Method and system for generating air tip type dry fog nano jet spray

Abstract

The invention relates to a spraying device used as an air tip type dry fog nano jet spraying device. The spraying device comprises a liquid channel, a gas channel and an acoustic structure. The liquid channel is configured to deliver a flow of liquid, convert the flow of liquid into a vortex flow, and discharge the vortex flow via a first outlet. The gas channel further includes a tapered section coupled to the second outlet. The tapered section is configured to convert a gas flow into a supersonic gas jet for release from the gas passage via the second outlet. The acoustic structure is configured to control dispersion of a mixture of the supersonic gas jet and the vortex flow and reduce a noise level of the spray device.

Description

[0001] Related Applications This application is a continuation of International Patent Application No. PCT / US24 / 25231, filed on April 18, 2024, entitled “Methods and Systems for Generating Aerospike Dry Fog Nanojet Spray,” which claims priority to U.S. Provisional Application No. 63 / 531,044, filed on August 7, 2023, entitled “Reduced-Noise Aerospike Dry fog Nanojet for Generating Spray with High Flow Rate and Ultrafine Droplet at Low Operation Pressure,” which is incorporated by reference in its entirety. Technical Field

[0002] The present application relates generally to spray devices, including but not limited to methods and systems for producing air-spike dry mist sprays. Background Art

[0003] Spraying devices are widely used in different applications to build mist generation systems. For example, a two-fluid atomizing spraying device includes a spraying device body with two separate channels (one channel for liquid and one channel for gas), and encounters the challenge of achieving both high flow rate and ultra-fine mist particles at low operating pressure. It is difficult for a two-fluid atomizing spraying device to consistently produce fine droplets in various industries and meet the required effectiveness. Alternatively, a pre-filming spraying device includes two air inlets (e.g., an inner air inlet and an outer air inlet) and a water inlet between the air inlets. Water enters through the water inlet and flows through a narrow gap, thereby forming a thin water sheet that is segmented into water filaments and accelerated by an air flow from the inner air inlet. The mixture of water and air flows downstream and interacts with another air flow from the outer air inlet. The pre-filming spraying device relies on a thin liquid film to produce fine droplets, thereby producing inconsistent droplet sizes. This inconsistency hinders the precise control of spraying characteristics and affects the effectiveness of the spraying device and any associated mist generation system. Furthermore, pre-filming spray devices are sensitive to the characteristics of the liquid being sprayed and can only be used in limited applications. Summary of the invention

[0004] Some embodiments of the present application are directed to an air-tip dry mist nano-jet spraying device, which utilizes air-tip and supersonic air flow to produce trillions of high-speed and ultra-fine nano droplets (e.g., liquid mist) at high flow rates and low operating pressures. The liquid mist made of fine liquid droplets exhibits fine droplet sizes of nanometer or micrometer scale. Specifically, a large volume of liquid mist is produced at a high flow rate in a short duration to effectively and quickly cover a large area. In some embodiments, the spraying device further includes or is coupled to a three-dimensional sawtooth structure (e.g., sawtooth edge, V-shaped edge) at the orifice of the spraying device to control the noise generated during the process of generating liquid mist by the spraying device. By these means, the spraying device can effectively produce high-speed and low-pressure liquid mist with fine droplet size to meet the requirements of various applications (e.g., air purification, disinfection, sterilization, dust suppression, painting, fuel injection, material coating, and cooling) in different industries (including but not limited to health care, agriculture, transportation, construction, power generation industry, and household use).

[0005] More specifically, in some embodiments, the spraying device produces ultrafine droplet sizes mainly in the nanometer range. Ultrafine droplets have a large surface to volume ratio, thereby resulting in an improvement in atomization and an increase in the contact area with the target surface. This improves the processing efficiency of the application including coating, humidification and insecticide. In some embodiments, the spraying device operates at a low operating pressure, which reduces the energy consumption and operating cost of the spraying device compared to many other spraying devices using higher operating pressures. Low operating pressure minimizes the risk of damaging precision surfaces and / or materials, and is suitable for applications that require gentle handling. In some embodiments, the spraying device includes a three-dimensional sawtooth structure configured to reduce the noise generated during the atomization process. The sawtooth structure further includes a streamwise vortex coupled in a shear layer between a high-speed spraying device flow and a slow ambient air flow. The sawtooth structure smoothes and disrupts the liquid mist flow, thereby reducing both the turbulence in the flow and the noise generated by the turbulence and enhancing the user experience of the spraying device with a quieter operating environment.

[0006] In various embodiments of the present application, the spray device operates with a combination of high flow rate, ultra-fine droplet size and low operating pressure, thereby providing an air-tip flow pattern that allows faster and more comprehensive spatial coverage, reduced material waste, enhanced spray quality and improved process performance. The application of such a spray device improves the efficiency and effectiveness of producing a mixture of liquid and gas.

[0007] In one aspect of the present application, a spraying device includes a first shell structure, a second shell structure, and a gas channel. The first shell structure includes a liquid channel. The liquid channel is configured to convey a liquid flow, convert the liquid flow into a vortex liquid flow, and discharge the vortex liquid flow from the first shell structure via a first outlet. The second shell structure surrounds the first shell structure. The gas channel is formed between the first shell structure and the second shell structure. The gas channel further includes a tapered section coupled to the second outlet. The tapered section has a variable width that continuously decreases relative to the length of the extended section. The tapered section is configured to convert the gas flow into a supersonic gas jet to be released from the gas channel via the second outlet.

[0008] In another aspect of the present application, a method is implemented to provide a spraying device. The method includes providing a first housing structure including a liquid channel, and the liquid channel is configured to convey a liquid flow, convert the liquid flow into a vortex liquid flow, and discharge the vortex liquid flow from the first housing structure via a first outlet. The method further includes: providing a second housing structure surrounding the first housing structure; and providing a gas channel formed between the first housing structure and the second housing structure. The gas channel further includes a tapered section coupled to the second outlet. The tapered section has a varying width that continuously decreases relative to the length of the extended section, and is configured to convert the gas flow into a supersonic gas jet to be released from the gas channel via the second outlet.

[0009] In another aspect of the present application, a method is implemented by a spraying device for generating a nanojet spray. The method includes: conveying a liquid flow in a liquid channel of a first shell structure; converting the liquid flow into a vortex liquid flow; and discharging the vortex liquid flow from the first shell structure via a first outlet of the liquid channel. The method further includes converting the gas flow into a supersonic gas jet to be released from the gas channel via a second outlet of the gas channel. The gas channel is formed between the first shell structure and a second shell structure surrounding the first shell structure, and includes a tapered section coupled to the second outlet, and the tapered section has a variable width that continuously decreases relative to the length of the extended section.

[0010] Mentioning these illustrative aspects does not limit or define the present disclosure, but rather provides examples to aid understanding of the present disclosure.Additional implementations are discussed in the detailed description, and further description is provided therein. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a better understanding of the various described embodiments, reference should be made to the following embodiments in conjunction with the following drawings, wherein like reference numerals refer to corresponding parts throughout the several views.

[0012] Figure 1A FIG. 4 is a cross-section of a first example spray device of a mist generating system according to some embodiments.

[0013] Figure 1B FIG. 4 is another cross-section of a first example spray device labeled with geometric parameters according to some embodiments.

[0014] Figure 2A is an exploded perspective view of a three-dimensional cross-section of a second example spray device according to some embodiments.

[0015] Figure 2B is a cross-sectional view of a three-dimensional cross-section of a second example spray device according to some embodiments.

[0016] Figure 2C A perspective view, a top view, and a bottom view are depicted of a scroll assembly according to some embodiments.

[0017] Figure 3 is a flow chart of an example method of providing a spray coating apparatus according to some embodiments.

[0018] Like reference numerals refer to corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0019] Reference will now be made in detail to various implementations, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described implementations. However, it will be apparent to one of ordinary skill in the art that the various described implementations may be practiced without these specific details. In other cases, well-known methods, procedures, components, circuits, and networks are not described in detail to avoid unnecessarily obscuring aspects of the implementations.

[0020] Some embodiments of the present application are directed to an air-tip dry mist nano-jet spraying device configured to produce ultra-fine droplets at a high flow rate and low inlet pressure without using moving components, for example. The nano-jet spraying device can be streamlined so that the streamlined nano-jet spraying device can reduce the pressure required to atomize the liquid. The streamlined nano-jet spraying device produces an air tip near the outlet of the spraying device, thereby allowing the initial droplets to collapse. In some cases, a supersonic air flow is induced around the air tip, causing the secondary droplets to collapse and atomize the liquid into micron-sized or nano-sized mist droplets. The mist droplets are then discharged through the spraying device to form a high-flow dry mist. In addition, in some embodiments, the spraying device is used together with an acoustic structure (e.g., an acoustic shielding member having a three-dimensional sawtooth structure). The acoustic structure smoothes the mixture of high-speed flow and slow ambient air flow discharged from the spray device, for example by introducing streamwise vortices into the shear layer, and effectively reduces the noise level of the spray device without compromising the performance of the spray device in mist generation.

[0021] Figure 1A is a cross-section 140 - 1 of a first example spraying device 100 of a mist generating system according to some embodiments, and Figure 1B 140 - 2 is another cross-section of the first example spraying device 100 marked with geometric parameters according to some embodiments. The first example spraying device 100 represents an embodiment of an air-tip dry mist nano jet spraying device. The first example spraying device 100 includes a first shell structure 102 and a second shell structure 104. The first shell structure 102 includes a liquid channel 106 (e.g., a streamlined liquid channel). The liquid channel 106 is configured to convey a liquid stream 150 (e.g., received from a liquid inlet), convert the liquid stream 150 into a vortex liquid stream 154, and discharge the vortex liquid stream 154 from the first shell structure 102 via a first outlet 112. The second shell structure 104 surrounds the first shell structure 102. A gas channel 108 (e.g., a streamlined gas channel) is formed between the first shell structure 102 and the second shell structure 104. The gas channel 108 further includes a tapered section 110 coupled to the second outlet 114. The tapered section 110 has a length relative to the extension section ( L taper )Continuously decreasing tapered width ( W taper ). The tapered section 110 is configured to convert the gas flow 152 (eg, air inlet) into a supersonic gas jet 156 for release from the gas passage 108 via the second outlet 114. In some embodiments, the first shell structure 102 and the second shell structure 104 are coupled to each other using a threaded connection.

[0022] In some embodiments, the extended section length ( L taper ) is within a predetermined length range. The tapered width ( W taper ) is within a predetermined width range. The volume flow rate of the gas channel 108 is within a predetermined flow rate range. In some embodiments, the predetermined length range is greater than 1 mm. The predetermined width range is greater than 0.01 mm. The predetermined flow rate range is greater than 10 liters per minute (L / min). In some embodiments, the extended section length ( L taper ) is configured to vary with a target flow rate associated with the gas channel 108. In some implementations, the liquid stream 150 and / or the gas stream 152 are mixed to form a converging gas tip mixture, and the droplet size of the liquid droplets of the mixture is in the range of 0.05 μm to 50 μm. Conversely, in some scenarios, the droplet size (e.g., diameter) of the liquid droplets of the mixture is less than 50 nm (e.g., equal to or less than 10 nm).

[0023] In some embodiments, the spraying device 100 has a central axis 180 ( Figure 1B ) and a plurality of cross sections intersecting therewith. Each cross section is symmetrical with respect to a corresponding intersection node with the central axis 180. In one example, a cross section cutting through the area near the first outlet 112 and the second outlet 114 AA Symmetrical with respect to a node 182 of intersection with the central axis 180 . In some implementations, the first shell structure 102 and the second shell structure 104 are substantially cylindrically symmetric along the central axis 180 .

[0024] In some embodiments, the outer surface 130 of the first housing structure 102 is conical and has a first angle ( θ 1), and the inner surface 134 of the second housing structure 104 is conical and has a greater angle than the first angle ( θ 1) The second angle ( θ 2). For example, the first corner ( θ 1) is within the first predefined range, and the second angle ( θ 2) Within a second predefined range.

[0025] In some embodiments, the gas channel 108 is formed between the outer surface 130 of the first housing structure 102 and the inner surface 134 of the second housing structure 104. The gas channel 108 is configured to increase the gas flow velocity of the gas flow 152. For example, the tapered width ( W taper) relative to the extension segment length ( L taper ) changes and continues to decrease. This structure allows the conical section 110 to convert the airflow 152 into a supersonic gas jet 156, so that the airflow velocity of the airflow 152 is enhanced through the conical section 110.

[0026] In some embodiments, the second outlet 114 of the gas channel 108 has a ring shape and substantially surrounds the first outlet 112 of the liquid channel 106. This is because the first housing structure 102 and the second housing structure 104 can be substantially cylindrically symmetrical. In some embodiments, the width ( W outlet_2nd ) is within a predetermined width range. In some embodiments, the predetermined width range may be greater than 0.01 mm. In some embodiments, the width ( W outlet_2nd ) are subject to design specifications (e.g., mechanical design, aerodynamics, etc.).

[0027] The first example spray device 100 further includes an air apex region 158 coupled proximate to both the first outlet 112 of the liquid channel 106 and the second outlet 114 of the gas channel 108. The air apex region 158 is configured to receive the vortex liquid flow 154 and the supersonic gas jet 156 and form a converging air apex mixture 160. As shown in FIG. 1 , the discharged vortex liquid flow 154 and the discharged supersonic gas jet 156 circulate in the air apex region 158 at a high flow rate relative to air flow dynamics, so that the air apex region 158 is in the form of an air apex.

[0028] In some embodiments, the droplet size of the liquid droplets (e.g., ultrafine droplets) of the converging air-tip mixture is in the range of 0.05 micrometers to 50 micrometers (µm). Conversely, in some contexts, the droplet size (e.g., diameter) of the liquid droplets of the mixture is less than 50 nm (e.g., equal to or less than 10 nm).

[0029] In some embodiments, the second housing structure 104 further includes an expansion portion 116 extending beyond the second outlet 114 of the gas channel 108. The expansion portion 116 is configured to confine the converging gas tip mixture 160 in the gas tip region 158 adjacent to the first outlet 112 of the liquid channel 106 and the second outlet 114 of the gas channel 108. Specifically, the expansion portion 116 is formed such that the width ( W 1) Narrower than the width of the bottom portion 116b of the extension portion 116 ( W2). The expansion portion 116 gradually narrows in the top portion 116a and expands in the bottom portion 116b, thereby confining the converging gas tip mixture 160 in the gas tip region 158.

[0030] The first example spray device 100 further includes an acoustic structure 118 coupled to the second housing structure 104. The acoustic structure 118 is configured to generate a streamlined conical coaxial gas channel 120, control the dispersion of the mixture of the supersonic gas jet 156 and the vortex liquid flow 154, and reduce the noise level of the first example spray device 100. In some embodiments, the acoustic structure 118 further includes a supersonic zone 162. The converging gas tip mixture 160 in the gas tip zone 158 includes a supersonic liquid mist 164 flowing at a high flow rate (e.g., above a flow rate threshold) in the supersonic zone 162. The supersonic liquid mist 164 is discharged from the acoustic structure 118. In some embodiments, the supersonic liquid mist 164 includes a plurality of liquid droplets having a diameter in the nanometer or micrometer range. For example, the diameter of the liquid droplets is 0.05 μm to 50 μm.

[0031] In some embodiments, the streamlined conical coaxial gas passage 120 of the acoustic structure 118 optimizes air flow dynamics and promotes the desired air tip flow pattern. The supersonic liquid mist 164 is accelerated to supersonic speeds, forming a spray device stream 166 that is discharged from the acoustic structure 118 and becomes a downstream apex. This promotes efficient liquid atomization for the production of ultra-fine droplets.

[0032] In some embodiments, the acoustic structure 118 has a sawtooth edge 122. The sawtooth edge 122 is a three-dimensional pattern and introduces a streamwise vortex 170 into a shear layer 172 between a spray device flow 166 at a high flow rate and an ambient air flow 168 at a low flow rate. The spray device flow 166 is the output of the supersonic liquid mist 164 discharged from the acoustic structure 118. Specifically, the streamwise vortex 170 disturbs and smoothes the spray device flow 166, thereby reducing the turbulence and noise generated during atomization. This brings the benefits of maintaining a quiet working environment and improving the user experience, solving problems related to occupational health and safety. In some embodiments, the sawtooth edge 122 is a V-shaped edge.

[0033] In some implementations, the design (e.g., geometry) of the first example spray device 100 including the acoustic structure 118 is changed to achieve similar benefits. For example, the acoustic structure 118 may include a curved or tapered gas passage rather than a conical coaxial gas passage. In another case, the acoustic structure 118 utilizes an alternative mechanism to produce the desired air tip flow pattern and supersonic flow. In yet another case, the first example spray device 100 includes an alternative geometry of the gas passage or an alternative method of introducing the streamwise vortex 170 into the shear layer 172 to reduce noise.

[0034] As discussed above, the air-tip dry mist nano-jet spraying device (e.g., a streamlined nano-jet spraying device) produces an air-tip zone 158, which includes a supersonic liquid mist 164 having a fine liquid droplet size. The liquid stream 150 and the air stream 152 are received at low pressure at the liquid channel 106 and the gas channel 108, and the supersonic liquid mist 164 is produced at a high flow rate. The first example spraying device 100 uses a streamlined gas channel (e.g., a streamlined conical coaxial gas channel 120 of a conical section 110 and an acoustic structure 118) to produce an air-tip zone and a supersonic zone 162 surrounded by an acoustic structure 118. Such a design avoids the need to use additional complex mechanical components within a single spraying device assembly. This can eliminate the necessity for precision manufacturing in some cases.

[0035] In addition, the air-tip dry mist nano-jet spraying device characterized by an acoustic sawtooth structure (e.g., sawtooth edge 122) also provides additional functional benefits, including but not limited to enhancing device efficiency, spraying performance, handling of sensitive materials, versatility and adaptability, and occupational health and safety. First, for efficiency enhancement, the streamlined gas channel of the spraying device produces an air-tip zone and a supersonic zone, and thus it enables the spraying device to operate at low pressure. Specifically, the ability to generate a spray with ultra-fine droplets at high flow rates enhances the efficiency of a variety of applications. On the one hand, this ability allows faster and more comprehensive coverage of the target surface, thereby reducing the total time required for spraying. On the other hand, this ability can also improve productivity and cutting costs, especially in applications where large areas and / or volumes need to be processed or coated.

[0036] In addition, the droplet collapse involves two steps to improve the spraying performance. In the initial step, the spraying device collapses the droplets from the water orifice (also called the outlet) with high turbulence in the air tip area. In the secondary step, the spraying device further reduces the droplet size by supersonic flow to form ultrafine droplets. Spraying ultrafine droplets can enhance the uniformity of coverage and cause excellent adhesion to the target object, thereby minimizing the risk of uneven distribution and / or missed areas. Therefore, the mist generation system air tip dry mist nano jet spraying device can enhance energy efficiency, reduce material waste and improve product performance in various applications including car painting, food processing and building disinfection.

[0037] In addition, to gently handle sensitive materials, the spraying device supports low operating pressure, thereby allowing the gentle handling of sensitive materials during spraying. Specifically, this ability adds value to industries (including medicine, food processing and cosmetics) where delicate substances or heat-sensitive formulations are the target objects to be sprayed. The gentle atomization process also alleviates the risk of material degradation, protects product integrity and quality. In addition, the spraying device further provides versatility and adaptability by generating a spray with ultra-fine droplets (e.g., diameters less than 1 μm), which are injected into the environment at a high flow rate. The spraying device can use a sawtooth structure for noise reduction. These capabilities ensure versatility and adaptability for various applications including agriculture, healthcare, sanitation and industrial manufacturing. These capabilities enhance the precise control of spraying features customized for specific application requirements and required performance. In addition, the spraying device provides occupational health and safety. The sawtooth structure for noise reduction addresses concerns related to occupational health and safety. This is because reducing noise levels will promote a safer operating environment and therefore prevent potential hearing damage to consumers. Therefore, the air-tip dry mist nano jet spray device is configured to operate at low pressure to produce a spray with ultra-fine droplets at a high flow rate while generating low or no noise, which brings advancement in spray technology in a wide range of applications.

[0038] Figures 2A to 2C A series of views are depicted of a second example spray device 200 of a mist generating system according to some embodiments. Figure 2A is an exploded perspective view of a three-dimensional cross-section 201 of a second example spray device 200 according to some embodiments. Figure 2B is a cross-sectional view of a three-dimensional cross-section 201 of a second example spray device 200 according to some embodiments. Figure 2C A perspective view, a top view, and a bottom view of a vortex assembly (eg, 202c) are shown according to some embodiments. Figure 2A , in some embodiments, the second example spraying device 200 represents another embodiment of the air-tip dry mist nano jet spraying device. Similar to the first example spraying device 100, the second example spraying device 200 produces a spray with a controlled droplet size at a higher flow rate. The second example spraying device 200 includes a vortex component for generating a vortex liquid flow 254. The second example spraying device 200 includes a first shell structure 202 and a second shell structure 204. The first shell structure 202 and the second shell structure 204 are symmetrical relative to the central axis 280 of the second example spraying device 200. The first shell structure 202 further includes a connecting component 202a, a delivery component 202b, a vortex component 202c and a central channel component 202d.

[0039] In some embodiments, the second example spray device 200 includes separate channels for liquid and air. The liquid channel 206 of the second example spray device 200 (e.g., a streamlined liquid channel along the second example spray device 200) includes five sections (e.g., first to fifth sections 210, 212, 214, 216, and 218) formed by the connection component 202a, the delivery component 202b, the swirl component 202c, and the central channel component 202d. The gas channel 208 of the second example spray device 200 (e.g., a streamlined gas channel along the second example spray device 200) includes one or more of the four sections (e.g., 230, 232, 234, 236) formed by the connection component 202a, the delivery component 202b, the central channel component 202d, and the second housing structure 204.

[0040] In some embodiments, the liquid channel 206 further comprises a first liquid channel segment 210 formed by the connecting component 202a. The first liquid channel segment 210 is connected to an external input pipe or tube ( Figure 2A 202c) for liquid feeding. Optionally, the gas channel 208 closes or exposes the first liquid channel section 210. The second liquid channel section 212 is formed by the delivery component 202b. The second liquid channel section 212 has a constant cross-sectional area and acts as a straight tube. In some embodiments, the liquid channel 206 further includes a second liquid channel section 212, which is used to adjust the uneven liquid flow from the external pipe or tube to a uniform flow before feeding into the vortex assembly 202c.

[0041] In some embodiments, the liquid channel 206 includes a third liquid channel segment 214 and a fourth liquid channel segment 216 (hereinafter referred to as Figures 2B to 2C 214b). For example, the vortex assembly 202c includes a plurality of recessed channels 214b. The vortex assembly 202c further includes an incoming channel portion 214a and an ejection path 214c. The vortex assembly 202c is configured to guide a liquid stream 250 into the incoming channel portion 214a, split the liquid stream 250 into a plurality of lateral streams 252 traveling in the plurality of recessed channels 214b, guide the plurality of lateral streams 252 toward the ejection path 214c, and form a vortex liquid stream 254 that is substantially stable when ejecting the ejection path 214c. In some embodiments, the third liquid channel segment 214 includes an incoming channel portion 214a and a plurality of recessed channels 214b. In some embodiments, the fourth liquid channel segment 216 is part of the ejection path 214c. The fifth liquid channel segment 218 is formed by the central channel assembly 202d. In some embodiments, the fifth liquid channel segment 218 includes a converging conical portion ( Figure 2A The fifth liquid channel section 218 further includes a first outlet 240 (see Figure 2B ). In addition, the fifth liquid channel section 218 enables the liquid flow to form a conical liquid spray 256 after ejecting the liquid channel 206 from the first outlet 240 (refer to Figure 2B ).

[0042] In some embodiments, the gas channel 208 includes a first gas channel segment 230 formed by the connecting component 202a and the delivery component 202b. The first gas channel segment 230 is connected to an external input pipe or tube ( Figure 2A 200) for air feeding. Optionally, the first gas channel section 230 is oriented parallel to the central axis 280 of the second example spraying device 200 or at a certain angle thereto. In some embodiments, the gas channel 208 includes a second gas channel section 232, which is formed by the delivery component 202b and acts as a distributor to fix the gas channel 208 at the middle position of the second example spraying device 200. Specifically, the second gas channel section 232 includes a plurality of pores uniformly distributed around the second gas channel section 232. The parameters of the pores (e.g., pore size, pore length, number of pores, etc.) are determined based on the design specifications of the air-tip dry mist nano-jet spraying device (e.g., the cross-sectional area of ​​the air flow). This will ensure sufficient air pressure to allow the air flow to pass through the gas channel 208. In addition, the cross-section of the pores may be circular or in other shapes.

[0043] In some embodiments, the gas channel 208 includes a third gas channel segment 234 and a fourth gas channel segment 236 formed by the central channel component 202d and the second housing structure 204 (see Figure 2B ). The third gas channel section 234 has a constant cross-sectional area and acts as a straight tube. Specifically, the third gas channel section 234 is used to ensure a uniform air flow before being fed into the fourth gas channel section 236. Similar to the conical section 110 of the first example spraying device 100, the fourth gas channel section 236 is coupled with inner and outer conical walls or curved (e.g., conical) walls to increase the speed of the air flow. The fourth gas channel section 236 further includes a second outlet 242 (refer to Figure 2B ), the second outlet acts as a circular or annular orifice and forms a supersonic air spike air flow 258 (e.g., reference Figure 2B The diameter of the second outlet 242 is determined so that the converging gas tip mixture 260 can be formed outside the second outlet 242. In some embodiments, the second outlet 242 need not be circular, and various other shapes may be employed.

[0044] In addition, in some embodiments, the second example spray device 200 further includes a mixing section 270 formed by the second housing structure 204. The mixing section 270 is located downstream of the first outlet 240 and the second outlet 242. The mixing section 270 further includes a cylindrical wall 272 and a conical wall 274. On the one hand, the cylindrical wall 272 of the mixing section 270 allows the conical liquid spray 256 to be fully mixed with the supersonic air tip air flow 258, so that the conical liquid spray 256 is broken into droplets to form a supersonic liquid mist. On the other hand, the conical wall 274 allows the supersonic liquid mist to expand without interference. In some embodiments, the mixing section 270 generates at least part of the air tip zone and the supersonic zone.

[0045] refer to Figure 2B In some embodiments, the liquid channel 206 is symmetrical (e.g., located at the center) relative to the central axis 280 of the second example spray device 200. In addition, the gas channel 208 is coaxially arranged around the liquid channel 206, thereby enclosing a substantial portion of the liquid channel 206. In addition, long liquid channels and gas channels (e.g., Figure 2B The design of the liquid channel 206 and the gas channel 208 shown in FIG. 200 ensures uniform distribution of liquid and air discharge for producing consistent droplet size. In some embodiments, the delivery component 202b and the second housing structure 204 are coupled to each other along a common interface 285 using a threaded connection.

[0046] Figure 2C Draw along Z A top view 220 of the scroll assembly 202c viewed from the opposite direction of the axis. Figure 2C Further depiction along Z 222 is a bottom view of the vortex assembly 202c viewed from the axial direction. The vortex assembly 202c includes an inlet channel portion 214a, a plurality of recessed channels 214b, and an ejection path 214c. The vortex assembly 202c is configured to guide a liquid flow 250 into the inlet channel portion 214a, split the liquid flow 250 into a plurality of lateral flows 252 traveling in the plurality of recessed channels 214b, guide the plurality of lateral flows 252 toward the ejection path 214c, and form a substantially stable vortex liquid flow 254 in the ejection path 214c. In addition, the plurality of recessed channels 214b are arranged along the ejection path 214c. Z The shaft cuts through the scroll assembly 202c.

[0047] In some embodiments, the ejection path 214c further includes two side channels 224 and an ejection channel portion 226. The side channels 224 of the ejection path 214c are used to guide the plurality of lateral flows 252 from the plurality of recess channels 214b to the ejection channel portion 226 of the ejection path 214c. In some embodiments, the ejection channel portion 226 of the ejection path 214c includes or is coupled to the fourth liquid channel segment 216.

[0048] In some implementations, a plurality of side channels 224 are formed below and extend substantially parallel to a top surface 228 of a vortex assembly 202c configured to face the liquid flow 250. As shown in the top view 220 of the vortex assembly 202c, the plurality of side channels 224 are formed below and extend substantially parallel to the top surface. XY The scroll assembly 202c extends in a plane that is parallel to the top surface 228 of the scroll assembly 202c.

[0049] In some embodiments, the ejection channel portion 226 is connected to the plurality of side channels 224 and extends along the flow direction of the liquid stream 250 (e.g., along X axis) and perpendicular to the plurality of recessed channels 214b (e.g., along Z Specifically, as shown in the bottom view 222 of the vortex assembly 202c, the ejection channel portion 226 of the ejection path 214c is connected to the plurality of side channels 224 to receive the plurality of lateral flows 252.

[0050] In some embodiments, the vortex assembly 202c is configured to touch multiple locations of the inner wall of the first housing structure forming the liquid channel 206, and has multiple recesses 292 (e.g., cutouts) recessed from the inner wall of the first housing structure, which are configured to split the liquid flow. For example, as shown in the top view 220 and the bottom view 222 of the vortex assembly 202c, the vortex assembly 202c touches two locations 290 of the inner wall of the first housing structure 202, and has two recesses 292 recessed from the inner wall of the first housing structure 202. This structure forms two recess channels 214b for splitting the liquid flow 250.

[0051] In some embodiments, the side channels 224 of the vortex assembly 202c can be formed in a regular or irregular shape. In some embodiments, the side channels 224 of the vortex assembly 202c are configured to evenly split the liquid flow. In one example, the side channels 224 are radially symmetrical relative to the central axis of the vortex assembly. For example, Figure 2C , the scroll assembly 202c includes two recessed passages 214b that are radially symmetric with respect to the central axis 280. In another example, the side passages 224 may include four passages of the scroll assembly 202c (eg, that are radially symmetric with respect to the central axis (eg, central axis 280)).

[0052] In some embodiments, the width of the side channel 224 is substantially the same as the diameter of the ejection channel portion 226. For example, as shown in the bottom view 222 of the vortex assembly 202c, the width of the side channel 224 of the ejection channel portion 226 is ( W tunnel ) and the diameter of the ejection channel portion 226 of the ejection path 214c ( D central ) are substantially the same. In some embodiments, the design of the side channel 224 of the ejection path 214c can be changed to optimize the liquid flow. Therefore, the width of the side channel 224 of the ejection path 214c can be different from the diameter of the ejection channel portion 226.

[0053] Figure 3 300 is a flow chart of an example method of providing a spraying device according to some embodiments. Specifically, Figure 3 The flowchart can be used to provide the above reference Figures 1A to 2C The described air-tip dry mist nano jet spraying device. Method 300 includes providing (302) a first shell structure to the spraying device. The first shell structure includes (304) a liquid channel. The liquid channel is configured (306) to convey a liquid flow, convert the liquid flow into a vortex liquid flow, and discharge the vortex liquid flow from the first shell structure via a first outlet. Method 300 also includes providing (308) a second shell structure to the spraying device. The second shell structure surrounds (310) the first shell structure. Method 300 further includes providing (312) a gas channel to the spraying device. The gas channel is formed (314) between the first shell structure and the second shell structure. The gas channel further includes (316) a conical section coupled to the second outlet. The conical section has (318) a variable width that continuously decreases relative to the length of the extended section. The conical section is configured (320) to convert the gas flow into a supersonic gas jet to be released from the gas channel via the second outlet. The method 300 further includes providing (322) an air tip region to the spray device. The air tip region is coupled (324) proximate to both the first outlet of the liquid channel and the second outlet of the gas channel. The air tip region is configured (326) to receive the swirling liquid flow and the supersonic gas jet and form a converging air tip mixture. The method 300 further includes providing (328) an acoustic structure to the spray device. The acoustic structure is coupled (330) to the second housing structure. The acoustic structure is configured (332) to control the dispersion of the mixture of the supersonic gas jet and the swirling liquid flow and reduce the noise level of the spray device.

[0054] In some embodiments, the outer surface of the first shell structure is conical and has a first angle, and the inner surface of the second shell structure is conical and has a second angle greater than the first angle. In some embodiments, the gas channel is formed between the outer surface of the first shell structure and the inner surface of the second shell structure and is configured to increase the gas flow velocity of the gas flow.

[0055] In some embodiments, the second outlet of the gas channel has a ring shape and substantially surrounds the first outlet of the liquid channel, and the width of the second outlet of the gas channel is within a predetermined width range. It should be noted that in some embodiments, the second outlet of the gas channel is not limited to a ring shape and has a shape different from a ring shape. In some embodiments, the predetermined width range is greater than 0.01 mm.

[0056] In some embodiments, the gas tip region is coupled proximate to both the first outlet of the liquid channel and the second outlet of the gas channel. The gas tip region is configured to receive the vortex liquid flow and the supersonic gas jet and form a converging gas tip mixture. In addition, in some embodiments, the second housing structure further includes an extension portion extending beyond the second outlet of the gas channel. The extension portion is configured to confine the converging gas tip mixture in the gas tip region adjacent to the first outlet and the second outlet. In addition, in some embodiments, the droplet size of the liquid droplets of the converging gas tip mixture is in the range of 0.05 μm to 50 μm.

[0057] In some embodiments, an acoustic structure is coupled to the second housing structure. The acoustic structure is configured to control the dispersion of the mixture of the supersonic gas jet and the vortex liquid flow and reduce the noise level of the spraying device. In addition, in some embodiments, the acoustic structure has a serrated edge.

[0058] In some embodiments, the first housing structure further includes a vortex assembly disposed in the liquid channel and adjacent to the first outlet of the liquid channel. The vortex assembly includes a plurality of side channels. The vortex assembly is configured to split the liquid flow into a plurality of lateral flows traveling in the plurality of side channels, guide the plurality of lateral flows toward the ejection channel portion, and form a substantially stable vortex liquid flow in the ejection channel portion. In addition, in some embodiments, a plurality of side channels are formed below the top surface of the vortex assembly configured to face the liquid flow, and extend substantially parallel to the top surface. The ejection channel portion is connected to the plurality of side channels, and extends along the flow direction of the liquid flow and perpendicular to the plurality of side channels. In addition, in some embodiments, the vortex assembly is configured to touch a plurality of positions of the inner wall of the first housing structure forming the liquid channel. The vortex assembly has a plurality of recesses recessed from the inner wall of the first housing structure, and the recess is configured to split the liquid flow.

[0059] In some embodiments, the plurality of side channels include two identical side channels aligned to each other and connected at the ejection channel portion. In some embodiments, the plurality of side channels are connected at the ejection channel portion and have the same geometric features (e.g., length, width, shape).

[0060] In some embodiments, the extended section length of the conical section of the gas channel is within a predetermined length range, the conical width of the conical section of the gas channel is within a predetermined width range, and the volume flow rate of the gas channel is within a predetermined flow rate range. In some embodiments, the predetermined length range is greater than 1 mm. In some embodiments, the predetermined width range is greater than 0.01 mm. In some embodiments, the predetermined flow rate range is greater than 10 liters / minute (L / min). It should be noted that the different ranges used in the description of the various described embodiments herein are for the purpose of describing only specific embodiments and are not intended to be restrictive. A person of ordinary skill in the art will recognize that in other embodiment ranges different from those discussed in the present application, air-tip dry mist nano jet spray can also be achieved as required.

[0061] In some embodiments, the spray device has a plurality of cross sections that are perpendicular to and intersect the central axis, and each cross section is symmetrical with respect to a corresponding intersection node with the central axis.

[0062] In some embodiments, the first housing structure further comprises a delivery portion providing a gas inlet region and a gas channel section. The gas channel section is coupled to the second housing structure and has a plurality of gas holes coupling the gas inlet region to the gas channel.

[0063] In some embodiments, the gas channel further includes a straight section coupled to the tapered section and having a substantially constant cross-sectional area. The straight section is configured to deliver a gas flow having a substantially constant flow rate to the tapered section.

[0064] It should be understood that Figure 3 The specific order in which the operations in have been described is merely exemplary and is not intended to indicate that the described order is the only order in which the operations may be performed. A person of ordinary skill in the art will recognize various ways to manufacture an air-tip dry mist nano-jet spraying device as described herein. It should also be noted that more details on the method of manufacturing an air-tip dry mist nano-jet spraying device are described in the above reference. Figures 1A to 2C For the sake of brevity, these details are not repeated in the description herein.

[0065] It will also be understood that, although in some cases, the terms first, second, etc. are used to describe various elements in this article, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, without departing from the scope of the various described embodiments, the first spraying device may be referred to as the second spraying device, and similarly, the second spraying device may be referred to as the first spraying device. Both the first spraying device and the second spraying device are devices, but they are not identical devices.

[0066] The terms used to describe the various described embodiments herein are only for the purpose of describing specific embodiments, and are not intended to be limiting. As used in the description of the various described embodiments and the appended claims, unless the context clearly indicates otherwise, the singular forms "a", "an" and "said" are intended to also include plural forms. It will also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It should be further understood that the terms "includes", "including", "comprises" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements and / or components when used in this specification, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof.

[0067] As used herein, the term "if" is optionally interpreted to mean "when" or "after" or "in response to determining" or "in response to detecting" or "according to a determination of." Similarly, the phrases "if it is determined" or "if [a stated condition or event] is detected" are optionally interpreted to mean "after determining" or "in response to determining" or "after detecting [a stated condition or event]" or "in response to detecting [a stated condition or event]" or "according to a determination of detecting [a stated condition or event]," depending on the context.

[0068] Although the various figures depict several logical stages in a particular order, stages that are not order-dependent may be reordered and other stages may be combined or decomposed. Although some reorderings or other groupings are specifically mentioned, other reorderings or groupings will be apparent to one of ordinary skill in the art, and thus the orderings and groupings presented herein are not an exhaustive list of alternatives. Furthermore, it should be recognized that the stages may be implemented in hardware, firmware, software, or any combination thereof.

[0069] For purposes of explanation, the above description has been described with reference to specific implementations. However, the illustrative discussion above is not intended to be exhaustive or to limit the scope of the claims to the precise forms disclosed. In light of the above teachings, many modifications and variations are possible. The implementations are chosen in order to best explain the underlying principles of the claims and their practical application, thereby enabling those skilled in the art to best use the implementations with various modifications suitable for the specific purposes covered.

Claims

1. A spraying device, comprising: a first housing structure comprising a liquid passage, wherein the liquid passage is configured to convey a liquid flow, convert the liquid flow into a vortex liquid flow, and discharge the vortex liquid flow from the first housing structure via a first outlet; a second housing structure surrounding the first housing structure; as well as A gas channel formed between the first shell structure and the second shell structure, wherein the gas channel further includes a tapered section coupled to a second outlet, and the tapered section has a varying width that continuously decreases relative to an extended section length and is configured to convert a gas flow into a supersonic gas jet for release from the gas channel through the second outlet. 2 . The spraying device according to claim 1 , wherein an outer surface of the first shell structure is conical and has a first angle, and an inner surface of the second shell structure is conical and has a second angle greater than the first angle. 3 . The spray coating device according to claim 2 , wherein the gas channel is formed between the outer surface of the first housing structure and the inner surface of the second housing structure, and is configured to increase a gas flow velocity of the gas flow. 4 . The spraying device according to claim 1 , wherein the second outlet of the gas channel has a ring shape and substantially surrounds the first outlet of the liquid channel, and a width of the second outlet of the gas channel is within a predetermined width range.

5. The spraying device according to any one of claims 1 to 4, further comprising: A gas apex region is coupled proximate to both the first outlet of the liquid channel and the second outlet of the gas channel, the gas apex region being configured to receive the vortex liquid flow and the supersonic gas jet and form a converging gas apex mixture.

6. The spray device of claim 5, wherein the second housing structure further comprises an extension portion extending beyond the second outlet of the gas channel, and the extension portion is configured to confine the converging gas tip mixture in the gas tip region adjacent to the first outlet and the second outlet.

7. The spraying device of claim 6, wherein the droplet size of the liquid droplets of the converging air-tip mixture is in the range of 0.05 μm to 50 μm.

8. The spraying device according to any one of claims 1 to 7, further comprising: An acoustic structure is coupled to the second housing structure, the acoustic structure being configured to control the dispersion of the mixture of the supersonic gas jet and the swirling liquid flow and reduce the noise level of the spray device.

9. The spray device of claim 8, wherein the acoustic structure has a serrated edge.

10. A spraying device according to any one of claims 1 to 9, wherein the first housing structure further includes a vortex component disposed within the liquid channel and adjacent to the first outlet of the liquid channel, wherein the vortex component includes a plurality of side channels and is configured to split the liquid flow into a plurality of lateral flows traveling in the plurality of side channels, guide the plurality of lateral flows toward an ejection channel portion, and form the vortex liquid flow that is substantially stable in the ejection channel portion.

11. A spraying device according to claim 10, wherein the plurality of side channels are formed below a top surface of the vortex assembly configured to face the liquid flow and extend substantially parallel to the top surface, and the ejection channel is partially connected to the plurality of side channels and extends along a flow direction of the liquid flow and perpendicular to the plurality of side channels.

12. The spraying device according to claim 10 or 11, wherein the vortex assembly is configured to touch a plurality of locations of an inner wall of the first housing structure forming the liquid channel, and has a plurality of recesses recessed from the inner wall of the first housing structure, the recesses being configured to split the liquid flow.

13. The spraying device according to any one of claims 10 to 12, wherein the plurality of side channels include two identical side channels aligned with each other and connected at the ejection channel portion.

14. The spraying device according to any one of claims 10 to 13, wherein the plurality of side channels are connected at the ejection channel portion and have the same geometrical features.

15. The spraying device according to any one of claims 1 to 14, wherein the extended section length of the tapered section of the gas channel is within a predetermined length range, the tapered width of the tapered section of the gas channel is within a predetermined width range, and the volume flow rate of the gas channel is within a predetermined flow rate range.

16. The spraying device according to any one of claims 1 to 15, wherein the spraying device has a plurality of cross sections perpendicular to and intersecting the central axis, and each cross section is symmetrical with respect to a corresponding intersection node with the central axis.

17. The spraying device according to any one of claims 1 to 16, wherein the first housing structure further comprises a delivery portion providing a gas inlet region and a gas channel section, and the gas channel section is coupled to the second housing structure and has a plurality of gas holes coupling the gas inlet region to the gas channel.

18. The spraying device according to any one of claims 1 to 17, wherein the gas channel further includes a straight section coupled to the tapered section and having a substantially constant cross-sectional area, and the straight section is configured to deliver the gas flow having a substantially constant flow rate to the tapered section.

19. A method for providing a spraying device according to any one of claims 1 to 18.

20. A method for producing a nanojet spray using a spray device according to any one of claims 1 to 18.

21. A method for providing a spraying device, comprising: providing a first housing structure including a liquid channel, wherein the liquid channel is configured to convey a liquid flow, convert the liquid flow into a vortex liquid flow, and discharge the vortex liquid flow from the first housing structure via a first outlet; providing a second housing structure surrounding the first housing structure; and A gas passage is provided formed between the first shell structure and the second shell structure, wherein the gas passage further includes a tapered section coupled to a second outlet, and the tapered section has a varying width that continuously decreases relative to an extended section length and is configured to convert a gas flow into a supersonic gas jet for release from the gas passage through the second outlet.

22. A method for generating a nanojet spray, comprising: conveying a liquid flow in the liquid passage of the first housing structure; converting the liquid flow into a vortex liquid flow; discharging the swirling fluid flow from the first housing structure via a first outlet of the fluid passage; as well as The gas flow is converted into a supersonic gas jet for release from the gas channel through a second outlet of the gas channel, wherein the gas channel is formed between the first shell structure and a second shell structure surrounding the first shell structure and includes a tapered section coupled to the second outlet, and the tapered section has a varying width that continuously decreases relative to an extended section length.

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