Helix Cup Convergent Flow Path for Low-Pressure Atomization
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Solution Overview
Problem
Current atomizers fail to produce sufficiently small particle size distributions at relatively low propellant pressures, which is undesirable for safety and conservation of propellant material, and require rebalancing of flow areas to adjust spray patterns, limiting manufacturing flexibility and increasing costs.
Innovation Solution
A helix cup with a funnel wall geometry that provides a convergent surface of revolution with a curvilinear funnel wall, offering a longer flow path and adjustable grooves to enhance spray characteristics without the need for rebalancing entire cap components, allowing for improved particle size distribution at lower pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If straight sidewalls are used in the atomizer, then the flow path is shorter and frictional losses are reduced, but the particle size distribution is not sufficiently small at low propellant pressures
Solution Approach 1:
The patent applies curvature to the sidewalls of the atomizer, transitioning from straight sidewalls to curved sidewalls. This curvature modifies the flow path geometry to reduce frictional losses while maintaining effective atomization at low pressures, resolving the contradiction between energy loss and particle size control.
2Manufacturing precision
If propellant pressure is increased to achieve smaller particle size distribution, then atomization quality improves, but safety risks increase and propellant material is wasted
Solution Approach 1:
The patent changes the geometric parameters of the atomizer, specifically the sidewall curvature and flow path design, to optimize atomization performance. This allows achieving fine particle size distribution at lower propellant pressures, eliminating the need to increase pressure for improved atomization and thereby reducing safety risks and propellant waste.
3Adaptability or versatility
If the cone angle of the spray pattern is adjusted using straight sidewalls, then spray characteristics change, but rebalancing of flow areas is required which limits manufacturing flexibility and increases cost
Solution Approach 1:
The curved sidewalls provide a flow path geometry that maintains stable spray characteristics across different operating conditions. The curvature design inherently balances the flow areas, eliminating the need for complex rebalancing operations when adjusting spray patterns, thereby improving manufacturing flexibility and reducing costs.
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 helix cup design achieves a tighter particle size distribution and improved manufacturing flexibility by providing a convergent flow path that increases the flow area and subtended volume, enabling efficient atomization at lower pressures without significant increases in propellant pressure, thus reducing material usage and user fatigue.
Implementation Method 1
This geometry provides a flow area defined as a convergent surface of revolution having a curvilinear funnel wall
Data Source
Figure 1~2B
Figure 3~3B
Figure 4A~4C
AI summary
A spray system for dispensing fluid products. The spray system comprises a discrete inlet port. Fluids, such as liquid, admitted to the inlet port flows into an open volume defined by a convergent surface of revolution about a longitudinal axis. The convergent surface of revolution circumscribes the longitudinal axis and, fluid flowing therethrough, towards an outlet nozzle. At least a portion of the surface of revolution is convex, concave or a combination thereof, so as not to be rectilinear.