Belt Atomization of Reactive Two-Part Fluids Without Clogging
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Solution Overview
Problem
Existing filament extension atomizers struggle to effectively mix and atomize reactive, highly viscous fluids due to limited contact time and area between counter-rotating rollers, leading to clogging and reduced spray quality.
Innovation Solution
Employing a system with two belts instead of a single pair of counter-rotating rollers, utilizing guide devices to create a larger contact area and controlled mixing region, allowing for efficient mixing and atomization of reactive fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If counter-rotating rollers are used for atomization, then the system structure is simple, but the contact area and mixing efficiency are insufficient
Solution Approach 1:
The system divides the atomization function into multiple independent belts (first belt, second belt, third belt) instead of using a single roller assembly. Each belt can be independently controlled and optimized, allowing for increased total contact area while maintaining structural modularity and manageable complexity
Solution Approach 2:
The invention transitions from a single-plane roller contact to a multi-layer belt arrangement where belts are positioned at different heights and angles. This three-dimensional configuration significantly increases the effective contact area between materials and belts while distributing the mechanical load across multiple components
2Volume of stationary object
If counter-rotating rollers are used, then the device is compact, but the mixing time and area for reactive fluids are limited
Solution Approach 1:
The multiple belts are arranged to create continuous mixing zones where reactive materials undergo prolonged interaction as they pass through each belt's contact region. The sequential arrangement of belts ensures continuous mixing action without idle periods, maximizing mixing efficiency within the available space
Solution Approach 2:
The belts are arranged in a nested configuration where subsequent belts are positioned to utilize the space created by previous belts. This nesting allows the system to pack extended mixing pathways into a compact volume, increasing effective mixing time without proportionally increasing device footprint
3Stability of the object's composition
If pre-mixing is done in a chamber, then the fluids can react uniformly, but the dispenser clogs due to cross-linking
Solution Approach 1:
The system replaces traditional mechanical pre-mixing chambers with a belt-based friction mixing mechanism. The belts create shear forces and friction that mix reactive materials in situ during transport, eliminating the need for separate mixing chambers where cross-linking would cause clogging
Solution Approach 2:
The belts act as intermediary surfaces that facilitate mixing without direct material-to-material contact in a confined chamber. The flexible belt surface provides a controlled environment for gradual mixing while allowing easy release of materials, preventing the adhesion and clogging problems associated with rigid mixing chambers
4Productivity
If highly viscous fluids are sprayed, then the atomization challenge is addressed, but the fluid does not flow easily
Solution Approach 1:
The system changes the physical parameters of the viscous fluid through controlled friction and shear forces applied by the moving belts. The belts gradually reduce viscosity by generating heat and mechanical action, transforming the fluid from a highly viscous state to a sprayable state without requiring high-pressure forcing
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 belt-based system enhances mixing and atomization of reactive fluids, achieving improved spray quality and output while maintaining a compact footprint.
Implementation Method 1
Spraying or otherwise making a mist from highly viscous fluids presents several challenges. Viscous fluids do not flow easily and any process of breaking them up into particles has to overcome the inherent cohesiveness of the fluid.
Implementation Method 2
Viscous fluids do not flow easily and any process of breaking them up into particles has to overcome the inherent cohesiveness of the fluid.
Data Source
AI summary
An apparatus includes a first belt having an external surface, a second belt having an external surface opposite the external surface of the first belt, and a region in which the first belt and the second belt come in contact, a first material dispenser and a second material dispenser to dispense a first material and a second material on the external surface at least one of the first and second belts, and a power source to cause at least one of the first and second belts to move to cause the external surfaces of the first and second belts to contact and then diverge away from each other so that at least one of the first and second materials forms filaments that break up as the belts continue to diverge.