Apparatus for mixing materials which have a high mix proportion/ratio therebetween and preparation production system using the same

A mixing apparatus includes a first and a second feeding tube, a first and a second atomizing/refining dose control device, and a reaction chamber. The first and second feeding tubes are arranged in a multi-sleeves manner. The first and second atomizing/refining dose control devices are respectively disposed on terminal ends of the first and second feeding tubes. The reaction chamber accommodates the first and second feeding tubes and the first and second atomizing/refining dose control devices and has a liquid dose mixing wall. The first and second feeding tubes respectively receive a first and a second liquid dose. The first and second atomizing/refining dose control devices respectively atomize or refine the first and second liquid doses and spray the atomized or refined first and second liquid doses on a surface of the liquid dose mixing wall, so as to mix the first and second liquid doses.

REFERENCE TO RELATED APPLICATIONS

This non-provisional application claims priority claim under 35 U.S.C. § 119(a) on Taiwan Patent Application No. 108105890 filed Feb. 21, 2019 the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

The invention relates to a mixing apparatus for producing preparations mixed by materials which have a high mix proportion/ratio therebetween and a preparation production system using the same, more particularly, to a mixing apparatus and a preparation production system using the same that are reduced in size and has better mixing efficiency.

BACKGROUND

In semiconductor process, optoelectronic process, pharmaceutical process, chemical process, food process, or other processes, preparations mixed by different liquid doses are often required to prepare the product or to aid the production. During the material-mixing process of the preparation production, a large volume difference may exist between different liquid doses due to reacting time and mix ratio, in other words, the multiple liquid doses have, between them, a high mix proportion/ratio.

Conventionally, liquid doses having a high mix proportion/ratio between them are mixed by controlling the feeding ratio and injecting the liquid doses with a single injection hole or injection channel, wherein the liquid dose with smaller quantity is injected into the liquid dose with larger quantity by a single point and then the two liquid doses are stirred to mix them together. However, the mixing result obtained by this method is poor. In addition, in situations where there is a fast reaction between the liquid doses, the mixture may have defects, like acid-base neutralized polymer, unsuccessful mixing or poor mixing, due to the fact that the liquid doses were unable to be distributed evenly in the mixing process. On the other hand, the conventional mixing devices used in the semiconductor or optoelectronic factories are mostly equipment consist of large tanks combined with long pipeline systems, which take up a large space and is difficult to be moved or is a fixed facility.

SUMMARY

Therefore, to overcome the deficiencies in the conventional technology, an object of the invention is to provide an apparatus for mixing materials which have a high mix proportion/ratio therebetween and a preparation production system using the same, wherein a plurality of different liquid doses are atomized/refined and then sprayed on the surface of a liquid dose mixing wall in a reaction chamber, and thus the purpose of mixing the materials evenly, quickly and with high efficiency is achieved. Moreover, the mixing of different doses by the aforementioned mixing apparatus and preparation production system can be completed in a small and limited space, so an extra pre-treatment facility area is not needed, and hence a reduction in the quantity, cost, and space for equipment units is accomplished. In other words, the size of the mixing apparatus and preparation production system of the invention can be miniaturized for easy relocation or portability.

It is then an object of the invention to provide an apparatus for mixing materials which have a high mixing proportion/ratio therebetween. The mixing apparatus includes a first feeding tube, a second feeding tube, a first atomizing/refining dose control device, a second atomizing/refining dose control device, and a reaction chamber. The first and second feeding tubes are arranged in a multi-sleeves manner where the second feeding tube is sleeved over the first feeding tube. The first and second atomizing/refining dose control devices are respectively disposed at one ends of the first and second feeding tubes. The reaction chamber accommodates the first and second feeding tubes and the first and second atomizing/refining does control devices therein and includes a liquid dose mixing wall. The first and second feeding tubes receive, respectively, a first liquid dose and a second liquid dose. The first and second atomizing/refining dose control devices atomize/refine the first and second doses, respectively, for distribution and respectively spray the atomized/refined first and second doses on a surface of the liquid dose mixing wall in the reaction chamber to mix the first and second doses.

Optionally, the mixing apparatus further includes a first dosage control device and a second dosage control device. The first dosage control device is disposed at the other end of the first feeding tube for receiving the first liquid dose and adjusting a feeding dosage and a pressure of the first liquid dose so as to input the first liquid dose to the first feeding tube. The second dosage control device is disposed at the other end of the second feeding tube for receiving the second liquid dose and adjusting a feeding dosage and a pressure of the second liquid dose so as to input the second liquid dose to the second feeding tube.

Optionally, the mixing apparatus further includes an end mixer disposed at one end of the reaction chamber for mixing the first and second doses flown down from the surface of the liquid dose mixing wall.

Optionally, the surface of the liquid dose mixing wall is a smooth surface.

Optionally, the liquid dose mixing wall includes at least one drainage pattern on the surface.

Optionally, the first and second feeding tubes are horizontally parallel and overlapping or are horizontally parallel and staggered.

Optionally, each of the first and second atomizing/refining dose control devices includes at least one microporous structure disposed on a side thereof.

Optionally, the liquid dose mixing wall is made of a corrosion-resistant hydrophobic material or is coated or plated with the corrosion-resistant hydrophobic material on the surface.

Another object of the invention is to provide a preparation production system that includes the aforementioned mixing apparatus, a first pressure-regulating device, a second pressure-regulating device, and a preparation output device. The mixing apparatus is connected to the first and second pressure-regulating devices and the preparation output device.

Optionally, the preparation production system further includes a first monitoring and verification device, a second monitoring and verification device, and a real-time monitoring device. The first monitoring and verification device is disposed between the first pressure-regulating device and the mixing apparatus. The second monitoring and verification device is disposed between the second pressure-regulating device and the mixing apparatus. The real-time monitoring device is disposed between the preparation output device and the mixing apparatus.

In short, the invention provides a mixing apparatus for producing preparations and a preparation production system using the same that is capable of mixing materials with a high mix proportion/ratio therebetween evenly and quickly in a small facility and with low cost.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

According to embodiments of the invention, an apparatus for mixing materials which have a high mix proportion/ratio therebetween and a preparation production system using the same are provided, wherein several different liquid doses are separately atomized or refined and then sprayed on a same surface of a liquid dose mixing wall of a reaction chamber, so as to mix the different liquid doses on a layer-by-layer (coating to coating) basis, thereby mixing the materials having a high mix ratio proportion/ratio therebetween evenly and quickly. Through the aforementioned mixing apparatus and preparation production system, the mixing can be completed in a small and confined space or area, and therefore the invention has the technical benefits of requiring less facility space and cost and can be easily relocated to be close to the product processing line which would save on factory facilities and costs. Moreover, the aforementioned mixing apparatus may be a mini apparatus with capacity of 300 milliliter or less or a mega apparatus with capacity up to multi-tons, or anything in-between, and there is no limitation on the type or the mass of the liquid dose used for mixing.

The mixing apparatus and the production system using the same according to embodiments of the invention can achieve the object of mixing materials having a high mix proportion/ratio therebetween. In correspondence to the reaction time between the mixed liquid doses, some liquid doses with small quantity can be quickly integrated into other liquid doses with large quantity to obtain the best dose-mixing reaction efficiency. For example, the ratio between liquid doses can be from 1:10 to 1:500, but the invention is not limited thereby. The aforementioned mixing apparatus and the preparation production system using the same can be used in many fields, such as the chemical or slurry preparation in semiconductor or optoelectronics industries, unique functional-medicine preparation for special medical treatment, medicine preparation for general medical treatment, preparation of chemicals with fast reaction rate like KOH, preparation of other chemical substances, food preparation mixed with nutritional supplements or spices.

In general, the apparatus for mixing materials having a high mix proportion/ratio therebetween according to an embodiment of the invention is a multiple-input and single-output mixing apparatus that can precisely mix the materials in a limited mixing space. The mixing apparatus includes a plurality of feeding tubes, a plurality of atomizing/refining dose control devices and a reaction chamber, wherein the plurality of feeding tubes correspondingly connect to the plurality of atomizing/refining dose control devices, and the reaction chamber accommodates the plurality of feeding tubes and the plurality of atomizing/refining dose control devices and includes a liquid dose mixing wall. The plurality of feeding tubes receive a plurality of different liquid doses, and the plurality of atomizing/refining dose control devices atomize/refine these different liquid doses for distribution and spray the atomized/refined liquid doses on a surface of the liquid dose mixing wall in the reaction chamber to mix the different liquid doses, wherein the surface of the liquid dose mixing wall is smooth or non-smooth.

FIG. 1is a functional block diagram of a preparation production system according to a preferred embodiment of the invention. Referring toFIG. 1, the preparation production system1includes a plurality of pressure-regulating devices111-114, a plurality of monitoring and verification devices131-134, an apparatus for mixing materials having a high mix proportion/ratio therebetween14, a real-time monitoring device15, and a preparation output device16. The pressure-regulating devices111-114are respectively connected to the monitoring and verification devices131-134, and the monitoring and verification devices131-134are also connected to the mixing apparatus14. The mixing apparatus14is connected to the real-time monitoring device15, and the monitoring device15is also connected to the preparation output device16.

The pressure-regulating devices111-114receive, respectively, a first, a second, a third, and a fourth doses101-194, wherein the first to fourth doses101-194are mainly liquids and the types thereof are not limited in anyway; the doses can be, for example, semiconductor slurry, chemical liquids, solid-contained liquids, or other liquids that require mixing. The pressure-regulating devices111-114regulate the pressures in the pipelines and modulate the dose flow so that the first to fourth doses101-114are transported with stable flow and speed.

The monitoring and verification devices131-134respectively verifies whether the qualities of the first to fourth doses101-104meet a production standard to determine whether to input the first to fourth doses101-104to the mixing apparatus14. The verification test includes testing at least one of pH, concentration, particle distribution, particle size, specific gravity, temperature, density, conductivity, pressure, flow rate, and mass. Correspondingly, the monitoring and verification devices131-134include the essential elements and functions for the aforementioned tests.

The mixing apparatus14mixes the first to fourth doses101-104according to different ratios by spraying, in small mists of water fog, the first to fourth doses101-104on the surface of the liquid dose mixing wall of the reaction chamber. Preferably, the mixing apparatus14further includes an end mixer disposed at one end of the reaction chamber to conduct a second mixing of the doses. The mixing apparatus14will later be described and thus is not put in details herein.

The real-time monitoring device15receives the preparation produced by the mixing apparatus14and determines whether the preparation meets the quality standard. In other words, the real-time monitoring device15verifies and tests the liquid characteristic of the preparation to determine whether to output the preparation, wherein the verification test includes testing at least one of pH, concentration, particle distribution, particle size, specific weight, temperature, density, conductivity, pressure, flow rate, and mass. Correspondingly, the real-time monitoring device15includes the essential elements and functions for the aforementioned tests.

The preparation output device16receives the preparation output from the real-time monitoring device15and as well as an incoming-request command from a user end, so as to provide, based on the dosage requested in the incoming-request command and in consideration of the transporting pressure and pulsation control in the pipeline, a corresponding volume of the dosage to the user end.

During the operation, each of the pressure-regulating devices111-114regulates the pressure in each pipeline before transporting the first to fourth doses101-104respectively to the monitoring and verification devices131-134. If the pressure is uneven, then the evaluation of the verification may fail and the ratio calculation and supply of the first to fourth doses131-134in the subsequent mixing stage would be affected. Moreover, before the mixed preparation is output, the real-time monitoring device15, other than monitoring the quality of the preparation, also controls the pressure-regulating devices111-114, the monitoring and verification devices131-134, the mixing apparatus14, and the preparation output device16for commanding operations like collecting data, production scheduling, or safe shutdown of the production. It is to be noted that the preparation production system1is merely one of the embodiments of the invention, wherein when the quality of the preparation is less of a concern or not as cared, the monitoring and verification devices131-134and the real-time monitoring device15may be removed from and not be implemented in the preparation production system1.

Next, the apparatus for mixing materials which have a high mix proportion/ratio therebetween is described herein.FIG. 2is a schematic sectional side view of a mixing apparatus according to an embodiment of the invention. Although the mixing apparatus14inFIG. 1is input with four doses (first to fourth doses101-104) and the mixing apparatus2inFIG. 2is depicted to be input with three doses, through the description of the mixing apparatus2, person skilled in the art would know how to implement the mixing apparatus14with four doses input thereto.

Referring toFIG. 2, the mixing apparatus2includes a plurality of dosage control devices201-203, a plurality of feeding tubes211-213, a plurality of atomizing/refining dose control devices221-223, a reaction chamber23, and an end mixer24. Each of the dosage control devices201-203respectively connects to a first end of each of the feeding tubes211-213, and each of the atomizing/refining dose control devices221-223respectively connects to a second end of the each of the feeding tubes211-213. The feeding tubes211-213are in a layered configuration, for instance, when viewing from atop, they are concentric circles vertically offset outward and arranged concentrically in vertical layers to isolate the liquid doses in the feeding tubes211-213as shown inFIGS. 3A and 3B. The end mixer24is disposed at one end of the reaction chamber23.

The dosage control devices201-203are used to receive different liquid doses and capable of adjusting the feeding dosage and pressure to input the received liquid doses respectively to the feeding tubes211-213. Referring toFIGS. 2, 3A, and 3B, the feeding tubes211-213are several pipelines in an offset arrangement (on a vertical distribution plan). In addition, the first ends of the feeding tubes211-213can be located either at the same-side region or at regions on different sides of the reaction chamber23. It is to be noted that in some situations, the dosage control devices201-203are not essential elements, whereby the feeding is then simply controlled by the atomizing/refining dose control devices221-223.

As shown inFIG. 3A, the feeding tubes211-213are horizontally parallel and staggered (on a horizontal distribution plan) and the first ends of the feeding tubes211-213are located at regions on different sides of the reaction chamber23. The feeding tubes211-213shown inFIG. 3Bare horizontally parallel and overlapping each other such that the first ends of the feeding tubes211-213are located on the same-side region of the reaction chamber23, and thus the consistency and minimal-space configuration of the feeding tubes211-213need not be considered, and the diameters of the feeding tubes211-213are less limited by space arrangement. Simply, the feeding tubes211-213are arranged in a multi-sleeves manner in a limited space to form multiple channels for liquid doses and to create a controlled space, so that feeding with a specific pressure is made possible. The arrows inFIG. 2represent the feeding directions of the liquid doses.

The atomizing/refining dose control devices221-223receive the liquid doses from the feeding tubes211-213, atomize/refine the liquid doses for distribution, minimizing or atomizing or refining the liquid doses into sprayable particles, and spray the atomized/refined liquid doses on a surface of a liquid dose mixing wall231in the reaction chamber23. In this embodiment, the atomizing/refining dose control devices221-223include a plurality of microporous structures2211,2221,2231disposed on the sides thereof. The microporous structures2211,2221,2231and their micropores can be disposed in intervals, like the microporous structure2231shown inFIG. 3Chas a plurality of micropores22311disposed in intervals and a plurality of the microporous structures2231are disposed in intervals, or without intervals, wherein the diameter of the micropores may vary depending on the characteristics of the liquid dose. Moreover, to obtain a finer spraying effect, besides arranging the micropore structures2211,2221,2231and the plurality of micropores according to the characteristics of the liquid dose, the atomizing/refining dose control devices221-223further may include ultrasonic spraying devices.

Optionally, the atomizing/refining dose control device221-223is a feeding device controlled by pneumatic continuous pressure, wherein the atomized/refined liquid dose is sprayed by continuously providing pressure from nitrogen pressurization or a pump to conduct feeding. In addition, pneumatic pump and software are used together to achieve the feeding accuracy of this control method.

Optionally, the atomizing/refining dose control devices221-223is a feeding device that feeds by quantitative batches, wherein the atomized/refined liquid dose is sprayed by creating a confined space and squeezing therefrom to conduct feeding with continuous batches. The feeding accuracy of this control method is achieved by the creation of the confined space and together with the mechanical squeezing device.

It is to be noted that the embodiments of the atomizing/refining dose control devices221-223do not limit the invention thereby; any device or equipment that is able to atomize or refine the liquid doses in the feeding tubes211-213for distribution may be used to realize the invention.

The surface of the liquid dose mixing wall231in the reaction chamber23acts as a primary mixing zone for liquid doses input to the mixing apparatus14, wherein the reaction chamber23is a cylindrical container or a container of other shapes, and the invention is not limited thereby. Each liquid dose is sprayed, in mists of water fog, evenly on the surface of the liquid dose mixing wall231and is mixed in a layer-by-layer (coating-to-coating) manner, and therefore each liquid dose can mix evenly and react in a short time under the circumstance of high mix proportion/ratio. Subsequently, the tiny spray mists of each liquid dose combine to form larger droplets, and then the droplets merge and thereafter flow along the wall surface into the end mixer for a second mixing.

The surface of the liquid dose mixing wall231is a smooth surface. The liquid dose mixing wall231is made of polytetrafluoroethylene (PTFE), other fluorine-based materials, or other corrosion-resistant and thermal-resistant hydrophobic materials, or is coated or plated with polytetrafluoroethylene (PTFE), other fluorine-based materials, or other corrosion-resistant and thermal-resistant hydrophobic materials on the surface. Since the surface is hydrophobic, each liquid dose being sprayed on the surface of the liquid dose mixing wall231and being mixed is quickly flown down through natural paths to the end mixer24connected at the end of the reaction chamber23. The smooth surface is a seamless smooth surface or a smooth surface with seams or slits, wherein the seamed/slitted smooth surface further includes at least one drainage pattern.

Optionally, when the surface of the liquid dose mixing wall231is a seamed/slitted smooth surface, it may have different drainage patterns2311-2314as shown inFIGS. 4A to 4D, whereby after each liquid dose has been mixed on the surface of the liquid dose mixing wall231, the liquid doses are guided by the drainage patterns2311-2314and drained quickly to the end mixer24connected to the end of the reaction chamber23. InFIGS. 4A to 4D, the drainage patterns2311-2314are formed by processing or incised inscription and are, respectively, a polygonal-bump pattern, polygonal being triangular, quadrilateral, pentagonal, or hexagonal, a circular-bump pattern like bumps with circular or oval shape, an elongated-bump pattern, and a wave or curved pattern, but the invention is not limited thereby.

The drainage patterns2311-2314are uniformly or non-uniformly distributed on the surface of the liquid dose mixing wall231, and can be arranged in any combination thereof, for instance, disposing the drainage patterns2311and2312alternately on the surface of the liquid dose mixing wall231. It is to be noted that according to the types of different liquid doses, different drainage patterns are designed to enhance the mixing effect and to reduce reaction time.

On the contrary, the surface of the liquid dose mixing wall231can also be a non-smooth surface. The selection of a smooth or a non-smooth surface for the liquid dose mixing wall231is based on the type of the different liquid doses to enhance the mixing efficiency. Other than that, the non-smooth surface can be a seamless non-smooth surface or a seamed/slitted non-smooth surface, wherein the seamed/slitted non-smooth surface further includes at least one of the aforementioned drainage patterns. In short, the designs of the liquid dose mixing wall231are not to be used to limit the invention, but relate to the types of the liquid doses and the requirements of the mixing efficiency. As for most mixings of different liquid doses, the seamed/slitted smooth surface design usually has a better mixing efficiency.

The end mixer24is used for a second mixing to enhance the mixing result. After the second mixing, the end mixer24transports the mixed preparation to the real-time monitoring device or the preparation output device. In some embodiments, the end mixer24is not an essential element. The end mixer24can be a non-powered and fixed mixer shown in5A, or a dynamic mixer shown inFIG. 5B.

The end mixer24is a static mixer inFIG. 5A, which has no moving parts and is composed of staggered fan blades241for forming a turbulent flow when the liquid doses pass through so as to mix the liquid doses for a second time. Since the static mixer does not have powered components, the cost is lower. InFIG. 5B, the end mixer24is a dynamic mixer with moving parts241, like a cutter wheel component, that rotates or stirs along and with the axis, which stirs the solid particles in the liquid doses, and thereby enhancing the mixing result and producing preparations with better quality.

In conclusion, the technical benefits of the mixing apparatus and the preparation production system using the same of the invention are:

1) conventional technology mixes the different liquid doses with a single point of entry and so cannot mix the liquid doses of large and small dosages evenly, but the invention provides a mixing apparatus that sprays the different atomized/refined liquid doses on the surface of the liquid dose mixing wall in the reaction chamber to mix the liquid doses in a layer-by-layer (coating-to-coating) manner, and thus the invention can evenly mix the liquid doses of large quantity and small quantity.

2) Each liquid dose in the conventional technology was not treated for distribution before being mixed and so needs to be stirred for a long time, but the mixing apparatus of the invention atomizes or refines the liquid doses for distribution and thus a uniform mixing is assured. And, optionally, an end mixer is disposed at an end of the reaction chamber for a second mixing and so a better mixing result in a short time is obtained.

3) In the conventional technology, a larger space is required for mixing and stirring and, due to poor mixing rate, a plurality of equipment units are required to operate simultaneously. The conventional technology may even need more equipment unit and pipelines with the setup of pre-treatment area and temporary storage area. In other words, issues like demanding for large space, high manufacturing cost, and inability to move the system, remain in the conventional technology. The mixing apparatus and the preparation production system of the invention can mix different liquid doses in a confined space and has a high mixing efficiency and a high mixing speed, so the pre-treatment area is not needed and thereby reducing the number of equipment units, the setup cost and the space occupied, and the aforementioned mixing apparatus and the preparation production system can be miniaturized for easy relocation or portability.

The above disclosure is only the preferred embodiment of the present invention, and not used for limiting the scope of the present invention. All equivalent variations and modifications on the basis of shapes, structures, features and spirits described in claims of the present invention should be included in the claims of the present invention.