Central Feed Roller for High Surface Tension Atomization
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Solution Overview
Problem
Existing filament extension atomizer systems struggle with fluids having high surface tensions, which either fail to flow through tight contact setups or are flung off high-speed rollers, limiting the ability to produce a range of droplet sizes due to reliance on doctor blades and nips.
Innovation Solution
A central feed roller system with a hollow channel and array of holes on its surface, connected via veins, allows fluid to flow from the channel to the surface holes, forming filaments and droplets without relying on doctor blades, enabling control of droplet size through backpressure and geometric design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If doctor blades and nips are used to control the film, then fluid distribution is improved, but the ability to alter droplet size is limited
Solution Approach 1:
The roller is segmented into multiple independent feed channels, each capable of producing filaments of different sizes. This allows the system to generate a range of droplet sizes simultaneously from a single roller, resolving the contradiction between precise fluid distribution and droplet size variability.
Solution Approach 2:
The system transitions from static doctor blade control to dynamic roller-based control, where the rotation speed and feed channel geometry can be adjusted to vary droplet size. This dynamic approach enables adaptability in droplet size while maintaining fluid distribution through the roller's rotational motion.
2Productivity
If high-speed rollers are used, then productivity is improved, but fluids with high surface tension are flung off
Solution Approach 1:
The system uses a hollow roller design with internal fluid channels to deliver fluid directly to the roller surface, replacing the need for external fluid reservoirs and high-speed pumping. This hydraulic approach allows precise control of fluid delivery to match roller speed, maintaining fluid retention even at high rotation speeds.
Solution Approach 2:
The system changes the physical parameters of fluid delivery by using multiple feed channels with varying geometries and positions on the roller surface. This allows optimization of fluid flow rate and distribution pattern to match the roller's rotational speed, preventing fluid flinging while maintaining high productivity.
3Device complexity
If a single roller is used, then device complexity is reduced, but the ability to produce a range of droplet sizes is limited
Solution Approach 1:
A single roller is segmented into multiple independent feed channels, each capable of producing filaments of different sizes. This internal segmentation allows the system to generate a range of droplet sizes simultaneously from one roller, achieving versatility without increasing the number of rollers or overall device complexity.
Solution Approach 2:
The single roller performs multiple functions by incorporating various feed channel geometries and positions, allowing it to produce different droplet sizes. This multi-functional design eliminates the need for multiple rollers or complex changeover mechanisms, maintaining simplicity while achieving adaptability.
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 the production of a spray of droplets with varying sizes from fluids with high surface tension, improving the system's ability to handle such fluids and offering flexibility in droplet formation.
Implementation Method 1
veins connecting the channels to the holes
Implementation Method 2
the pressure formed between the two surfaces
Implementation Method 3
fluids having extremely high surface tensions will either be flung off the high-speed rollers or not flow through tight contact blade set ups
Implementation Method 4
stretching a liquid filament between two diverging surfaces until the filament breaks up into a spray of droplets
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A roller (300) has an outer cylindrical surface having an array of holes, a central feed channel (302) inside the roller (300), and veins (304) connecting the channel (302) to the holes, forming a path for liquid between the channel (302) and the holes. An atomization system having a fluid reservoir (312); a pair of rollers (300, 400), at least one (300) of the rollers (300, 400) having: a central feed channel (302), the channel (302) fluidically connected to the fluid reservoir (312), an array of holes on a surface of the roller, and veins (304) connecting the channel (302) to the holes, a nip (402) formed between the rollers (300, 400), and a receiving surface positioned to receive droplets formed when liquid exits the holes, stretches between the rollers (300, 400) as they counterrotate to form filaments and the filaments break into droplets.