Concurrent air-assisted dispersion of liquids

Abstract

A dual-liquid air-assisted spray nozzle assembly, for dispensing two different liquids simultaneously as droplets, having two air-assist spray nozzles, with each nozzle having a nozzle axis, a first swirler including a plurality of curved vanes that curve radially inwardly in a first rotational direction, and a second swirler including a plurality of curved vanes that curve radially inwardly in a second rotational direction that is counter-rotational to the first rotational direction. A dual-liquid air-assisted spray apparatus using the spray nozzle assembly has a means for supplying pressurized carrier air, means for supplying the first and second liquid compositions to the respective first and second nozzles, for dispensing a swirling, dispersed-droplet stream from the first nozzle in the first rotational direction around the first nozzle axis, and for dispensing a swirling, dispersed-droplet stream from the second nozzle in the second rotational direction around the second nozzle axis that is counter-rotational to the first rotational direction.

Description

Attorney docket: HYT-009R-PCT ^ CONCURRENT AIR-ASSISTED DISPERSION OF LIQUIDS Field of the Invention

[0001] This invention is related to the field of air-assisted dispersing liquids, typically aqueous, compositions into rooms or other volumetric spaces. Background of the Invention

[0002] Often, there is a need to disperse two or more liquid or aqueous compositions into a room or other volumetric space, for distribution and depositing onto one or more surfaces within. The compositions can either be dispersed sequentially, to form one or more layers of material on the surface(s), or simultaneously, where the compositions can interact with each other within the airspace and / or on the surface(s). In some instances, it can be advantageous to delay or prevent the liquid compositions or droplets thereof from contacting each other in the airspace, prior to depositing onto a surface, for example, to comply with regulatory requirements, promote safety, enhance composition stability, avoid a chemical reaction between a first reactive components in one liquid composition with a second reactive component in a second liquid composition, and / or optimize the benefits of the combined liquid compositions on the surface(s).

[0003] As a result, there is a need to develop an improved method and system for distributing at least two different liquid compositions from a single device while delaying or preventing the liquid compositions or droplets thereof from interacting or coalescing with each other, in an airspace and in flight within a volumetric space, prior to the depositing of the two liquid compositions onto a surface, and coalescing the two or more different compositions into a combined layer of the two or more different compositions. Summary of the Invention

[0004] The present invention relates to a system(s), device(s) and method(s) for the concurrent air-assisted dispersion of at least two liquid compositions, into and through an airspace, while reducing, minimizing, or eliminating the mixing or coalescing together of the two or more liquid compositions within the airspace. The at least two concurrently-dispersed liquid compositions are dispersed through two side-by-side nozzles, each nozzle including an air swirler to disperse the respective liquid as droplets within a swirling stream of air, wherein the two 1 ^Attorney docket: HYT-009R-PCT ^ swirling streams of air with the entrained droplets swirl counter-rotationally along the line of dispersion of the liquid droplets from the spray nozzles.

[0005] In some embodiments, the present invention provides a dual-liquid air-assisted spray apparatus, for dispensing two different liquids simultaneously as droplets, comprising: a spray nozzle assembly comprising two air-assist spray nozzles, each nozzle having a nozzle axis, a means for supplying pressurized carrier air, a first means for supplying the first liquid composition to the first nozzle, and a second means for supplying the second liquid composition to the second nozzle, a first swirler including a plurality of curved vanes that curve radially inwardly in a first rotational direction, for dispensing a swirling, dispersed-droplet stream from the first nozzle in the first rotational direction around the first nozzle axis, and a second swirler including a plurality of curved vanes that curve radially inwardly in a second rotational direction, for dispensing a swirling, dispersed-droplet stream from the second nozzle in the second rotational direction around the second nozzle axis that is counter-rotational to the first rotational direction.

[0006] In some embodiments, the two air-assist spray nozzles are side-by-side spray nozzles, and the outer tangential peripheries of the two side-by-side swirling, dispersed-droplet streams converge tangentially in a downward direction with gravity.

[0007] In some embodiment, the present invention provides a dual-liquid air-assisted spray nozzle assembly, for dispensing two different liquids simultaneously as droplets, comprising: two air-assist spray nozzles, each nozzle having a nozzle axis, a first swirler including a plurality of curved vanes that curve radially inwardly in a first rotational direction, and a second swirler including a plurality of curved vanes that curve radially inwardly in a second rotational direction that is counter-rotational to the first rotational direction.

[0008] The at least two swirling streams of air, with the respective entrained droplets of the first and second liquid compositions, are dispersed from the respective nozzles simultaneously, and either continuously or in a series of dispersing periods. Without being bound by any particular theory of operation or function, the simultaneous dispersing of the first and second liquid compositions into a volumetric space improves the reliability and uniformity of the volume or mass of the first and second liquid compositions, and their relative volumes and / or masses, deposited and coalesced onto the one or more target surfaces. In some embodiments, each portion, region or area of the one or more target surfaces is covered by a reaction liquid layer comprising a reaction product, which is formed by the first reactant compound of the first liquid composition, 2 ^Attorney docket: HYT-009R-PCT ^ and the second reactant compound of the second liquid composition, where the first and second reactant compounds and / or the reaction product are present within each portion, region or area of the one or more target surfaces, in an amount or concentration that is similar, the same, or uniform, or within a predetermined or acceptable range. <Dispersed droplet and swirling air stream forms>

[0009] The dispersion from each nozzle consists of a stream of swirling air carrying droplets of a liquid. The separate dispersions of the at least two liquid compositions from the two nozzles subsequently deposit independently onto a surface or plurality of surfaces. The dispersions can be aimed and directed at the surface or surfaces, or can be aimed and directed into the airspace of volumetric space, for example a room, or enclosed or open area, to travel through the airspace and deposit under the force of gravity onto a surface.

[0010] The present invention provides for a single device or multi-device system for, and a method for, dispersing the at least two liquid compositions as droplets entrained within two separate swirling streams of air. The apparatus and method for air-assisted dispersing the at least two liquid compositions are configured to reduce, minimize, or eliminate the mixing or coalescing together of the respective droplets and streams of the at least two liquid compositions within the airspace, prior to their respective depositing onto the surface or surfaces.

[0011] The present invention also provides a spray nozzle assembly including at least, and preferably, two air-assisted spray nozzles oriented side-by-side, each nozzle having a central axis, with the central axes lying in a horizontal plane during normal use of the spray nozzle assembly.

[0012] The two or more liquid compositions can be and typically are different or distinct liquid compositions. In various embodiments, the first and second liquid compositions are dispersed independently and separately as a multiplicity of droplets.

[0013] Droplets of the respective liquid composition from the air-assist spray nozzle are propelled in the two-fluid (liquid and air) spray nozzle assembly by a volumetric flow of a pressurized, swirling air stream passing through the spray nozzle assembly. The pressurized air stream can be generated by an air pump or a high-pressure air blower, for example a Hurricane fogger available from B&G Equipment Company. A stream of dispensed liquid composition can be drawn through a venturi portion of the spray nozzle using a portion of the pressurized air stream. 3 ^Attorney docket: HYT-009R-PCT ^

[0014] An interaction of the droplets of the first liquid composition dispersed from the first air-assisted liquid nozzle with the droplets of the second liquid composition dispersed from the second air-assisted liquid nozzle is reduced and / or eliminated by rotating in a first rotational direction the swirling stream of air through the first air-assisted liquid nozzle and along the line of dispersion of the droplets of the first liquid composition, and rotating in a second rotational direction the swirling stream of air through the second air-assisted liquid nozzle and along the line of dispersion of the droplets of the second liquid composition, wherein the first rotational direction is counter-rotational to the second rotational direction. In a preferred embodiment, the outer tangential peripheries of the two side-by-side swirling, dispersed-droplet streams, consisting of a carrier air with entrained liquid droplets, converge tangentially in a downward direction with gravity. In an alternative embodiment, the outer tangential peripheries of the side-by-side swirling, dispersed-droplet streams converge tangentially in an upward direction against gravity.

[0015] Without being bound by any particular theory, it is believed and can be shown that the concurrent spraying of two swirling, side-by-side, droplet-entrained streams of air that rotate co-rotationally (in the same rotational direction) results in the two streams migrating away from the lines of dispersion of the dual spray nozzles in the direction corresponding to the downward, tangential direction of the swirling streams. In other words, and viewed from behind the spray nozzles, two side-by-side streams swirling clockwise away from the nozzles will migrate laterally to the right, while two side-by-side streams swirling counter-clockwise away from the nozzles will migrate laterally to the left. When the two side-by-side streams are swirling counter-rotationally, the two streams disperse away from the spray nozzles without migrating laterally to one side or the other. Further, it has been shown that the two side-by-side, counter-rotating streams of air remain separated and resist blending or mixing with one another when the outer tangential flow of the side-by-side swirling streams of air converge in a downward direction with gravity.

[0016] In various embodiments, the interaction between the dispersed droplets of the first and second liquid compositions can be further minimized by 1) increasing the lateral (horizontal) distance of the first nozzle and its dispersion vector (or nozzle axis) from the second nozzle and its dispersion vector (or nozzle axis), 2) increasing the relative dispersing angle between the nozzle axis of the first nozzle and the nozzle axis of the second nozzle, 3) reducing, minimizing, or preferably avoiding, dispersing of the droplets of the second liquid compositions while the droplets 4 ^Attorney docket: HYT-009R-PCT ^ of the first liquid compositions are being dispersed, and vice versa, and 4) adding the same electrostatic charge to each of the droplet dispersions of the liquid compositions. <Counter-rotational swirler elements>

[0017] A dual-liquid spray nozzle assembly includes a first air-assist spray nozzle and a second air-assist spray nozzle. Each air-assist spray nozzle includes a liquid supply port in fluid communication with a liquid outlet to disperse a stream and / or droplets of liquid. Various means for dispensing a stream and / or droplets of a liquid composition from the nozzle assembly can be employed. In some embodiments, each liquid supply port delivers the liquid to a liquid outlet port at a venturi where the liquid is drawn out by a pressured volume of air flowing through an inner swirler at the venturi, and dispersed out through the liquid outlet port as a stream and / or droplets of liquid. In other embodiments, the dispensing means can include a liquid pump.

[0018] A volume of pressurized air is supplied to the dual-liquid spray nozzle assembly as carrier air for fluidizing and carrying the dispersed stream and / or droplets of liquid in a stream into a volumetric space. In some embodiments, the volume of pressurized air passes in substantially equal portions through each of the two air-assist spray nozzles. In embodiments using a venturi, the equal portion of pressurized air is further divided into a venturi portion of air that passes an inner swirler at the venturi, with the remaining swirl portion passing through an outer swirler that causes the pressurized air to rotate around the longitudinal axis in the direction of air flow. The combination of the venturi portion and swirl portion of pressurized air provides a swirling, dispersed-droplet stream that is dispensed from each of the spray nozzles.

[0019] Each inner swirler and outer swirler has a plurality of circumferentially-spaced axially-extending curved vanes secured to a swirl plate that provide a plurality of swirl channels, each channel having a radially-outer inlet for the pressurized supply air along the outer periphery of the swirler, and having a radially-inner outlet at the center of the swirler.

[0020] The venturi passage of the spray nozzle is formed between the outer surface of the liquid outlet port and the swirl plate of the inner swirler. The venturi portion of the pressurized air enters the inlets of the swirl channels along the outer periphery of the inner swirler, and exits and swirls from the outlet of the inner swirler at the venturi, to both draw the liquid through the liquid outlet port and fluidize the stream of drawn liquid into droplets. The venturi air-droplet mixture is discharged from a venturi outlet port. Concurrently, the outer swirl portion of the pressurized 5 ^Attorney docket: HYT-009R-PCT ^ air enters the inlets of the swirl channels along the outer periphery of the outer swirler, and exits and swirls from the outer swirler along the periphery of droplet feed port of the outer swirler. The swirling air from the outer swirler mixes with the air-droplet mixture of the droplet feed port, to further entrain the liquid droplets with the carrier air, which is dispersed from the air / liquid discharge ports as a swirling stream of carrier air and entrained (fluidized) droplets that rotates around the longitudinal axis in the direction of air flow.

[0021] Depending on the orientation of the swirler and its curved vanes, the swirling, dispersed-droplet streams will rotate in either a clockwise or counter-clockwise direction while advancing away from the air air / liquid discharge ports. Facing the air / liquid discharge ports, arranging the curved vanes of the outer swirler to curve radially inwardly in a clockwise direction rotates the swirling volume of carrier air in the same clockwise direction while exiting the air / liquid discharge ports, while arranging the curved vanes of the outer swirler to curve radially inwardly in a counter-clockwise direction rotates the swirling volume of carrier air in the same counter- clockwise direction while exiting the air / liquid discharge ports.

[0022] The present invention provides that the direction of rotation of the swirling, dispersed-droplet streams dispersed from the first air-assist spray nozzle is opposite the direction of rotation of the swirling, dispersed-droplet streams dispersed from the second air-assist spray nozzle. Likewise, the direction of rotation of the curved vanes of the outer swirler of the first air- assist spray nozzle, radially from the outer inlet to the inner outlet, is opposite the direction of rotation of the curved vanes of the outer swirler of the second air-assist spray nozzle.

[0023] Facing the air / liquid discharge ports, in a preferred embodiment, the direction of rotation of the swirling, dispersed-droplet streams dispersed from the right-side air-assist spray nozzle, of the pair of side-by-side nozzles, is counter-clockwise, and the direction of rotation of the swirling, dispersed-droplet streams dispersed from the left-side air-assist spray nozzle is clockwise. Consequently, facing the air / liquid discharge ports, in a preferred embodiment, the direction of rotation of the curved vanes of the outer swirler of the right-side air-assist spray nozzle, radially from the outer inlet to the inner outlet, is counter-clockwise, and the direction of rotation of the curved vanes of the outer swirler of the left-side air-assist spray nozzle is clockwise. As a result, the outer tangential peripheries of the side-by-side swirling, dispersed-droplet streams interface in a downward direction with gravity. 6 ^Attorney docket: HYT-009R-PCT ^

[0024] Alternatively, the direction of rotation of the swirling, dispersed-droplet streams dispersed from the right-side air-assist spray nozzle is clockwise, and the direction of rotation of the swirling, dispersed-droplet streams dispersed from the left-side air-assist spray nozzle is counter-clockwise; and the direction of rotation of the curved vanes of the swirler of the right-side air-assist spray nozzle is clockwise, the direction of rotation of the curved vanes of the swirler of the left-side air-assist spray nozzle is counter-clockwise.

[0025] In embodiments of the spray nozzle having a venturi, direction of rotation of the curved vanes of the inner swirler of either air-assist spray nozzle can, independently, be the same or opposite to the direction of rotation of the curved vanes of the corresponding outer swirler. The portion of air exiting the venturi carries the formed droplets and any remaining liquid stream to the air / liquid discharge ports where it mixes with the swirling pressurized air exiting the outer swirlers to form the swirling, dispersed-droplet stream. <Separation distance of two nozzles >

[0026] In various embodiments, the distance between the first and second nozzles is at least 1 cm, or at least 2 cm, or at least 4 cm, and up to about 10 cm, or up to about 6 cm. The distance should be sufficient to minimize or avoid overlapping and impingement of the dispersion of the first liquid composition with the second liquid composition when dispersed simultaneously. <Reactant Compounds>

[0027] In various embodiments, the two or more liquid compositions each can comprise a respective and different reactant compound, and when the two or more liquid compositions are combined into a mixed composition, the two different reactant compounds can react with one another to form a reaction product within the mixed composition. For example, a first liquid composition can comprise, consist of, or contain a first reactant compound, and a second liquid composition can comprise, consist of, or contain a second reactant compound. Upon combining the first liquid composition with the second liquid composition to form a resulting mixed, liquid composition, the first reactant compound and the second reactant compound react to form the reaction product. 7 ^Attorney docket: HYT-009R-PCT ^ <Catalyzed Reaction>

[0028] In alternative embodiments employing a method, device or system described herein, a first liquid composition can comprise two or more reactant compounds that are stable, minimally reactive or non-reactive within the first liquid composition, while a second liquid composition can comprise a catalyst material that can trigger or initiate a reaction, or increase a rate of a reaction, among the two or more reactant compounds to form a target product. <Divergent Dispersing>

[0029] In various embodiments of a system or method, the two swirling streams of air with the respective entrained droplets of the first and second liquid compositions, are dispersed from the respective nozzles counter-rotationally along diverging lines of dispersion. In the various embodiments, the at least two swirling streams of air, and preferably two swirling streams of air, with the respective entrained droplets of the first and second liquid compositions, are dispersed both simultaneously and along divergent lines of dispersion.

[0030] The diverging lines of dispersion are provided by a spray nozzle assembly comprising side-by-side first and second spray nozzles that are arranged and configured so that the central axis of the at least two nozzles diverge at a diverging angle in a horizontal plane, and are not parallel to one another. In various embodiments, the diverging angle is at least 1 degree, or at least 3 degrees, and preferably at least 6 degrees, or at least 10 degrees, and up to 30 degrees, or up to 20 degrees. The first nozzle and the second nozzle are preferably disposed within a single dispersing apparatus. <Reactant liquid compositions>

[0031] In various embodiments of the invention, the first liquid composition and the second liquid composition each comprise at least one reactant compound and / or a reactant catalyst. In one embodiments of the invention, the first liquid composition comprises hydrogen peroxide or a peroxide-producing compound, and the second liquid composition comprises an organic acid, and preferably acetic acid, and the formation of droplets of the mixed composition results in situ in the formation of peracid, and preferably a peracetic acid. The formation of particles or droplets of a mixed composition comprising a peracid, such as peracetic acid, raise a risk of inhalation of droplets comprising peracid, or peracetic acid, which can be harmful to humans and mammals. In another embodiment of the invention, the first liquid composition comprises hydrogen peroxide or 8 ^Attorney docket: HYT-009R-PCT ^ a peroxide-producing compound, and the second liquid composition comprises an iodide salt, and the formation of droplets of the mixed composition results in situ in the formation of an iodine species.

[0032] To provide an effective mixture of the coalesced droplets onto a surface or surfaces sufficient to form an efficacious reaction product, it is important for sufficient quantities of droplets of both of the two different liquid compositions to travel through the airspace, and to descend, land on, and coalesce on a surface, to form a coalesced mixed composition contained the reactant product. When the two different liquid compositions are being dispersed as respective patterns of droplets, reducing, minimizing or eliminating any diverging angle Į of the two nozzle axes increases the delivery and coalescing of sufficient amounts of droplets from both different liquid compositions to provide effective performance on all surfaces toward which the dispersing spray patterns were directed. For example, in the case of two reactant compounds that form a sanitizing reactant product, it can be important to deliver sufficient (for example, stoichiometric) quantities of both reactant compounds onto the surface or surfaces, to form an effective sanitizing product that can sanitize such surfaces. <Aqueous liquid compositions>

[0033] In various embodiments, one or more of the liquid compositions is an aqueous composition comprising water as a solvent. In various embodiments, one or more of the liquid compositions can be non-aqueous compositions, including but not limited to oil-based compositions, organic compounds or compositions, and other volatile compounds or compositions that are substantially free of water. In various embodiments, all of the liquid compositions that are dispersed are aqueous compositions. <Droplet size>

[0034] In various embodiments, the equivalent diameter of the multiplicity of droplets can be controlled to be small enough to enable the droplets to distribute the airspace and throughout a portion of the volumetric space. In various embodiments, the formation of droplets of the liquid compositions can be controlled so that at least 90%, typically at least 95%, and even more typically at least 99% of the droplets, by volume of the dispersed liquid composition, have a diameter (or equivalent diameter) within a desired or target droplet-size range. For the formation of droplets (smaller droplets) that can be carried through the airspace and remain suspended in the airspace 9 ^Attorney docket: HYT-009R-PCT ^ for a distance of about 10 feet (about 3.3 meters) or more, the target droplet-size range is at least 10 microns, or at least 15 microns, and up to 100 microns; preferably up to 80 microns, or up to 50 microns, or up to 25 microns. For the formation of droplets (medium droplets) that can be carried through the airspace but descend by gravity within a distance of about 15 feet (about 5 meters) or less, the target droplet-size range is at least 25 microns, or at least 50 microns, and up to 250 microns; preferably up to 125 microns, or up to 100 microns, or up to 75 microns.

[0035] In various embodiments, the dispersion and distribution of one or more aqueous compositions can be controlled to increase, enhance, or maximize the combining of the compositions within the volumetric space, prior to depositing onto target surfaces. In various embodiments, the dispersion and distribution of one or more aqueous compositions can be controlled to reduce, minimize, or prevent the combining of the compositions within the volumetric space, prior to depositing onto target surfaces. <multi-sprayer dispersion>

[0036] In various embodiments, the two or more liquid or aqueous compositions can be dispersed using a system comprising multiple spray devices situated at different locations within the volumetric space. In various embodiments, the two or more liquid or aqueous compositions can be dispersed as a multiplicity of droplets using a system comprising a single spray device. <Airspaces >

[0037] Non-limiting examples of volumetric spaces having an airspace can include rooms, buildings, shipping containers, and transportation compartments, whereas non-limiting examples of target surfaces are food-processing surfaces, health care surface and instruments, laboratory surfaces, industrial or commercial machinery, or surfaces in homes and residences. The potential applications are diverse. One non-limiting example of such an application is the disinfecting of surfaces using two or more aqueous compositions. Such methods, systems, and devices are described in U.S. Patent Nos. 9,861,102 and 10,603,396; U.S. Patent Publication Nos. 2019 / 0091360 and 2020 / 0306399; U.S. Patent Application No.62 / 985,783 and PCT Publication Nos. WO 2017 / 205649, 2019 / 075176, and 2021 / 178774, the disclosures of which are incorporated by reference in their entireties. 10 ^Attorney docket: HYT-009R-PCT ^ <Nozzle outlet shapes>

[0038] The shape of the design of the spray nozzle can affect the shape of pattern of dispersed droplets from the spray nozzle assembly. In most conventional spray nozzles, the shapes of the liquid supply and outlet tubes, and of the air supply, venturi, and air / liquid discharge ports, are circular in cross section along the nozzle axes, resulting in a dispersed pattern of droplets being emitted from the spray nozzle having a circular pattern in a cross section normal to the dispersing vector.

[0039] In various embodiments, the shape of the liquid outlet tube, and the air venturi and air / liquid discharge ports, are either rectangular or elliptical, oriented with the long axis in the vertical direction (direction of gravitational force during spraying use), which is turn results in a dispersed pattern of droplets being emitted from the spray nozzle having a circular pattern in a cross section normal to the dispersing vector. The narrowing of the dispersed pattern of droplets in the horizontal or lateral direction helps to reduce and minimize the overlapping of the respective dispersed patterns of the first and second liquid compositions. <ESS>

[0040] In various embodiments, though preferred in the systems and methods of the present invention that generate droplets of the two liquid composition, a droplet of either one or both the first and second liquid compositions dispersed from a nozzle can be charged electrostatically. In some embodiments, the droplets of both the first and second liquid compositions dispersed from a nozzle can be charged electrostatically with the same electrostatic charge, which can be either a positive charge or a negative charge.

[0041] The electrostatic charge is usually applied to the dispersed droplets of the liquid composition as the exit the spray nozzles, using ionizing or high voltage charging system comprising pin electrodes and a charging (ground) ring, which pass the high voltage charge to the liquid droplets passing therebetween. Typical electrostatic charges on the dispersed droplets are between 5 to 20 kilovolts (kV), such as 8-10 kV.

[0042] Without being bound by any particular theory, use of an electrostatic charge of the dispersions of droplets of both the first and second liquid compositions causes individual droplets to repel electrostatically one another. When the two dispersed streams of droplets are emitted at high velocity and momentum from the spraying apparatus, collisions between droplets that might 11 ^Attorney docket: HYT-009R-PCT ^ occur will involve droplets of the same liquid composition, so that reaction products are not formed. As the droplets proceed along their respective dispersing vectors, their velocity and momentum slow, and the distance between droplets in each dispersing patterns expand laterally, away from the dispersing vector, as the result of the repelling force of the electrostatic charge between droplets (the repulsive force between two droplets due to electrostatic charge is proportional to the square of the distance between the droplets). The collisions between and mixing of any two droplets, including droplets of the same liquid compositions and droplets of different liquid compositions, are reduced because of droplets’ mutual electrostatic repulsion, until substantially all the droplets eventually descend, land on, and coalesce on a surface. <Axial velocity and kinetics>

[0043] In various embodiments, the kinetic energy and axial velocity of the dispersed droplets of each of the first and second liquid compositions can be affected and controlled by an amount of power applied per unit of liquid dispersed. The amount of power applied by an air pump or a blower is believed to correlate with the airflow rate and air pressure generated within the housing, and the amount of the liquid solutions drawn by venturi action from the liquid container(s). The amount of power applied by a liquid pump sprayer is believed to correlate with the volumetric flow rate and liquid pressure generated within the housing. Without being bound by any particular theory of operation or function, an increase in the amount of power applied per unit of liquid dispersed can result in an increase in the volumetric output of the dispersed liquid composition(s), a decrease in droplet diameter or size, an increase in the time-of-flight and travel distance of the droplets, and an increase in the interaction of dispersed droplets, while a decrease in the amount of power applied per unit of liquid dispersed can result in an increase in droplet diameter or size, and a decrease in the time-of-flight of the droplets. Significantly increased droplet size and the decrease in time-of-flight can result in pre-mature coalescing of droplets and deposition of the dispersed liquid composition in the immediate area, such as on the floor, surrounding the spray device. <Auxiliary electronic device>

[0044] A dual-liquid droplet sprayer apparatus of the present invention can also include an auxiliary electronic device, such as an illuminating lamp or a directional signal, illustrated as element 31 in Figure 1. The auxiliary electronic device can be connected for power and control to 12 ^Attorney docket: HYT-009R-PCT ^ the respective power and control units of the dual-liquid spray nozzle assembly. In one example, an auxiliary electronic device can be an ultraviolet light lamp, such a UV-light emitting diode (UV- LED) for illuminating the space in front of the dual-liquid spray nozzle assembly with UV light, for providing or assisting sanitizing operations using the dual-liquid spray nozzle assembly and apparatus. In another example, an auxiliary electronic device can be a laser lamp, for emitting a beam of visible or invisible laser light in front of the dual-liquid spray nozzle assembly, to provide a directional signal for the dual-liquid spray nozzle assembly and apparatus.

[0045] The invention is further illustrated by the following working and prophetic examples, neither of which should be construed as limiting the invention. Additionally, to the extent that section headings are used, they should not be construed as necessarily limiting. Any use of the past tense to describe an example otherwise indicated as constructive or prophetic is not intended to reflect that the constructive or prophetic example has actually been carried out. Brief Description of the Figures

[0046] Figure 1 shows a dual-liquid droplet sprayer apparatus of the present invention.

[0047] Figure 2 shows a front, right perspective view of a dual-liquid spray nozzle assembly having a pair of spray nozzles, illustrating the side-by-side swirling, dispersed-droplet streams.

[0048] Figure 3 shows an exploded view of the dual-liquid spray nozzle assembly.

[0049] Figure 4 shows a rear, right perspective view of a the dual-liquid spray nozzle assembly.

[0050] Figure 5 shows a sectional view of the side-by-side first and second air-assist spray nozzles, taken along line 5-5 of Figure 2.

[0051] Figure 6 shows a top plan schematic view of the side-by-side first and second air- assist spray nozzles (without showing other structures of the dual-liquid spray nozzle assembly, for clarity), illustrating the dispersing angles ȕ1and ȕ2of the side-by-side swirling, dispersed- droplet streams.

[0052] Figure 7 illustrates the counter-rotation of the side-by-side swirling, dispersed- droplet streams, viewed from line 7-7 of Figure 6.

[0053] Figure 8 illustrates a top perspective view of an alternative dual-liquid spray nozzle assembly. 13 ^Attorney docket: HYT-009R-PCT ^ Detailed Description of the Invention Definitions

[0054] As used inand in the claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise.

[0055] The term “about” as used herein, refers to variation in the numerical quantity that can occur, for example, through typical measuring and liquid handling procedures used for making concentrates or use solutions in the real world; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients used to make the compositions or carry out the methods; and the like. The term “about” also encompasses amounts that differ due to different equilibrium conditions for a composition resulting from a particular initial mixture. Similarly, whether or not a claim is modified by the term, “about,” the claims included equivalents to the quantities recited.

[0056] As used herein, the term “aqueous composition” refers to a combination of liquid components that includes water. Most commonly, aqueous compositions are synonymous with the term “solution” as it is commonly used in the art for this invention. However, depending on the identity of components in the composition in addition to water, “aqueous compositions” can also encompass mixtures, emulsions, dispersions, suspensions or the like. Furthermore, while water must be present, it need not comprise the majority of the aqueous composition.

[0057] As used herein, the term, “concurrent” means the two or more liquid compositions are both dispersed independently within a period of time, or within each of a series of periods of time.

[0058] As used herein, an “equivalent diameter” of a non-spherically-shaped droplet refers to the diameter of a sphere of a liquid that is equivalent in mass to the non-spherical-shaped droplet of the liquid, such as where gravity causes a droplet to form a “teardrop” or “raindrop” shape.

[0059] As used herein, the terms “free” or “substantially free” refer to the total absence or near total absence of a particular compound in a composition, mixture, or ingredient.

[0060] As used herein, the term “reaction layer” refers to a layer formed on a surface arising from the combining or coalescing of at least a first aqueous composition and a second aqueous composition upon the surface. Each aqueous composition can comprise one or more compounds, whereupon the formation of a reaction layer, react with each other within the reaction layer to form a product in situ. 14 ^Attorney docket: HYT-009R-PCT ^

[0061] As used herein, the term, “volumetric space” refers to atmosphere or the air space within a room or other contained space, typically on fixed and determinable volume, and typically containing objects or structure therein having surfaces.

[0062] In describing embodiments of the methods and systems in the present disclosure, reference will be made to “first” or “second” as they refer to aqueous compositions. Except when there is clear context that a specific order is intended, “first” and “second” are merely relative terms, and a “first” composition described could just as easily and conveniently be referred to as a “second” composition, and such description is implicitly included herein. Embodiments of the Invention In situ peracid formation

[0063] In one non-limiting embodiment of the invention, a first liquid composition comprises an aqueous composition with a first reactant compound comprising hydrogen peroxide, and a second liquid composition comprises an aqueous composition with a second reactant compound comprising an organic acid, or alternatively an iodide salt. The first liquid composition comprises at least 0.1% and up to 15% hydrogen peroxide, and the second liquid composition comprises at least 0.1% and up to 20% an organic acid (or alternatively an iodide salt) . The two liquid compositions are dispersed simultaneously as droplets within the respective swirling stream of air into a volumetric space (airspace). Either or both of the first liquid composition and the first liquid composition can also comprise independently from at least 0.1% and up to 25% an alcohol, which can be one or more alcohols of the following: ethanol, propanol, isopropanol, butanol and its isomeric structures, pentanol and its isomeric structures, and hexanol and its isomeric structures.

[0064] Non-limiting examples for first and liquid compositions comprising respective first and second peracid reactant compounds, such as hydrogen peroxide and organic acid, can be found in US Patent Publications 2020 / 0306399 and 2021 / 0015954, and International Patent Publication WO 2021 / 178774, the disclosures of which are incorporated by reference in their entireties.

[0065] Each of the first and second liquid compositions can be contained within and dispensed by a multi-nozzle liquid dispensing device illustrated in Figure 1. The multi-nozzle liquid dispensing device includes a blower assembly, a nozzle system comprising at least two nozzles including a first nozzle and a second nozzle formed within a nozzle body, a housing for the blower and the nozzle body, at least two separate formulation tanks, including a first tank and 15 ^Attorney docket: HYT-009R-PCT ^ a second tank, and at least one or more metering valves in fluid communication with and between the first tank and the first nozzle, and the second tank and the second nozzle. The blower can be a two-stage axial compressor driven by a universal motor operating at a speed of up to 20,000 RPM. The blower moves a large mass and volume of air through the nozzles of the nozzle system. A volumetric flow of both the air and respective liquid compositions are drawn through each of the two nozzles, with the respective liquid compositions dispersed into tiny aerosol droplets and dispersed into the atmosphere. The flow rate of the first and second liquid compositions can be controlled manually or remotely with the metering valve. Each of the first and second liquid compositions is contained within the separate and respective first and second tanks. Generally, the sizes of the output droplets increase with increasing liquid flow rate and with increasing viscosity of the liquid being dispensed.

[0066] Other means of imparting energy to dispense a stream or a dispersion of droplets of a liquid composition can include pumps, centrifugal misters, and piezo-electric misters.

[0067] In various embodiments, a conventional multi-nozzle liquid dispensing device can be modified to form the multi-nozzle liquid dispensing device of the present invention. A modification of or change from a conventional multi-nozzle liquid dispensing device can include the addition of a second formulation tank, or the replacement of the conventional formulation tank with at least two separate formulation tanks. A modification of or change from a conventional multi-nozzle liquid dispensing device can include the modification or the replacement of the conventional nozzle body to provide a nozzle body having a pair of (two) nozzles that have separate and respective fluid communication with first nozzle and second nozzle of the present invention through separate liquid supply lines. with two separate formulation tanks. A conventional nozzle body has preferably three nozzles that are in fluid communication to a single common liquid supply line to the single formulation tank. Non-limiting examples of a conventional nozzle body include the spraying and fogging apparatus available from B&R Equipment Company under the brand names Dyna-Fog and Hurricane.

[0068] The first and second nozzles are disposed within the nozzle body with the outlets of the nozzles positioned along respective axes. The first and second nozzles outlets are spaced apart by a horizontal distance of about 1-3 inches (2.5-7.6 cm), though larger spacing can be used. 16 ^Attorney docket: HYT-009R-PCT ^ Working Examples

[0069] The following examples illustrate the embodiments of the invention that are presently best known. However, it is to be understood that the following are only exemplary or illustrative of the application of the principles of the present invention. Numerous modifications and alternative compositions, methods, and systems may be devised by those skilled in the art without departing from the spirit and scope of the present invention. Thus, while the present invention has been described above with particularity, the following examples provide further detail in connection with what are presently deemed to be the most practical and preferred embodiments of the invention. Example 1: Dual liquid spraying

[0070] A dual-liquid spray nozzle assembly can be made by modification of a spray nozzle taken from a conventional Hurricane ES hand-carry electrostatic ULV fogger, available from B&G Equipment Company, that is conventionally configured to spray a single liquid from a single container through each of three spray nozzles simultaneously. Other dual-liquid air-assist sprayers can be made using other pressurized air blowers and dual liquid containers. The three spray nozzles are arranged in a triangular pattern, each with a respective air-assist spray nozzle. The conventional spray nozzle assembly also has separate air swirl channels, each channeling air from the blower through respective inner swirlers to a venturi passage, and respective outer swirlers for carrying and dispersing the liquid droplets outward and along the dispersing vector. Each of the three outer swirlers has a construction as described herein above, including a plurality of circumferentially-spaced axially-extending curved vanes that provide a plurality of swirl channels, though wherein the swirl channels of each of the three outer swirlers rotate in the same rotational direction; either all clockwise or all counterclockwise.

[0071] The dual-liquid spray nozzle assembly is assembled into a dual-liquid droplet sprayer apparatus as shown in Figures 1-7. The sprayer apparatus 1 includes a housing body 2 for housing a blower 3 and a nozzle assembly 4, and has a housing base for connecting a cylindrical container 5. The cylindrical container 5 consists of a pair of semi-cylindrical-shaped containers 5a,5b assembled and secured together, and having a common upper connection for connecting to the base of the housing 2. Each of the first container 5a and the second container 5b has respective outlet ports 6a,6b, a pair of flow control valves 7a,7b to control liquid flow from the respective 17 ^Attorney docket: HYT-009R-PCT ^ containers 5a,5b, and liquid supply tubes 8a,8b connecting the outlets of the flow control valves 7a,7b to respective supply ports 11,21 (see Figure 4) of the modified nozzle assembly 4. The spray nozzle assembly also includes an ionizing device 9, illustrated in FIG. 1 as an ionizing or high voltage charging system comprising pin electrodes and a charging (ground) ring, proximate to the nozzles 10 and 20, for electrostatically charging the microdroplets of the aqueous composition dispensed by the nozzles. Typical electrostatic charges on the dispersed droplets are between 5 to 20 kilovolts (kV), such as 8-10 kV.

[0072] Figure 2 shows the spray nozzle assembly 4 having an overall size and shape for mounting within the housing body 2. The liquid supply port and manifold of the conventional nozzle assembly are replaced or modified to provide separate, dedicated supply ports 11,21 (see Figure 4) to feed liquid from the flow control valves 7a,7b to the respective spray nozzles 10,20. One of the three spray nozzles (the nozzle shown at the 12-o'clock position in a front view) of the conventional model was deleted or blocked off, and / or replaced with a blank position 30.

[0073] The remaining two spray nozzles provide a pair of air-assist spray nozzles having respective inner and outer swirlers for swirling of the pressurized air supplied to the spray nozzles, a venturi function, and air / liquid discharge ports, within the pair of spray nozzles oriented along the parallel axes S1 and S2. As shown in Figure 3, the outer swirlers 14,24 are constructed and oriented to provide opposite, counter-rotation of the swirling, dispersed-droplet streams dispersed from the first and second air-assist spray nozzles. The right-side outer swirler 14 includes a plurality of swirl vanes 42 attached to a swirl plate 54 that curve radially inwardly in a clockwise direction toward a droplet feed port 15, when viewed facing the front of the spray nozzle assembly 4, while the left-side outer swirler 24 includes a plurality of swirl vanes 43 attached to a swirl plate 55 that curve radially inwardly in a counter-clockwise direction toward a droplet feed port 25.

[0074] Figure 3 shows an exploded view of a dual-liquid, air-assist spray nozzle made of four segments: a spray outlet segment 4a, a carrier air swirler segment 4b, a segment 4c consisting of a pair of inner swirlers, and a liquid supply segment 4d. Figure 4 shows a rear view of the dual- liquid, air-assist spray nozzle, and Figure 5 shows a sectional view of the dual-liquid, air-assist spray nozzle showing each of the four segments.

[0075] The liquid supply segment 4d provides a structure member having a pair of liquid supply ports 11,21 (see Figure 4) that is in liquid communication with respective liquid outlet ports 48,49 (see Figure 3), and an outer surface 50,51 that cooperates with an inner surface 58,59 of the 18 ^Attorney docket: HYT-009R-PCT ^ inner swirler 12,22 to form a venturi passage. The inner swirlers 12,22 include a plurality of circumferentially-spaced axially-extending curved vanes 46,47 secured to a swirl plate 52,53 that provide a plurality of swirl channels, each channel formed between adjacent curved vanes 46,47 and the outer surface 50,51 of the liquid supply segment 4d. Each channel has a radially-outer inlet for the pressurized supply air along the outer periphery of the inner swirler 12,22, and having a radially-inner outlet that is in fluid communication with the venturi passage and surrounds a venturi outlet port 44,45 on the outer surface of the swirl plate 52,53. The venturi portion of the pressurized air enters the inlets of the swirl channels along the outer periphery of the inner swirler 12,22, and exits and swirls from the outlet of the swirl channels, to both draw the liquid through the liquid outlet port 48.49 and fluidize the stream of drawn liquid into droplets. The venturi air- droplet mixture is discharged from a venturi outlet port 44,45 of the respective inner swirler 12,22.

[0076] Concurrently, the outer swirl portion of the pressurized air enters the inlets of the swirl channels along the outer periphery of the outer swirler 14,24 (of the carrier air swirler segment 4b), and swirls as it exits along the periphery of droplet feed port 15,25 that is aligned co- axially with the venturi outlet port 44,45 of the inner swirler 12,22. The swirling air from the outer swirler 14,24 mixes with the air-droplet mixture from the droplet feed port 15,25, to further entrain the liquid droplets within the swirling carrier air, which is then dispersed through the air / liquid discharge ports 16,26 of the spray outlet segment 4a as a swirling stream of carrier air and entrained (fluidized) droplets that rotates around the longitudinal axis in the direction of air flow.

[0077] As shown in Figure 3, facing the air / liquid discharge ports, the curved vanes 42 of the outer swirler 14 of the spray nozzle on the right side are configured to curve radially inwardly in a clockwise direction, whereby the swirling volume of carrier air swirls in the same clockwise direction while exiting the air / liquid discharge port 16. Conversely, the curved vanes 43 of the outer swirler 24 of the spray nozzle on the left side are configured to curve radially inwardly in the same counter-clockwise direction, whereby the swirling volume of carrier air swirls in the same counter-clockwise direction while exiting the air / liquid discharge port 26. As a result shown in Figures 6 and 7, the outer tangential peripheries of the side-by-side swirling, dispersed-droplet streams 51,52 interface in a downward direction with the force of gravity, illustrated by the black arrows in Figure 7. 19 ^Attorney docket: HYT-009R-PCT ^

[0078] The direction of rotation of the curved vanes 46,47 of the inner swirlers 12,22 of are counter-rotational, and opposite the respective direction of rotation of the curved vanes 42,43 of the corresponding outer swirler 14,24.

[0079] First and second spray liquid compositions were supplied, and placed into the first and second containers 5a,5b. At a reduced setting of the power delivered to the blower (about 70% of the amount of power delivered by the blower when spraying a single liquid through the three nozzles of the conventional single-liquid spray nozzle assembly), the dispersing angles ȕ1 and ȕ2 of the spray patterns of the first and second liquid compositions, shown in Figure 6, were about 20° to 30°. The simultaneous spraying of the first and second liquid compositions resulted in side- by-side swirling, dispersed-droplet streams that resisted intermixing of the respective streams and droplets.

[0080] In an alternative embodiment, another dual-liquid air-assist spray nozzle assembly includes side-by-side first and second spray nozzles that are arranged and configured with respective counter-rotational outer swirlers, and where the central axis of the two spray nozzles diverge at a diverging angle of about 5 degrees in a horizontal plane, and are not parallel to one another, as shown in Figure 8. No or negligible droplets of mixed composition within the airspace to a distance of at least about 10 feet (3.3 meters) from the spray nozzle apparatus 1 are detected. The distribution of the size of the droplets of each of the first and second liquid compositions result in the accumulation of coalescing droplets onto the target surfaces along the entire pathway. 20 ^

Claims

Attorney docket: HYT-009R-PCT ^ We claim:

1. A dual-liquid air-assisted spray apparatus, for dispensing two different liquids simultaneously as droplets, comprising: a spray nozzle assembly comprising two air-assist spray nozzles, each nozzle having a nozzle axis, a means for supplying pressurized carrier air, a first means for supplying the first liquid composition to the first nozzle, and a second means for supplying the second liquid composition to the second nozzle, a first swirler including a plurality of curved vanes that curve radially inwardly in a first rotational direction, for dispensing a swirling, dispersed-droplet stream from the first nozzle in the first rotational direction around the first nozzle axis, and a second swirler including a plurality of curved vanes that curve radially inwardly in a second rotational direction, for dispensing a swirling, dispersed-droplet stream from the second nozzle in the second rotational direction around the second nozzle axis that is counter-rotational to the first rotational direction.

2. The dual-liquid spray apparatus according to Claim 1, wherein the two air-assist spray nozzles are side-by-side spray nozzles, and respective outer tangential peripheries of the two side-by-side swirling, dispersed-droplet streams converge tangentially in a downward direction with gravity.

3. A dual-liquid air-assisted spray nozzle assembly, for dispensing two different liquids simultaneously as droplets, comprising: two air-assist spray nozzles, each nozzle having a nozzle axis, a first swirler including a plurality of curved vanes that curve radially inwardly in a first rotational direction, and a second swirler including a plurality of curved vanes that curve radially inwardly in a second rotational direction that is counter-rotational to the first rotational direction. 21 ^

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