Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
Patent Application
G. J. Shore
MICROWAVE REACTOR VESSEL
FIELD OF THE INVENTION
[001] The present invention relates generally to microwave assisted
apparatus for heating a media, more specifically but not by way of limitation,
a microwave reactor vessel that includes a wall having a microwave
sensitized element that is operable to produce heat with reduced power and
further functions to provide a homogeneous temperature profile across the
reactor vessel.
BACKGROUND
[002] Microwave reactors are known in the art and are utilized to apply
microwave radiation to a chemical reaction to a media disposed within the
reactor vessel. The application of microwave radiation to a reactor vessel
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results in the heating of the vessel and as such the media disposed therein
and the purpose thereof is to execute a desired organic synthesis.
Conventional synthesis methods will utilize other sources of heat such as but
not limited to an electric heater or a flame. These methods have proven to be
slow and inefficient as conventional heating is dependent upon thermal
conductivity. These conventional processes require a significant amount of
energy and have shown to produce inconsistent distribution of temperature
across the vessel and media disposed therein.
[003] The process of heating by microwave radiation is based on the remote
energy transfer to materials by dielectric heating with microwaves. The
irradiated materials absorb the microwave energy exposure and convert the
energy to heat. Various microwave reactor vessel exist and are constructed
from alternate materials. Conventional microwave reactor vessels are
manufactured from materials such as but not limited to quartz, ceramic and
certain types of glass such as but not limited to borosilicate glass. The
aforementioned exemplary construction of conventional microwave reactor
vessels result in a transparent to microwave irradiation and as such ensure
the energy transfer occurs in the media disposed within the vessel so as to
avoid the overheating of the vessel itself.
[004] There are two known types of microwave devices, multimode and
monomode devices. Multimode devices are similar to household microwave
ovens. Monomode microwave devices are more commonly utilized in
chemical and pharmaceutical applications. Monomode reactors have
relatively small interiors and the irradiation is directed by a rectangular or
circular waveguide onto the reactor vessel which is located a fixed distance
from the irradiation source. The two main factors that determine the
propensity of heat generation and distribution inside a microwave reactor
vessel are structural composition and penetration depth of microwaves.
[005] One problem with existing microwave reactor vessels is the material has
a non-homogeneous structural composition which results in a relatively
low penetration depth of microwaves. Existing structural compositions of
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microwave reactor vessels make it very difficult to achieve uniform heat
distribution inside the microwave irradiated media.
[006] Accordingly, there is a need for a microwave reactor vessel that
provides a superior structure for heating media disposed therein wherein
the microwave reactor wall includes a microwave sensitive element that the
heat thereof can be transferred to the media disposed within the reactor so
as to ensure a homogeneous temperature distribution.
SUMMARY OF THE INVENTION
[007] It is the object of the present invention to provide a microwave
reactor vessel having a structural composition configured to provide a
homogeneous temperature distribution of media disposed therein that
includes a microwave sensitized element in the wall of the reactor.
[008] Another object of the present invention is to provide a microwave
reactor vessel operable to facilitate chemical and/or non-chemical processes
by providing heat thereto wherein the heating of the microwave sensitized
element is transferred via conductivity to the media disposed within the
reactor vessel.
[009] A further object of the present invention is to provide a microwave
reactor vessel having a structural composition configured to provide a
homogeneous temperature distribution of media disposed therein wherein
the microwave sensitized element is comprised of a primary non-metal
carbide element and a secondary non-metal element.
[0010] Still another object of the present invention is to provide a
microwave
reactor vessel operable to facilitate chemical and/or non-chemical processes
by providing heat thereto wherein the secondary non-metal element is a
metal oxide.
[0011] An additional object of the present invention is to provide a
microwave reactor vessel having a structural composition configured to
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provide a homogeneous temperature distribution of media disposed therein
wherein the secondary non-metal element comprising the microwave
sensitized element could further be comprised of a ferrite or a nitride.
[0012] Yet a further object of the present invention is to provide a
microwave
reactor vessel operable to facilitate chemical and/or non-chemical processes
by providing heat thereto wherein the primary non-metal carbide element
comprises fifty to ninety-nine percent of the microwave sensitized element.
[0013] Another object of the present invention is to provide a microwave
reactor vessel having a structural composition configured to provide a
homogeneous temperature distribution of media disposed therein wherein
the microwave sensitized element further includes a thin metallic film
extending therethrough.
[0014] An alternative object of the present invention is to provide a
microwave reactor vessel operable to facilitate chemical and/or non-
chemical processes by providing heat thereto wherein the primary non-
metal element and the secondary non-metal element can be either solid or
granular in form.
[0015] An additional object of the present invention is to provide a
microwave reactor vessel having a structural composition configured to
provide a homogeneous temperature distribution of media disposed therein
wherein the secondary non--metal element is sized either equal to or less
than the primary non-metal element.
[0016] Yet a further object of the present invention is to provide a
microwave
reactor vessel operable to facilitate chemical and/or non-chemical processes
by providing heat thereto wherein the general formula for the primary non-
metal element is AnCm.
[0017] Another object of the present invention is to provide a microwave
reactor vessel having a structural composition configured to provide a
homogeneous temperature distribution of media disposed therein wherein
the secondary non-metal element has a general formula of at least one of the
following: Dg0p; LbFE204 or MzNy.
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[0018] To the accomplishment of the above and related objects the
present
invention may be embodied in the form illustrated in the accompanying
drawings. Attention is called to the fact that the drawings are illustrative
only. Variations are contemplated as being a part of the present invention,
limited only by the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] A more complete understanding of the present invention may be had
by reference to the following Detailed Description and appended claims
when taken in conjunction with the accompanying Drawings wherein:
[0020] Figure 1 is a side cross-sectional view of a microwave vessel
reactor
body of the present invention; and
[0021] Figure 2 is a cross-sectional view of the present invention; and
[0022] Figure 3 is a cut-away perspective view of an embodiment of the
present invention; and
[0023] Figure 4 is a cross-sectional view of the vessel reactor body of
the
present invention; and
[0024] Figure 5 is an exemplary temperature distribution of the reactor
vessel of the present invention; and
[0025] Figure 6 is a an exemplary embodiment of the present invention
with
an inner coil.
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DETAILED DESCRIPTION
[0026] Referring now to the drawings submitted herewith, wherein various
elements depicted therein are not necessarily drawn to scale and wherein
through the views and figures like elements are referenced with identical
reference numerals, there is illustrated microwave reactor vessel 100
constructed according to the principles of the present invention.
[0027] An embodiment of the present invention is discussed herein with
reference to the figures submitted herewith. Those skilled in the art will
understand that the detailed description herein with respect to these figures
is for explanatory purposes and that it is contemplated within the scope of
the present invention that alternative embodiments are plausible. By way of
example but not by way of limitation, those having skill in the art in light
of
the present teachings of the present invention will recognize a plurality of
alternate and suitable approaches dependent upon the needs of the
particular application to implement the functionality of any given detail
described herein, beyond that of the particular implementation choices in the
embodiment described herein. Various modifications and embodiments are
within the scope of the present invention.
[0028] It is to be further understood that the present invention is not
limited
to the particular methodology, materials, uses and applications described
herein, as these may vary. Furthermore, it is also to be understood that the
terminology used herein is used for the purpose of describing particular
embodiments only, and is not intended to limit the scope of the present
invention. It must be noted that as used herein and in the claims, the
singular
forms "a", "an" and "the" include the plural reference unless the context
clearly dictates otherwise. Thus, for example, a reference to "an element" is
a
reference to one or more elements and includes equivalents thereof known
to those skilled in the art. All conjunctions used are to be understood in the
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most inclusive sense possible. Thus, the word "or" should be understood as
having the definition of a logical "or" rather than that of a logical
"exclusive
or" unless the context clearly necessitates otherwise. Structures described
herein are to be understood also to refer to functional equivalents of such
structures. Language that may be construed to express approximation should
be so understood unless the context clearly dictates otherwise.
[0029] References to "one embodiment", "an embodiment", "exemplary
embodiments", and the like may indicate that the embodiment(s) of the
invention so described may include a particular feature, structure or
characteristic, but not every embodiment necessarily includes the particular
feature, structure or characteristic.
[0030] Referring in particular to Figures 1 and 2 the microwave reactor
vessel 100 includes body 10. The body 10 is manufactured from a suitable
material for conducting chemical and/or non-chemical processes wherein
the body 10 is subjected to various microwave radiation as part of a chemical
and/or non-chemical processes. It should be understood within the scope of
the present invention that the body 10 could be formed in various sizes and
shapes and the dimensions of the body are not subject to minimal or maximal
requirements other than that required by the process. It should be further
understood that the body 10 could be constructed as a flow-through reactor
wherein the materials traverse through the interior volume 9 of the body 10
from a first end 7 to a second end 8 or as enclosed reactor wherein materials
are deposited within the interior volume 9 of the body 10 and remain therein
during the course of the chemical and/or non-chemical processes. The body
includes an exterior wall 12. The exterior wall 12 is constructed to receive
direct microwave irradiation, which provides heat in order to facilitate the
desired chemical and/or non-chemical processes. The exterior wall 12 is
manufactured from microwave transparent materials so as to facilitate the
passage of the microwave irradiation therethrough to subsequent layers of
the body 10 as will be further discussed herein. It is contemplated within the
scope of the present invention that the exterior wall 12 could be
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manufactured from numerous materials in order to accomplish the foregoing
stated objective. By way of example but not limitation, the exterior wall 12
could be manufactured from materials such as: borosilicate glass, quartz,
fiberglass, plexiglass, ceramic, ceramic fiber, carbon fiber, calcium silicate
or
Teflon.
[0031] Adjacent to
the exterior wall 12 is a microwave sensitized element
layer 20. The microwave sensitized element layer 20 includes first layer 25
and second layer 35 manufactured from a mixture of first material and a
second material. The microwave sensitized element layer 20 further includes
a metal film layer 30. As will be further discussed herein, it should be
understood that alternate configurations of construction of the microwave
sensitized element layer 20 are within the scope of the present invention that
could be organized into a first layer and second layer only. The first layer
25
and second layer 35 are manufactured from a mixture of a first material and
a second material wherein the first material is a carbide. The first material
of
the present invention is a carbide having the general formula of AnCm. N and
M in the general formula for the carbide mixture are full integers such as but
not limited to 1,2 and 3. The C in the general formula represents carbon
while the A could be comprised of various elements. It is contemplated
within the scope of the present invention that the A could represent the
following elements: Si, Mg, Ti, Al, Fe, W, Cr and B. It should be understood
that the first material of the present invention could be produced in either a
solid or granular form. A preferred embodiment of the first material of the
present invention is granular and is discussed herein for exemplary
purposes. The first material is desired as disclosed as carbides have the
required semi-conductive properties and provide excellent absorption of
electromagnetic energy to produce heat. Additionally, carbides are efficient
heat conductors. Microwave penetration depth of carbides at ambient
temperature can range from 2 millimeters to over 5 centimeters depending
upon purity and structure of the carbide. As higher temperatures result in
lower microwave penetration depth due to the conductivity of carbides, the
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Patent Application
G. J. Shore
second material to create the carbide mixture of the first layer 25 and second
layer 35 is required to provide the desired functionality of the present
invention discussed herein.
[0032] The first
layer 25 and second layer 35 of the microwave sensitized
element layer 20 further includes a second material that forms the mixture of
the present invention which comprises the first layer 25 and second layer 35.
The second material mixed with the carbide to form the first layer 25 and
second layer 35 is comprised of at least one of the following general
formulas: Dg0p; LbFE204 or MzNy. It is desired within the scope of the present
invention that the particle size of the second material is less than that of
the
particle size of the first material when constructed in granular form. A
particle size of the second material that is less than that of the particle
size of
the first material functions to fill the void intermediate the particles of
the
first material. The aforementioned particle size of the second material
provides a construction of the first layer 25 and second layer 35 that
functions to minimize microwave reflection from the carbide particles. If
carbide particles become reflective, then they will serve as a barrier to
microwave energy, preventing the microwave energy from penetrating further
inside the microwave sensitized element. The penetration depth of microwave
irradiation will be significantly decreased, causing only a narrow layer of
the
microwave sensitized element to be heated. The energy efficiency of the device
can also decrease significantly since a considerable part of the irradiation
will be
reflected off, instead of being transformed into heat. Further the benefits of
the
described construction of the carbide mixture of the present invention are
improved microwave absorption, heat generation and distribution upon
exposure to microwave irradiation as the second material is microwave
active. The second material and its aforementioned particle size functions to
substantially eliminate any void volume present in the first layer 25 and
second layer 35. Elimination of void volume provides improved structural
stability and microwave absorption, which provides improved energy
efficiency of the microwave reactor vessel 100. The second material of the
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mixture of the present invention utilized to construct the first layer 25 and
second layer 35 minimize microwave reflection from the carbides and add to
the heat generation.
[0033] As previously stated herein the second material is comprised
of at
least one of the following general formulas: Dg0p; LbFe204 or MzNy. DgOp is a
metal oxide where G and P are full integers. D represents one of the
following elements: Co, Cr, Fe, Mn, Ni, Al or Ca and 0 represents oxygen. A
second embodiment of the second material is LbFe204. The second
embodiment of the second material is a ferrite where L represent one of the
following elements: Mn, Ni, Cu, Zn, Mg, Co and Fe represents iron. 0
represent oxygen and B is a full integer such as but not limited to 1,2 or 3.
A
third embodiment of the second material is a nitride having the general
formula of MzNy. Z and Y are full integers such as but not limited to 1, 2 or
3.
M represents on of the following elements: Cr,A1, Mg, Ca, Si, B, Ti or N. N
represents nitrogen.
[0034] The percentages of the first material within the mixture
creating the
first layer 25 and second layer 35 ranges from fifty to ninety-nine percent by
weight. The construction of the microwave sensitized element layer 20 is
such that the thickness of the first layer 25 and second layer 35 combined
could range from ten microns to ten centimeters. As will be further discussed
herein the microwave sensitized element layer 20 includes metal film layer
30 and depending upon the positioning thereof the first layer 25 and second
layer 35 could be combined to form a single layer as an alternate
configuration of the first layer 25 and second layer 35 discussed herein. The
thickness and composition of the first layer 25 and second layer 35 is
adjusted to produce a desired amount of heat upon exposure to microwave
irradiation. The distribution of the heat produced by the microwave
sensitized element layer 20 is homogeneous and a temperature plot of the
body 10 is provided in Figure 5 herein.
[0035] The microwave sensitized element layer 20 further includes a
metal
film layer 30. The metal film layer 30 is a thin metallic film having a
uniform
Date Recue/Date Received 2020-09-08
Patent Application
G. J. Shore
thickness and extends the entire length of the body 10. It is contemplated
within the scope of the present invention that the metal film layer 30 can be
prepared utilizing various suitable methods such as but not limited to
vacuum vapor deposition or chemical deposition, or it can be obtained
through manufacturing process using available metal works technologies. The
metal film layer 30 can be positioned within the microwave sensitized
element layer 20 in alternate positions with the exemplary positioning
illustrated herein being disposed so as to create a first layer 25 and second
layer 35 of generally equal thicknesses on opposing sides of the metal film
layer 30. It is contemplated within the scope of the present invention that
the
metal film layer 30 could be positioned in alternate positions as previously
discussed herein. The metal film layer 30 is manufactured in either a mesh or
solid construction and has a thickness ranging from 200 nanometers to 200
microns. The metal film layer 30 is manufactured from a suitable metal such
as but not limited to titanium, tungsten, steel or suitable metal alloys. It
is
contemplated within the scope of the present invention that the metal film
layer 30 could be placed in only a portion of the microwave sensitized
element layer 20 as desired for particular applications. The metal film layer
30 could be formed in various configuration such as but not limited to strips,
wires arranged either parallel or perpendicular to the axis of the microwave
reactor vessel 100. The metal film layer 30 is placed at the end of the
microwave penetration depth of the carbide mixture of the present invention
and functions to provide heat amplification over and above the amount of heat
generated by the carbide mixture and prevent further penetration of the
microwave irradiation so as to prevent the microwave irradiation from
contacting the inner layer 40 or the interior volume 9 and materials disposed
therein. The penetration depth of the carbide mixture of the present
invention is the distance at which the intensity of the microwave irradiation
falls below 1/e, where e is equal to 2.71828 or approximately thirty seven
percent of the generated intensity. It should be recognized by those skilled
in
the art that the penetration depth will vary based upon the percentages of
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the first material and second material. By way of example but not limitation,
if a higher temperature is required for the microwave reactor vessel 100 the
metal film layer 30 is positioned within the microwave sensitized element
layer 20 closer to microwave irradiation source. Both the above mentioned
non-metal carbide mixture and thin metallic films are capable of generating
heat
under microwave irradiation conditions when used separately. However the
combination of both elements under the same design can provide the best
results by eliminating any shortcomings associated with separate application
of
these elements. A non-metal carbide mixture by itself requires a considerable
amount of time and microwave power to generate an appreciable amount of
heat and therefore temperature for the system under microwave irradiation.
Alternatively, a thin metallic film under microwave irradiation can generate a
profuse amount of heat in just seconds requiring a minimal amount of
microwave power, however the metallic film can be prone to violent electrical
discharges/arcing in the microwave chamber ultimately causing significant
damage to the device. Application of both these elements utilized in
combination
ensures the reliability of the system and achievement of very high
temperatures
with minimal microwave power. The majority of the microwave power is absorbed
by the non-metal carbide mixture allowing the thin metal film to absorb a
reduced amount of microwave irradiation that will nevertheless contribute to a
fast
generation of heat. The metal film is isolated within the non- metal carbide
mixture in an almost air-tight environment so as to significantly reduce the
occurrence of electrical arcing. Any incidental arcing can then be absorbed by
the
carbide mixture particles in contact with the metal film layer.
Very high temperatures can be achieved in the matter of seconds using the
design of the present invention.
[0036] The body 10
further includes an inner layer 40 that is adjacent the
interior volume 9. The inner layer 40 is in direct contact with any materials
disposed in or flowing through the interior volume 9. The main function of
the inner layer 40 is to transfer the heat of the microwave sensitized element
layer 20 the materials within the interior volume 9. The inner layer 40 is
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constructed from materials such as but not limited to borosilicate glass,
quartz, fiberglass, plexiglass, ceramic, ceramic fiber, carbon fiber, calcium
silicate, Teflon, stainless steel, aluminum or other metal alloys.
[0037] While not particularly illustrated herein, it is contemplated
within the
scope of the present invention that the body 10 could be partially or
completely covered with a thermal insulation material to reduce heat loss to
the environmental surroundings and provide a means for an individual to
grasp the microwave reactor vessel 100. As shown in Figure 6 herein, the
microwave reactor vessel 100 could be provided in an alternative
embodiment wherein the interior volume 9 has a inner coil 5 constructed to
have materials disposed therein. The construction of the body 10 is identical
to what has been disclosed herein with the exception that the metal film
layer 30 is placed adjacent to the interior volume 9 and the first material
and
second material utilized to create the carbide mixture of the present
invention is disposed intermediate the metal film layer 30 and the exterior
wall 12. It should be understood by those skilled in the art that the
microwave reactor vessel 100 could be utilized in numerous applications. By
way of example but not limitation, the microwave reactor vessel 100 could
be utilized to thermally treat waste for biofuel production,
beverage/milk/juice pasteurization and ultra high temperature treatment, DNA
amplification or saline/brackish water desalination via distillation. The
microwave reactor vessel 100 is constructed to be suitable for any available
microwave frequency, including radio frequency, and could be used in
multimode or monomode methods.
[0038] It is further contemplated within the scope of the present
invention that
the body 10 could be constructed so as to provide a temperature gradient
across
the length thereof. In order to generate a temperature gradient throughout the
length of the body 10 several microwave sensitized elements of different
length,
composition and also containing metal film layers of different thickness can
be
placed adjacent to each other. This arrangement can generate a non-uniform
temperature profile, thus producing a temperature gradient throughout the
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length of the body 10 as required by a specific process. Another preferred
arrangement would be to place two or more identical microwave sensitized
elements placed at a certain distance from each other so as to allow
subsequent
cooling of materials after being heated in the reactor zone covered by the
first
microwave sensitized element, then heated again when reaching the portion of
the body 10 covered by the second microwave sensitized element. Any preferred
heating-cooling patterns can be achieved in this way by alternating the
position
of microwave sensitized elements.
[0039] In the preceding detailed description, reference has been made to
the
accompanying drawings that form a part hereof, and in which are shown by
way of illustration specific embodiments in which the invention may be
practiced. These embodiments, and certain variants thereof, have been
described in sufficient detail to enable those skilled in the art to practice
the
invention. It is to be understood that other suitable embodiments may be
utilized and that logical changes may be made without departing from the
spirit or scope of the invention. The description may omit certain
information known to those skilled in the art. The preceding detailed
description is, therefore, not intended to be limited to the specific forms
set
forth herein, but on the contrary, it is intended to cover such alternatives,
modifications, and equivalents, as can be reasonably included within the
spirit and scope of the appended claims.
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