Hollow Sphere Nozzle Assembly with Adjustable Gas-Liquid Outlets
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Solution Overview
Problem
Existing hollow sphere forming systems are not easily adjustable, scalable, or manufacturable, particularly for high-temperature and high-pressure materials like metallic glasses, which suffer from material property degradation due to temperature changes and require robust components to handle pressure differentials.
Innovation Solution
A hollow sphere forming apparatus with a modular nozzle assembly and pressure vessel configuration that allows adjustable positioning of gas and liquid outlets, incorporating a heatable crucible within a pressure vessel for hydrostatic balance, and using insulation to maintain mechanical strength and isolate high-temperature regions, enabling the formation of hollow spheres under various conditions without ultrasonic or air puff driving forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing hollow sphere forming systems are used, then hollow spheres can be formed, but the systems are not easily adjustable, scalable, or manufacturable
Solution Approach 1:
The apparatus is divided into separate functional modules: a pressure vessel for containing and pressurizing the liquid material, a heatable crucible for heating and melting the material, and a nozzle assembly for forming the hollow spheres. This segmentation allows each component to be manufactured, adjusted, and scaled independently, improving both adaptability and ease of manufacture.
Solution Approach 2:
The nozzle assembly includes adjustable components that allow dynamic positioning of the gas outlet and liquid outlet relative to each other. This dynamic adjustability enables optimization of the annular flow pattern for different materials and applications, while the modular design maintains ease of manufacture through standardized adjustment mechanisms.
2Adaptability or versatility
If high-temperature and high-pressure materials like metallic glasses are used, then hollow spheres can be formed from difficult-to-process materials, but material property degradation occurs due to temperature changes
Solution Approach 1:
The apparatus applies different thermal conditions to different regions: the crucible is heated to high temperatures to melt the material, while the nozzle assembly and cooling tube are maintained at lower temperatures to preserve material properties during formation. This local differentiation of thermal quality allows processing of high-melting-point materials without degrading their properties in the forming region.
Solution Approach 2:
A cooling tube acts as an intermediary between the hot crucible and the forming nozzle. The cooling tube receives molten material from the crucible and transports it to the nozzle assembly, providing a thermal transition zone that protects the material from excessive heat exposure while maintaining the necessary temperature for forming.
3Productivity
If pressure differentials are used to drive material flow, then hollow spheres can be formed, but component failure risks increase due to pressure handling requirements
Solution Approach 1:
The pressure-containing functions are segmented into separate components: the pressure vessel handles high-pressure containment, while the nozzle assembly handles pressure-driven flow. This segmentation allows each component to be optimized for its specific pressure requirements, improving overall reliability while maintaining forming capability.
Solution Approach 2:
A seal assembly acts as an intermediary between the pressure vessel and the nozzle assembly, managing pressure differentials through controlled sealing. This intermediary component protects other parts from direct pressure exposure while maintaining the necessary pressure-driven flow for hollow sphere formation.
4Adaptability or versatility
If adjustable outlet positioning is implemented, then flexible design and optimization are enabled, but device complexity increases
Solution Approach 1:
The adjustable positioning system is segmented into independent adjustment mechanisms for the gas outlet and liquid outlet. Each outlet can be positioned independently relative to the other, allowing flexible annular flow pattern optimization. The modular segmentation keeps the complexity manageable by dividing the adjustment function into separate, standardized components.
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 reproducible formation of uniform hollow spheres using materials with high melting points and viscosity, reducing material property degradation and component failure risks by maintaining hydrostatic stress and allowing flexible design with adjustable outlet alignment and pressure management.
Implementation Method 1
a heatable liquid material reservoir defining a heatable inner volume
Implementation Method 2
pressure vessel configuration that allows adjustable positioning of gas and liquid outlets, incorporating a heatable crucible within a pressure vessel for hydrostatic balance
Implementation Method 3
a cooling tube having at least one opening disposed adjacent the outer opening of the fluid outlet, and being of sufficient height to allow the spheres to cool and solidify therein during transit therethrough
Implementation Method 4
using insulation to maintain mechanical strength and isolate high-temperature regions
Data Source
AI summary
Apparatuses and methods of forming hollow spheres are provided. Hollow sphere forming apparatus incorporate a bubble forming nozzle assembly in which outlets for gas and liquid materials are disposed substantially coaxially. The relative positions of the gas and liquid outlets are adjustable in at least one dimension (e.g., axially, radially or angularly relative to each other), such that a more uniform annular exit region for the gas and liquid outlets may be configured, such that more symmetric bubbles may be formed thus reducing the rejection rate in solidified bubbles due to asymmetry or decentering of entrapped gas.