Ultrasonic powder dispersion technology for handling cohesive material powders

Suboptimal handling of cohesive materials is a leading cause of operational inefficiencies in materials handling systems. Feeding and dispersing dry powders is traditionally prone to jamming, relies on heavy pneumatic compressors, and lacks precision. Based on our patented ultrasonic dispersion technology [US Patent 11,358,112], the proposed dry powder delivery platform solves these problems by providing precise and repeatable acoustic fluidization without any moving parts and associated logistics. In prior [Aerosol Science and Technology 53, 321 (2019), Powder Technology 376, 52 (2020)] and current work, we have shown that our technology can produce steady dry aerosol from off-the-shelf powders for many hours with tunable concentrations and mass feed rates of powdered cohesive materials (ceramics, metals, carbonaceous, amorphous powders, plastic polymers, …). A multi-purpose, material-agnostic Ultrasonic Dry Powder Delivery Platform (UDP2) based on the patented ultrasonic dispersion technology is proposed to fulfill gaps in logistics and adaptive infrastructure. This contactless and steady powder fluidization technology could be a foundational capability rather than a single-use tool and is aimed at reducing complexity and increasing operational flexibility of powder handling and manufacturing systems. Current systems rely on brute force (heavy compressors, mechanical agitators, pressurized gas) or payload dilution (flow aids). These solutions come with the burden of multiple components to keep a powder feeding arrangement functional. By using solid-state ultrasonic fluidization, a means to break up cohesive bonds and feed pure, high-density powders instantly. Also, current methods have particular disadvantages in delivering low flowrates of cohesive materials (~1 mg/min to 10 g/min) at high precision. Sustaining a high concentration and steady feed rate with high precision (control) is the key problem addressed by the patented ultrasonic dispersion technology.