Enhanced flow in agglomerated and bound materials and process therefor

Abstract

In broad terms, this process adds organic material to particulate solids and works the mix. Resolification in a unique way creates improved binding of the particulate solids. The particulate solids are materials such as metal, semi-metal, ceramic, glass, plastic, or rubber, alloy, composite, agglomerate, or other organic. The organic selection should remain solid in handling and may become liquid during compaction. These materials may consist of a liquid, solid or mixture selected from the group consisting of fatty acids; and amides, bisamides, soaps and salts of fatty acids, waxes, resin, oils, hydrogenated fats and oils, polymers, mold release or friction reducing agent. With lubricity enough to enable ejection of a molded compact, flow and adequately low molecular weight and formulation to enable clean burn off if desired. With inputs that may include either pressure, solvents, chemical activation of polymers, or thermal heat; and working so as to enhance the gluing of particulates together and rounding of the agglomerate to provide flowability.

1 . A process for producing rounded agglomerates comprising the steps of providing a mixture of particulate solids and organic material, thermal, solvent, pressured, or chemical activated processing critical to the achievement of a sound composite or agglomerate without excessively degrading the organic material, and working during processing necessary to form rounded agglomerates; and attain enhanced flow characteristics.  
     
     
         2 . A process for producing rounded agglomerates comprising the steps of providing a mixture of particulate solids and organic material; heating the mixture at a temperature above the melting temperature of the organic material; maintaining the temperature above the melting temperature of the organic material; and slowly cooling and simultaneously working the heated mixture to below the softening point of the organic material to form rounded agglomerates of the cooled mixture.  
     
     
         3 . A process according to  claim 2  wherein the particulate solids is metal, semi-metal, ceramic, glass, plastic, rubber, alloy, composite, agglomerate or other organic thereof.  
     
     
         4 . A process according to  claim 2  wherein the heating is maintained at a temperature below the boiling point of the organic material.  
     
     
         5 . A process according to  claim 4  wherein the heating is maintained at a temperature below the vapor point of the organic material.  
     
     
         6 . A process according to  claim 5  wherein the heating is maintained at a temperature below less than one half of the range between the vapor point and the melting point of the organic material.  
     
     
         7 . A process according to  claim 6  wherein the heating is maintained at a temperature below less than one quarter of the range between the vapor point and the melting point of the organic material.  
     
     
         8 . A process according to  claim 7  wherein the heating is maintained at a temperature below less than one tenth of the range between the vapor point and the melting point of the organic material.  
     
     
         9 . A process according to  claim 8  wherein the heating is maintained at a temperature slightly above the melting point of the organic material.  
     
     
         10 . A process according to  claim 2  wherein the working and cooling are carried out for a period of time of 5 minutes or less.  
     
     
         11 . A process according to  claim 2  wherein the working and cooling are carried out for a period of time of less than one minute.  
     
     
         12 . A process according to  claim 2  wherein the working and cooling are carried out rapidly.  
     
     
         13 . A process according to  claim 2  wherein the production of rounded agglomerates comprises the steps of providing a mixture of particulate solids; heating the mixture to a temperature above the melting temperature of an organic material; then adding the organic material maintaining the temperature of the particulates above the melting temperature of the organic material; and slowly cooling and simultaneously working the heated mixture to below the softening point of the organic material to form rounded agglomerates of the cooled mixture.  
     
     
         14 . A process according to  claim 2  wherein the heating is maintained at a temperature below the boiling point of the organic material.  
     
     
         15 . A process according to  claim 13  wherein the heating is maintained at a temperature below the vapor point of the organic material.  
     
     
         16 . A process according to  claim 13  wherein the heating is maintained at a temperature below less than one half of the range between the vapor point and the melting point of the organic material.  
     
     
         17 . A process according to  claim 13  wherein the heating is maintained at a temperature below less than one quarter of the range between the vapor point and the melting point of the organic material.  
     
     
         18 . A process according to  claim 13  wherein the heating is maintained at a temperature below less than one tenth of the range between the vapor point and the melting point of the organic material.  
     
     
         19 . A process according to  claim 13  wherein the heating is maintained at a temperature slightly above the melting point of the organic material.  
     
     
         20 . A process according to  claim 1  wherein the production of rounded agglomerates comprises the steps of providing a mixture of particulate solids and organic material; dissolving the organic material in a solvent; and simultaneously working the mixture as the solvent is allowed to evaporate solidifying the organic material and forming rounded agglomerates.  
     
     
         21 . A process according to  claim 1  wherein the production of rounded agglomerates comprises the steps of providing a mixture of particulate solids; dissolving an organic material in a solvent, then adding the organic material to the mixture of particulate solids; and simultaneously working the mixture as the solvent is allowed to evaporate solidifying the organic material and forming rounded agglomerates.  
     
     
         22 . A process according to  claim 1  wherein the production of rounded agglomerates comprises the steps of providing a mixture of particulate solids; dissolving the organic material in a solvent, then adding the particulate solids to the dissolving organic material and solvent; and simultaneously working the mixture as the solvent is allowed to evaporate solidifying the organic material and forming rounded agglomerates.  
     
     
         23 . A process according to  claim 1  wherein the production of rounded agglomerates comprises the steps of providing a mixture of particulate solids and solvent, then adding the organic material to the mixture of particulate solids and solvent; dissolving the organic material in a solvent; after the organic material is dissolved simultaneously working the mixture as the solvent is allowed to evaporate solidifying the organic material and forming rounded agglomerates.  
     
     
         24 . A process according to  claim 1  wherein the production of rounded agglomerates comprise the step of providing a mixture of particulate solids and organic material; changing pressure enough to allow the organic material to phase change to a liquid or vapor, then restoring pressure and simultaneously working the mixture as the organic material solidifies forming rounded agglomerates.  
     
     
         25 . A process according to  claim 1  wherein the production of rounded agglomerates comprises the steps of providing a mixture of particulate solids and a polymer or resin; chemically activating the polymer or resin while simultaneously working the mixture so as to form rounded agglomerates.  
     
     
         26 . A process according to  claim 1  wherein the production of rounded agglomerates comprises the steps of providing a mixture of particulate solids and/or pre-agglomerated particulates and organic material; heating the mixture at a temperature above the melting temperature of the organic material, and below the melting point of the previous organic used in making the pre-agglomerated particulates; maintaining the temperature above the melting temperature of the most recently added organic material, and below the melting point of the previous organic used in making the pre-agglomerated particulates; and slowly cooling and simultaneously working the heated mixture to below the softening point of the organics materials to form rounded agglomerates of the cooled mixture.  
     
     
         27 . A process according to  claim 1  wherein the production of rounded agglomerates comprise the steps of providing a mixture of particulate solids and/or pre-agglomerated particulates; heating the mixture to a temperature above the melting temperature of an organic material that is to be introduced, but allow that used in making the pre-agglomerated particulates; then adding this new organic material maintaining the temperature of the particulates above the melting temperature of the most recently added organic material; and slowly cooling and simultaneously working the heated mixture to below the softening point of the organic materials to form rounded agglomerates of the cooled mixture.  
     
     
         28 . A process according to  claim 1  wherein the production of rounded agglomerates comprise the step of providing a mixture of particulate solids and/or pre-agglomerated particulates and organic material; dissolving the new organic material in a solvent in which the organic used in making the pre-agglomerates is less dispersible or dissolvable; and simultaneously working the mixture as the solvent is allowed to evaporate solidifying the organic material and forming rounded agglomerates.  
     
     
         29 . A process according to  claim 1  wherein the production of rounded agglomerates comprise the steps of providing a mixture of particulate solids and/or pre-agglomerated particulates and organic material; changing pressure enough to allow the newly added organic material to phase change to a liquid or vapor without allowing the organic material used to manufacturing the pre-agglomerates to phase change, then restoring pressure and simultaneously working the mixture as the organic material solidifies forming rounded agglomerates.  
     
     
         30 . A process according to  claim 1  wherein the production of rounded agglomerates comprises the steps of providing a mixture of particulate solids and/or pre-agglomerated particulates and polymer; chemically activating the polymer while having little effect on the organic material used in the manufacture of the pre-agglomerates while simultaneously working the mixture so as to form rounded agglomerates.  
     
     
         31 . A product produced according to the process of  claim 1.