Device and method for forming spherical particle clusters with ultrafine powders

A device suitable for forming spherical particle clusters from fine powder, comprising:

• a preforming device, a spheroidizing device and a grading device,
• wherein the preforming device comprises a first screen, a cylindrical hopper connected to a position under the first screen, a rotating scraper arranged on the first screen, pressing the clusters to pass through the first screen and disposed on the center of the cylindrical hopper, a V-shaped vibration groove made of metal, a vibration unit driven by a vibration controller and a base adjustable in angle, wherein the pore size of the first screen is 300-600 μm and the scraper with adjustable directions and speeds is used for forcing fine powder clusters that do not pass through the screens to pass through the screens;
• the vibration groove is connected to the vibration unit and disposed under the first screen, and the preforming device prepares powder having a particle size in micron level into the clusters and the clusters passing through the first screen fall onto the V-shaped vibration groove through the hopper;
• by adjusting the angle of the base, an inclination angle of the V-shaped vibration groove is changed from 0 to 15°;
• and the V-shaped vibration groove 4 continuously beats the clusters, making the clusters move forward continuously;
• wherein,
• the spheroidizing device comprises a rotating metal cylindrical container, wherein the bottom of the metal cylindrical container is provided with one or more baffles for promoting the flow of clusters within the cylindrical container;
• an inner wall of the metal cylindrical container is coated with one or more coatings comprising, but not limited to, one or a combination of more of Teflon, polyurethane, polyurethane resin, epoxy resin, hydroxypolyester resin, and epoxy/polyester resin;
• and the metal cylindrical container is fixed on a rotating shaft which is rotatable and has an adjustable rotation speed and angle;
• wherein a motor controls the rotating shaft to rotate and drives the rotating cylindrical container to rotate, and a spheroidizing controller controls a rotation speed and an elevation angle of the rotating shaft;
• and
• the grading device comprises one or more second screens for grading the clusters according to particle sizes, which are stacked with each other according to pore sizes, the larger the pore size of a screen, the higher the position where the screen is located, and a collection tray for collecting finest particles is located at the lowermost part;
• wherein the second screens and the collection tray are stacked with each other and fixed to a shaker, and the shaking amplitude and time are controlled by a shaking controller;
• wherein the clusters are treated by the preforming device, the spheroidizing device and the grading device in a sequential order, and the clusters passing through the preforming device are more compact and have better flowability than the clusters before passing through the preforming device, and the clusters enter the spheroidizing device for spheroidizing to obtain a desired roundness and hardness;
• and the clusters enters the grading device for grading according to different particle sizes to obtain the clusters of different sizes.