Aerosol Generator With Impactor For Cohesive Powder Deagglomeration
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Solution Overview
Problem
Existing aerosol generators struggle with cohesive powders that tend to agglomerate, leading to clogging and material losses, and fail to maintain controlled particle size distribution and dose accuracy for inhalable aerosolized products.
Innovation Solution
An aerosol generating apparatus with a partially spherical powder chamber and offset inlet conduits for pressurized gas, combined with an impactor having a conical and cylindrical surface to create a rotating flow and counteract agglomeration, ensuring efficient deagglomeration and controlled particle size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional aerosol generators are used with cohesive powders, then the device structure is simple, but the powder particles agglomerate leading to clogging and material loss
Solution Approach 1:
The apparatus divides the powder treatment process into multiple stages: initial suspension in the powder chamber, deagglomeration through the impactor with conical surface, and final aerosol formation. This segmentation allows each stage to address specific problems - the impactor specifically targets agglomerate breakdown while the narrow exit conduit ensures controlled aerosolization, preventing material loss from clogging or incomplete aerosolization
Solution Approach 2:
The impactor with conical surface acts as an intermediary element between the powder chamber and the aerosol output. It receives the powder-gas mixture, performs deagglomeration through its conical surface geometry, and delivers the processed mixture to the narrow exit conduit. This intermediary structure specifically addresses the agglomeration problem without compromising the simplicity of the overall device
2Manufacturing precision
If conventional aerosol generators are used, then the device structure is simple, but the particle size distribution becomes uncontrolled
Solution Approach 1:
The apparatus segments the aerosol generation process into distinct functional zones: the powder chamber for loading and initial mixing, the impactor region for deagglomeration with controlled particle breakdown, and the narrow exit conduit for final aerosol formation. This segmentation enables precise control over particle size distribution at each stage while maintaining overall device simplicity through straightforward geometric configurations
Solution Approach 2:
The apparatus controls particle size distribution by manipulating physical parameters: the impactor's conical surface geometry controls the deagglomeration force, the narrow exit conduit diameter controls the final aerosol particle size, and the gas flow rate controls the suspension dynamics. These parameter changes achieve precise manufacturing control without requiring complex additional components
3Productivity
If cohesive powders are aerosolized without special measures, then the process is simple, but clogging occurs in the exit conduit
Solution Approach 1:
The apparatus performs preliminary deagglomeration action in the impactor region before the powder-gas mixture reaches the narrow exit conduit. The conical surface of the impactor breaks up agglomerates in advance, ensuring that only properly sized particles attempt to pass through the exit conduit. This preliminary action prevents clogging and maintains continuous operation, improving both productivity and reliability
Solution Approach 2:
The impactor extracts and removes agglomerates from the powder-gas mixture through its conical surface geometry. By taking out the problematic agglomerated portions before they reach the narrow exit conduit, the system prevents clogging and ensures smooth, continuous aerosol generation without interruptions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus effectively deagglomerates cohesive powders, reducing clogging and material loss, while maintaining a controlled particle size distribution and improving dose accuracy for inhalable aerosolized products.
Implementation Method 1
the energy in a compressed gas to break up the powder in a powder chamber where the powder is instantaneously pressurized and suspended
Implementation Method 2
a turbulent non-rotating flow transports the powder for ejection through a narrow exit conduit
Implementation Method 3
The rapid expansion from the narrow exit conduit accomplishes deagglomeration and generation of a micrometer size aerosol
Implementation Method 4
the at least two inlet conduits have inlet orifices located the at least partially spherical part of the powder chamber... so a powerful rotating flow towards the exit conduit will become established
Implementation Method 5
an impactor having a conical and cylindrical surface to create a rotating flow and counteract agglomeration
Data Source
AI summary
The present invention is directed to improvements related to the generation of aerosols and outlines an apparatus and methods which supports deagglomeration and counteracts reagglomeration of aerosol particles. The apparatus is provided with an arrangement of inlet conduits for pressurized gas that promote transportation with a rotational flow towards an exit conduit. In order to further support production of high quality aerosols, the apparatus can be provided with an impactor aligned with the exit conduit with at least one impacting surface that minimizes formation of impact residues.