Aerosol Generator Replenishment for Continuous Filter Testing
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Solution Overview
Problem
Existing automated filter testers require manual replenishment of aerosol generator liquids, leading to shutdowns during refilling, and frequent emptying of drip jars, limiting continuous testing and requiring operator monitoring of liquid levels.
Innovation Solution
An apparatus that automatically replenishes the aerosol generator reservoir with liquid while creating an aerosol, using a pressurized gas and a microprocessor-controlled system to maintain liquid levels and heat the gas, reducing excess liquid collection and allowing continuous testing without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual replenishment of aerosol generator liquid is used, then the system can be simple to operate, but the testing process must be shut down during refilling, reducing productivity
Solution Approach 1:
The system automatically replenishes the aerosol generator liquid reservoir using a peristaltic pump that draws liquid from an external source and delivers it to the reservoir without operator intervention, allowing continuous operation
Solution Approach 2:
The manual mechanical refilling process is replaced with an automated peristaltic pump system that uses a motor-driven mechanism to transfer liquid, eliminating the need for manual operation while maintaining simple system design
2Reliability
If frequent emptying of drip jar is required, then liquid accumulation can be controlled, but the testing process must be interrupted, reducing productivity
Solution Approach 1:
The system continuously monitors and maintains liquid levels in the aerosol generator reservoir through automated replenishment, eliminating interruptions for manual emptying operations and ensuring uninterrupted testing
Solution Approach 2:
The system uses level sensors to detect when the reservoir is low and automatically activates the peristaltic pump to replenish liquid, creating a closed-loop feedback system that maintains optimal liquid levels without manual intervention
3Reliability
If operator monitoring of liquid level is required, then proper liquid levels can be maintained, but operator workload increases and attention must be diverted from testing
Solution Approach 1:
The system automatically monitors and maintains liquid levels through integrated level sensors and an automated peristaltic pump replenishment system, eliminating the need for operator monitoring while ensuring proper liquid levels are maintained throughout testing
4Reliability
If separate mixing chamber is used downstream of aerosol generator, then aerosol can be mixed with heated dilution air, but the system complexity increases
Solution Approach 1:
The aerosol generation and mixing functions are combined into a single integrated chamber where the aerosol is generated and immediately mixed with heated dilution air, eliminating the need for separate mixing chambers while maintaining effective mixing
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
Enables continuous testing without shutdowns for aerosol generator refilling or drip jar emptying, reducing operator workload and extending testing periods by automatically maintaining liquid levels and evaporating excess aerosol liquid, thus improving efficiency and operational duration.
Implementation Method 1
the aerosol generator in each of Models 8127 and 8130 must be manually replenished with liquid used to create the test aerosol
Implementation Method 2
a heater operably associated with the conduit for heating the pressurized gas directed into the reservoir
Implementation Method 3
heating the pressurized gas prior to entry into the aerosol generator to cause liquid droplets forming the aerosol to evaporate
Data Source
AI summary
The preferred form of the present invention is directed to systems and methods used to test objects including but not limited to filters, respirator cartridges and filter media. The object to be tested is subjected to an aerosol challenge while the penetration percentage and resistance at a given flow are monitored to ensure that the object will function as desired. Preferably, the test object is challenged with a salt aerosol. However, any suitable aerosol may be used. A replenishment member is provided for automatically and continuously replenishing the reservoir of an aerosol generator. The replenishment member is configured such that there is no need for an operator to monitor the liquid level in the aerosol generator reservoir either during replenishment or at anytime while the apparatus is operated. The replenishment member of the preferred form of the present invention does not require interruption of the filter testing process to replenish the aerosol generator reservoir. The preferred form of the present invention supplies heated air to the aerosol generator reservoir to significantly reduce the liquid needed to be collected in the drip jar of the impactor. This feature prolongs the run time of the test system. A control device is operably associated with the heater to activate and deactivate the heater depending upon detection of pressurized gas supplied to the aerosol generator. This feature prevents the heater from irreparably damaging the test unit and/or the surrounding environment.