Filament Extension Atomizers for Viscous Fluid Control
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Solution Overview
Problem
Conventional spray deposition systems face challenges in creating droplets of controlled size, distribution, and quantity, leading to overspray and inefficiency, especially when handling highly viscous or non-Newtonian fluids, and often lack the ability to treat fluids before atomization without affecting the environment.
Innovation Solution
The use of a mechanical filament extension atomization system with counter-rotating rollers and a baffle unit to control the stretching and breaking of fluid filaments into droplets, minimizing overspray through directional control and thermal isolation, allowing for precise droplet formation and treatment of fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spray deposition systems use highly pressurized air to atomize viscous fluids, then droplets can be generated, but the droplet size, distribution, and quantity cannot be controlled
Solution Approach 1:
The patent replaces the conventional pneumatic atomization system (using highly pressurized air) with a mechanical filament extension system using counter-rotating rollers. The rollers stretch the fluid into filaments that break into droplets through capillary forces, providing mechanical control over droplet formation instead of relying on uncontrolled pneumatic forces.
Solution Approach 2:
The patent controls droplet parameters by adjusting roller rotation speed, roller gap distance, and fluid feed rate. These parameter changes allow precise control over filament extension length and breaking point, thereby controlling droplet size, distribution, and quantity without increasing system complexity.
2Productivity
If mechanical spray deposition systems use diverging surfaces to atomize viscous fluids, then large volumes of spray droplets are produced, but overspray occurs and droplets are spread in many directions
Solution Approach 1:
The patent uses asymmetric roller surfaces where one roller has a smooth surface and the other has a textured or patterned surface. This asymmetry creates controlled filament formation and breaking patterns that direct droplets in a specific direction rather than spraying in many directions, reducing overspray while maintaining productivity.
Solution Approach 2:
The patent transitions from a conventional spray pattern (droplets dispersed in three-dimensional space) to a directed filament-based atomization where droplets form along a controlled path between the rollers. This dimensional control confines the atomization process to a narrower trajectory, reducing lateral dispersion and overspray.
3Reliability
If the atomized fluid requires heating or other treatment before spraying, then the fluid can be properly atomized, but the heat stress affects surrounding components
Solution Approach 1:
The patent incorporates a heating element positioned upstream of the roller atomization zone, allowing the fluid to be heated and treated before it contacts the rollers. This preliminary action ensures the fluid reaches the optimal temperature and viscosity for atomization without exposing surrounding components to heat stress during the atomization process itself.
Solution Approach 2:
The patent introduces a heated fluid conduit or channel that acts as an intermediary between the heat source and the atomization zone. This intermediary allows thermal energy to be transferred to the fluid in a controlled manner, isolating the heat source from surrounding components while still achieving the required fluid temperature for proper atomization.
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 system effectively produces droplets of controlled size and distribution, minimizing overspray and enabling efficient fluid use while protecting the environment from fluid contamination and thermal stress.
Implementation Method 1
The applied strain or continuous stretching to the fluid filaments causes them to stretch until beyond the point at which the fluid filaments break up from capillary forces
Implementation Method 2
The baffle unit is positioned within the housing to direct the formed droplets in a desired direction
Implementation Method 3
allowing for precise droplet formation and treatment of fluids... protecting the environment from fluid contamination and thermal stress
Data Source
Figure 1~2
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AI summary
An atomization device, comprising: • a first roller (720) having a plurality of grooves (724) disposed across a first surface (722) of the first roller, each of the plurality of grooves (724) enclosed by a pair of fins (726) that extend away from the first surface (722); • a second roller (710) configured to counter-rotate with respect to the first roller (720), the second roller (710) having a plurality of channels (714) disposed across a second surface (712); • the first (720) and second (710) rollers aligned with each other such that the plurality of grooves (724) of the first roller mate with the plurality of channels (714) of the second roller to form a plurality of enclosures; • a fluid source (800) configured to coat at least a surface of at least one of the rollers with a feed fluid; wherein a nip (706) is defined between each of the mated surfaces of the first (720) and second (710) rollers, and the feed fluid is drawn through each nip from an upstream side to a downstream side, such that the fluid is stretched on the downstream side of each nip as the first and second rollers counter-rotate.