Droplet Ejection Airflow Control for Uniform Particle Granulation
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Solution Overview
Problem
Conventional particulate material production methods using ejection granulation struggle to produce materials with a narrow particle diameter distribution due to droplet uniting issues, leading to uneven particle sizes and reduced efficiency.
Innovation Solution
A particulate material production apparatus and method employing a droplet ejector, solidifying device, and airflow systems, where a second airflow is applied perpendicular to the droplet ejection direction to prevent droplet uniting, utilizing a liquid column resonance type droplet ejecting device to ensure consistent droplet formation and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If droplets are ejected continuously to improve productivity, then production efficiency increases, but droplet uniting occurs causing poor particle diameter distribution
Solution Approach 1:
An airflow field is introduced as an intermediary between ejected droplets to prevent direct contact and uniting. The airflow acts as a mediator that separates droplets spatially and temporally, allowing continuous ejection while maintaining particle diameter distribution uniformity.
Solution Approach 2:
Pneumatic airflow is used to control droplet trajectories and prevent uniting. By applying controlled air streams, the system maintains droplet separation during flight, enabling high-speed continuous ejection without compromising particle size uniformity.
2Productivity
If droplet ejection speed is increased to improve productivity, then production efficiency increases, but droplet uniting becomes more likely occurring
Solution Approach 1:
The airflow field serves as a protective intermediary that scales with ejection speed. As droplets are ejected at higher velocities, the airflow dynamically adjusts to maintain adequate separation, preventing uniting even at increased production rates.
Solution Approach 2:
The airflow control system dynamically adapts to varying ejection speeds. By adjusting airflow parameters in real-time based on ejection velocity, the system maintains reliable droplet separation across different productivity levels.
3Productivity
If multiple nozzles are used to increase production volume, then productivity improves, but droplet uniting between adjacent nozzles occurs
Solution Approach 1:
The airflow field acts as a universal intermediary between droplets from multiple nozzles. It creates separation zones between adjacent nozzle outputs, preventing cross-contamination and uniting even as the number of nozzles increases to boost production volume.
Solution Approach 2:
The airflow system segments the ejection space into distinct zones for each nozzle. This spatial segmentation prevents interaction between droplets from different nozzles, allowing high-density nozzle arrays to operate without droplet uniting issues.
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 approach effectively prevents droplet uniting, resulting in a sharp particle diameter distribution of the produced particulate material, enhancing production efficiency and uniformity.
Implementation Method 1
a droplet ejecting device to eject droplets of a liquid including a particulate material composition or a melted particulate material composition; a liquid column resonance type droplet ejecting device in which a liquid column resonance standing wave is generated in a liquid column resonance chamber
Implementation Method 2
a vibration generating device to generate high-frequency vibration; a liquid column resonance standing wave is generated in a liquid column resonance chamber
Implementation Method 3
a solidifying device to solidify the droplets to form a solid particulate material
Data Source
Figure 1
Figure 2~3
Figure 4A~4D
AI summary
A particulate material production apparatus (1) is disclosed. The particulate material production apparatus (1) includes a droplet ejector (2; 105) to eject droplets of a particulate material composition liquid or a melted particulate material composition in a droplet ejection direction from nozzles (19); a solidifying device (60) to solidify the droplets; a first airflow forming device (7) to form a first airflow to feed the ejected droplets to the solidifying device (60) with the first airflow; and a second airflow forming device (108; 108-2, 106;108-3, 106; 108-4) to form a second airflow to apply the second airflow the droplets before the droplets are fed by the first airflow. The second airflow forming device (108; 108-2, 106;108-3, 106; 108-4) forms the second airflow by supplying a pressed gas from a slit (103), and the traveling direction of the first airflow is substantially perpendicular to the droplet ejection direction.