Droplet Generation System with Cyclic Valve for Variable Aerosol
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Solution Overview
Problem
Current droplet generation systems lack flexibility in producing aerosol mixtures with variable droplet sizes and flow rates, limiting their utility in thermochemical reactions, particularly in flame spray pyrolysis applications where different chemical compounds require specific residence times for complete reaction.
Innovation Solution
A droplet generation system featuring a two-nozzle configuration with controllable inlet passages for liquid and gas, a cyclically operable valve mechanism, and solenoid actuation to produce micro-dimensional droplets with adjustable mean diameter and flow rate, allowing for narrow droplet size distribution and variable flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional atomizers and mist makers are used, then fine aerosol mixtures can be produced, but the mean droplet size and flow rate are fixed and cannot be adjusted
Solution Approach 1:
The patent employs a dynamically controllable valve mechanism that can adjust droplet generation parameters in real-time. The valve is actuated by a solenoid that can be controlled electronically, allowing dynamic adjustment of droplet size and flow rate without requiring multiple fixed devices. This dynamic control system enables the same device to adapt to different chemical compounds and reaction requirements.
Solution Approach 2:
The system changes physical parameters (droplet size, flow rate) by adjusting valve opening degree and solenoid actuation frequency. By varying these parameters, the system can produce different aerosol characteristics from the same liquid feed, eliminating the need for multiple specialized atomizers and enabling versatile application across different thermochemical processes.
2Adaptability or versatility
If fixed flow rate devices are used, then simple device design is maintained, but different chemical compounds cannot be processed with appropriate residence times
Solution Approach 1:
The system incorporates feedback control through electronic monitoring of solenoid actuation and valve position. This allows precise control and adjustment of flow rate and droplet size based on process requirements. The feedback mechanism ensures consistent aerosol generation while enabling easy adaptation to different chemical compounds by adjusting operating parameters.
3Manufacturing precision
If narrow droplet size distribution is achieved, then reaction uniformity is improved, but device complexity increases
Solution Approach 1:
The patent segments the droplet generation process into distinct functional zones: liquid feed introduction, gas-liquid mixing region, and droplet ejection zone. Each segment is optimized to contribute to narrow droplet size distribution. The segmentation allows precise control over droplet formation mechanisms while maintaining relatively simple individual components that can be independently engineered and maintained.
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 nanoparticles with tailored properties by varying droplet sizes and flow rates, enhancing the production rate and versatility of the system for applications like flame spray pyrolysis, achieving droplet sizes from 3 to 80 microns and flow rates up to 1.5 liters per hour with improved throughput compared to existing systems.
Implementation Method 1
The valve mechanism is cyclically operable and is actuated by a solenoid
Implementation Method 2
respective inlet passages for a liquid, e.g. an inorganic or organic solution, and a gas, e.g. air, and merges the liquid and gas to form, in a downstream passage, an intermediate stream that is a mixture of the gas and of a dispersed phase of the liquid
Implementation Method 3
the liquid carrier is evaporated and nanoparticles of the reaction product are deposited on a substrate
Implementation Method 4
flame spray pyrolysis of an atomised dispersion of micro-dimensional droplets containing a nanophased precursor material
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A droplet generation system includes a first nozzle configuration (20) structured to receive a liquid and a gas under pressure in a controllable feed ratio, and to merge the liquid and gas to form an intermediate stream that is a mixture of the gas and of a dispersed phase of the liquid. A second nozzle configuration (30) is connected to receive the intermediate stream from the first nozzle configuration and has a valve mechanism (32) with one or more controllable operating parameters to emit a stream of droplets of the liquid. The mean size of the droplets is dependent on the controllable feed ratio of the liquid and gas and the flow rate of the stream of droplets is dependent on the controllable operating parameter(s) of the valve mechanism. A corresponding method is disclosed, as is the application of the system and method to the production of nanoparticles in a thermochemical reactor.