Apparatus, systems and methods for producing particles using rotating capillaries

Abstract

An apparatus for forming particles from a liquid, including a rotor assembly having at least one surface sized and shaped so as to define at least one capillary. Each capillary has an inner region adjacent an axis of rotation of the rotor assembly, an outer region distal from the axis of rotation, and an edge adjacent the outer region. The rotor assembly is configured to be rotated at an angular velocity selected such that when the liquid is received in the inner region of the at least one capillary, the liquid will move from the inner region to the outer region, adopt an unsaturated condition on the at least one surface such that the liquid flows as a film along the at least one surface and does not continuously span the capillary, and, upon reaching the edge, separates from the at least one surface to form at least one particle.

1 .- 26 . (canceled) 
     
     
         27 . A method for forming particles, comprising the steps of:
 a. providing at least one surface sized and shaped so as to define at least one capillary, said capillary having an inner region, an outer region, and an edge;   b. providing a liquid to the inner region of the at least one capillary; and   c. rotating the capillary at an angular velocity selected such that the liquid will move from the inner region to the outer region, adopt an unsaturated condition on the at least one surface such that the liquid flows as a film along the at least one surface and does not continuously span the capillary, and, upon reaching the edge, separates from the at least one surface to form at least one particle.   
     
     
         28 .- 54 . (canceled) 
     
     
         55 . The method of  claim 27 , wherein the particles are droplets. 
     
     
         56 . The method of  claim 55 , further comprising the step of mixing the droplets with at least one gas. 
     
     
         57 . (canceled) 
     
     
         58 . The method of  claim 56 , wherein the liquid includes a fuel and the gas includes oxygen, and further comprising the step of igniting the mixture in a combustion chamber. 
     
     
         59 .- 75 . (canceled) 
     
     
         76 . A method for emulsifying at least two immiscible liquids, comprising the steps of:
 a. providing at least one surface sized and shaped so as to define at least one capillary, said capillary having an inner region and an outer region;   b. providing the at least two immiscible liquids to the inner region of the at least one capillary; and   c. rotating the capillary at an angular velocity selected so as to generate shear forces within the capillary sufficient so that, as the at least two liquids move from the inner region to the outer region, the at least two immiscible liquids undergo shear and are mixed together.   
     
     
         77 . The method of  claim 76 , wherein the step of providing at least one surface sized and shaped so as to define at least one capillary includes providing a rotor assembly including two plates having opposing upper and lower surfaces spaced apart by a gap distance to define at least one capillary therebetween. 
     
     
         78 . The method of  claim 77 , wherein the angular velocity and plate diameter are selected such that the diameter of the plate times the rate of rotation is between about 10,000 cm·RPM and 1.4 million cm·RPM. 
     
     
         79 . The method of  claim 77 , wherein the angular velocity and plate diameter are selected such that the diameter of the plate times the rate of rotation is less than about 1.4 million cm·RPM. 
     
     
         80 . The method of  claim 77 , wherein the angular velocity and plate diameter are selected such that the diameter of the plate times the rate of rotation is greater than about 10,000 cm·RPM. 
     
     
         81 . A system for producing products, comprising:
 a. at least one apparatus for forming particles from a liquid, each apparatus having:
 i. a rotor assembly having at least one surface sized and shaped so as to define at least one capillary, each capillary having an inner region adjacent an axis of rotation of the rotor assembly, an outer region distal from the axis of rotation, and an edge adjacent the outer region; 
 ii. wherein the rotor assembly is configured to be rotated at an angular velocity selected such that when the liquid is received in the inner region of the at least one capillary, the liquid will move from the inner region to the outer region, adopt an unsaturated condition on the at least one surface such that the liquid flows as a film along the at least one surface and does not continuously span the capillary, and, upon reaching the edge, separates from the at least one surface to form at least one particle; and 
   b. a collection device for receiving the at least one particle.   
     
     
         82 . (canceled) 
     
     
         83 . (canceled) 
     
     
         84 . (canceled) 
     
     
         85 . (canceled) 
     
     
         86 . A product formed using the system of  claim 81 . 
     
     
         87 . The product of  claim 86 , wherein the product is configured to be used as at least one of the following:
 a. an air filter;   b. an acoustic barrier; as a chemical and particulate interceptor;   c. as an absorbant material; and   d. as a thermally insulating material.   
     
     
         88 . The product of  claim 86 , further comprising at least one additive. 
     
     
         89 . The product of  claim 88 , wherein the additive is a binder. 
     
     
         90 . The product of  claim 88 , wherein the additive comprises carbon. 
     
     
         91 . The product of  claim 88 , wherein the additive comprises zeolite. 
     
     
         92 . A cylindrical member formed by winding any one of the products as claimed in  claim 86 . 
     
     
         93 . The cylindrical member of  claim 92  further comprising a compressed central core region. 
     
     
         94 . A system for textile manufacturing, comprising:
 a. at least one apparatus for forming particles from a liquid, each apparatus having:
 i. a rotor assembly having at least one surface sized and shaped so as to define at least one capillary, each capillary having an inner region adjacent an axis of rotation of the rotor assembly, an outer region distal from the axis of rotation, and an edge adjacent the outer region; 
 ii. wherein the rotor assembly is configured to be rotated at an angular velocity selected such that when the liquid is received in the inner region of the at least one capillary, the liquid will move from the inner region to the outer region, adopt an unsaturated condition on the at least one surface such that the liquid flows as a film along the at least one surface and does not continuously span the capillary, and, upon reaching the edge, separates from the at least one surface to form at least one fiber; and 
   b. a processing device for receiving the at least one fiber.   
     
     
         95 . The system of  claim 94 , wherein the at least one apparatus includes a first apparatus configured to provide a first fiber and a second apparatus configured to provide a second fiber. 
     
     
         96 . The system of  claim 95 , wherein the processing device is a spinner configured to receive the first fiber and the second fiber and to generate a yarn therefrom. 
     
     
         97 . The system of  claim 96 , wherein the first fiber comprises a first material, the second fiber comprises a second material, and the yarn is a blend of the first material and the second material. 
     
     
         98 .- 111 . (canceled)