingDate-21-12-2023).pdf 2023-12-08
20 202041011845-COMPLETE SPECIFICATION [19-03-2020(online)].pdf 2020-03-19
20 202041011845-Correspondence to notify the Controller [18-12-2023(online)].pdf 2023-12-18
21 202041011845-DRAWINGS [19-03-2020(online)].pdf 2020-03-19
21 202041011845-Written submissions and relevant documents [02-01-2024(online)].pdf 2024-01-02
22 202041011845-FIGURE OF ABSTRACT [19-03-2020(online)].jpg 2020-03-19
22 202041011845-Retyped Pages under Rule 14(1) [02-01-2024(online)].pdf 2024-01-02
23 202041011845-FORM 1 [19-03-2020(online)].pdf 2020-03-19
23 202041011845-PETITION UNDER RULE 137 [02-01-2024(online)].pdf 2024-01-02
24 202041011845-2. Marked Copy under Rule 14(2) [02-01-2024(online)].pdf 2024-01-02
24 202041011845-FORM 18 [19-03-2020(online)].pdf 2020-03-19
25 202041011845-REQUEST FOR EXAMINATION (FORM-18) [19-03-2020(online)].pdf 2020-03-19
25 202041011845-PatentCertificate04-01-2024.pdf 2024-01-04
26 202041011845-STATEMENT OF UNDERTAKING (FORM 3) [19-03-2020(online)].pdf 2020-03-19
26 202041011845-IntimationOfGrant04-01-2024.pdf 2024-01-04

Search Strategy

1 202041011845_SearchStrategyE_26-01-2022.pdf

ERegister / Renewals

3rd: 25 Mar 2024

From 19/03/2022 - To 19/03/2023

4th: 25 Mar 2024

From 19/03/2023 - To 19/03/2024

5th: 25 Mar 2024

From 19/03/2024 - To 19/03/2025

6th: 28 Jan 2025

From 19/03/2025 - To 19/03/2026