Helix Cup Curvilinear Funnel Wall 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 change spray patterns, making them inflexible and costly to manufacture.
Innovation Solution
A helix cup with a funnel wall geometry that provides a convergent surface of revolution with a curvilinear funnel wall, increasing the flow area and subtended volume, allowing for improved spray characteristics and flexibility without the need to change the entire cap, using a frustro-conical design with grooves that influence flow direction and create a convergent helical flow path.
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 insufficiently small at low propellant pressures
Solution Approach 1:
The patent applies curvature to the funnel wall by replacing the conventional straight sidewall design with a curvilinear surface. This curved geometry modifies the flow characteristics of the liquid and propellant mixture, enabling sufficiently small particle size distribution at low propellant pressures while maintaining acceptable frictional losses through optimized flow path design.
2Adaptability or versatility
If the cone angle of the spray pattern is changed using straight sidewalls, then the spray characteristics are modified, but the flow areas must be rebalanced requiring changes to multiple components
Solution Approach 1:
The patent segments the atomizer system by making the funnel wall geometry an independent variable. The curvilinear funnel wall is designed as a separate geometric feature that can be optimized independently to achieve desired spray patterns, eliminating the need to rebalance multiple flow areas and reducing the complexity of modifications.
3Ease of manufacture
If conventional atomizer designs are used, then manufacturing is straightforward, but propellant pressure must be relatively high to achieve desired particle size distribution
Solution Approach 1:
The patent changes the geometric parameter of the funnel wall from straight to curvilinear. This parameter change fundamentally alters the flow dynamics within the atomizer, enabling effective atomization at lower propellant pressures while maintaining ease of manufacture through standard fabrication processes for curved surfaces.
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 improved particle size distribution and manufacturing flexibility at lower pressures, reducing the need for tight seals and manual force, while conserving propellant and material usage, and providing a more efficient and cost-effective spray system.
Implementation Method 1
This geometry provides a flow area defined as a convergent surface of revolution having a curvilinear funnel wall
Implementation Method 2
using a frustro-conical design with grooves that influence flow direction and create a convergent helical flow path
Data Source
AI summary
A helix cup for use in a pressurized dispenser. The helix cup has a convergent funnel wall. The funnel wall is not straight and does not satisfy the mathematical equations for surface area or for subtended volume of the frustrum of a cone. Instead, the funnel wall provides a longer flow path than is achieved with straight sidewalls. The longer flow path provides for a tighter particle size distribution at lower pressures than occurs in the prior art.