System and Method for Continuous Rapid Cooling of Molten Materials to Produce Uniformly-Shaped Solid Forms

Abstract

A system and method is disclosed for rapid cooling of hot molten liquid chemicals, and other materials, that go through a phase change to become a solid upon cooling, formed continuously on a single, rotating cylinder having detachable molds, to produce a high volume of uniformly shaped, solid forms.

1 . A system for rapid cooling of molten materials that go through a phase change to become a solid upon cooling, comprising:
 a. a rotatable cylinder;   b. a tray overlaying said cylinder, said tray further comprising a plurality of mold cavities;   c. a coolant within said rotatable cylinder for chilling the cylinder surface and the overlying tray; and   d. means for rotating said cylinder;   
     whereby a molten material may be applied to said tray and mold cavities, rotated upon said cylinder while being cooled through operation of heat transfer between the material, said tray and mold cavities, said cylinder, and said coolant, to produce a continuous number of solid forms. 
   
   
       2 . The system of  claim 1  wherein said tray comprises a plurality of trays. 
   
   
       3 . The system of  claim 1  wherein said tray conforms to an outer surface of said cylinder. 
   
   
       4 . The system of  claim 1  wherein a heat transfer agent is applied between said tray and an outer surface of said cylinder. 
   
   
       5 . The system of  claim 1  wherein said coolant is chilled water. 
   
   
       6 . The system of  claim 1  wherein said means for rotating said cylinder is an electrically powered motor. 
   
   
       7 . The system of  claim 1  wherein said cylinder comprises an outer cylinder and an inner cylinder, and opposing fluid-sealed endcaps overlaying said outer and inner cylinders, said outer and inner cylinders and opposing endcaps defining a space for containing said coolant. 
   
   
       8 . The system of  claim 7  wherein said coolant is passed through the space to absorb heat from said cylinder and to transfer heat from the system. 
   
   
       9 . The system of  claim 1  wherein each said mold cavity further comprises an indicia. 
   
   
       10 . A system for rapid cooling of molten materials that go through a phase change to become a solid upon cooling, comprising:
 a. a rotatable cylinder;   b. a plurality of trays overlaying said cylinder, each said tray further comprising a plurality of mold cavities;   c. a wiper disposed proximate a said tray, but offset a distance therefrom;   d. a coolant fluid within said rotatable cylinder for chilling the cylinder surface and each overlying tray; and   e. means for rotating said cylinder;   
     whereby a molten material may be applied to a said tray and at least a number of said mold cavities, spread across at least a portion of a said tray and a number of said mold cavities, rotated upon said cylinder while being cooled through operation of heat transfer between the material, a said tray and mold cavity, said cylinder, and said coolant, to produce a continuous number of uniformly shaped, solid forms. 
   
   
       11 . The system of  claim 10  wherein each said tray conforms to an outer surface of said cylinder. 
   
   
       12 . The system of  claim 10  wherein a heat transfer agent is applied between each said tray and an outer surface of said cylinder. 
   
   
       13 . The system of  claim 10  wherein said coolant is chilled water. 
   
   
       14 . The system of  claim 10  wherein said cylinder comprises an outer cylinder and an inner cylinder, and opposing fluid-sealed endcaps overlaying said outer and inner cylinders, said outer and inner cylinders and opposing endcaps defining a space for containing said coolant. 
   
   
       15 . The system of  claim 14  wherein said coolant is passed through the space to absorb heat from said cylinder and to transfer heat from the system. 
   
   
       16 . The system of  claim 1  wherein said means for rotating said cylinder is an electrically powered motor. 
   
   
       17 . The system of  claim 10  wherein each said mold cavity further comprises an indicia. 
   
   
       18 . A process for rapidly cooling molten materials that go through a phase change to become a solid upon cooling, comprising the steps of:
 a. flowing a molten material approximately across a rotatable cylinder carrying a plurality of trays overlaying said cylinder, each said tray further comprising a plurality of mold cavities;   b. passing a coolant fluid through said rotatable cylinder for chilling the cylinder surface and each overlying tray; and   c. rotating said cylinder;   d. providing sufficient residence time of material within a said mold cavity to ensure adequate cooling of said material;   e. removing from a said mold cavity a solid form.   
   
   
       19 . The process of  claim 18  wherein said step (a.) further comprises the step of wiping the material approximately uniformly into a plurality of said mold cavities. 
   
   
       20 . The process of  claim 18  wherein each said mold cavity carries an indicia, and wherein said indicia is transferred to a solid form prior to removal of the solid form from a said mold cavity.