Extended-Surface Element for Thermal Fogger Aerosol Stability
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Solution Overview
Problem
Existing thermal foggers face challenges in producing high-quality, stable aerosols efficiently, particularly in applications like potato storage facilities where uniformity and persistence of aerosols are crucial, due to limitations in heat transfer and flow dynamics within the aerosolization chamber.
Innovation Solution
The introduction of an extended-surface element with a convoluted shape, such as a helically-shaped mixing means, within the aerosolization chamber to enhance heat transfer and turbulence, ensuring the aerosol particles contact more hot surface area, thereby improving the stability and uniformity of the aerosol produced.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional aerosolization chamber is used, then the device structure is simple, but the heat transfer efficiency is insufficient and aerosol stability is poor
Solution Approach 1:
The aerosolization chamber is segmented into multiple zones with different functions: a heating zone with hot gas injection, a mixing zone with extended surface elements, and an aerosolization zone. This segmentation allows optimized heat transfer and mixing while maintaining overall structural clarity.
Solution Approach 2:
Extended surface elements are introduced into the aerosolization chamber to create additional dimensional surfaces for heat transfer. These elements extend the hot surface area beyond the chamber walls, increasing the dimensionality of heat transfer interfaces and improving aerosol stability.
2Manufacturing precision
If heat transfer is improved with extended surfaces, then aerosol quality improves, but energy consumption increases
Solution Approach 1:
The extended surface elements are designed to interact dynamically with the gas flow, creating turbulence that enhances heat transfer efficiency. This dynamic interaction allows more effective heat transfer per unit energy input, improving aerosol quality without proportional energy increases.
Solution Approach 2:
The system optimizes parameters such as hot gas temperature, liquid chemical flow rate, and extended surface geometry to achieve maximum aerosol quality with minimum energy consumption. By carefully controlling these parameters, the system achieves efficient heat transfer without excessive energy input.
3Power
If turbulence is increased with extended surfaces, then heat transfer improves, but flow stability becomes more complex
Solution Approach 1:
The extended surface elements act as intermediaries between the hot gas stream and the liquid chemical, facilitating controlled turbulence and heat transfer. These elements mediate the interaction between flow streams, creating beneficial turbulence while maintaining overall flow stability and predictability.
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
This solution significantly enhances the quality and stability of aerosols by increasing heat transfer and turbulence, leading to more efficient aerosol formation and improved treatment efficacy in crop storage facilities, such as potato storage units.
Implementation Method 1
the entrained liquid particles of the aerosol contact the hot extended surface more frequently, thereby improving heat transfer from the hot extended surface to the liquid particles
Implementation Method 2
The extended-surface element may include an auger or screw-shaped element. The extended-surface element may be in a fixed, but removable position within the aerosolization chamber
Data Source
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AI summary
A structural insert for installation into an aerosolization barrel of a thermal fogger comprises a mixing means (40) adapted and configured to contact the liquid material and the heated gas to cause the heated gas and the liquid material to travel a convoluted path before being discharged as an aerosol (35), wherein the mixing means comprises an extended-surface element configured to fit internally within an aerosolization chamber (20) of the thermal fogger, wherein the extended-surface element has a convoluted surface to interrupt and divert a flow of gas and liquid particles from a linear path to a circuitous path before exiting the aerosolization chamber as a stable aerosol, and characterised in that the extended-surface element comprises a central longitudinal core (45) and flow diversion blades (50) attached thereto, and has an outer dimension which is substantially similar to the inside diameter of the aerosolization chamber; and in that the extended-surface element increases the effective distance travelled by a forming aerosol by at least 25% of the length of the aerosolization chamber. Also disclosed is a heat exchange surface element for a tubular-shaped aerosolization chamber of a thermal fogger