Membrane Unit Vibration Control via Segmented Substrate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing membrane units for aerosol generators face challenges in accurately adjusting vibrational characteristics for reproducible nebulization and easy attachment to the generator, while also requiring increased integration and cost-effectiveness.
Innovation Solution
A membrane unit comprising a rigid substrate, a flexible circuit with a conductive pattern, and an oscillator, where the rigid substrate is made from materials like GRILAMID or Vectra, and the flexible substrate is adhered to the rigid one, allowing for adjustable vibrational characteristics and easy attachment through a compact and high-integration design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible substrate is used to support the membrane and oscillator, then the membrane unit can be easily attached to the aerosol generator, but the vibrational characteristics of the membrane cannot be accurately adjusted
Solution Approach 1:
The substrate is divided into two distinct parts: a rigid substrate portion that provides stable support for the membrane and oscillator, and a flexible substrate portion that enables easy attachment. This segmentation allows each part to fulfill its specific function optimally without compromise.
Solution Approach 2:
Different regions of the substrate have different mechanical properties: the rigid substrate portion located at the membrane support area provides structural stability for precise vibrational characteristics, while the flexible substrate portion at the attachment area provides ease of installation. This local differentiation resolves the contradiction between stability and flexibility.
2Ease of manufacture
If the substrate is made flexible to allow easy mounting, then attachment to the aerosol generator becomes simple, but the structural stability required for reproducible nebulization is compromised
Solution Approach 1:
The substrate is segmented into rigid and flexible portions, where the rigid portion ensures structural stability for reliable and reproducible nebulization performance, while the flexible portion enables easy mounting and disassembly for manufacturing and maintenance convenience.
Solution Approach 2:
The substrate exhibits asymmetric mechanical properties across its structure, with the rigid substrate portion providing stability for the nebulization function and the flexible substrate portion providing ease of mounting. This asymmetric design allows both contradictory requirements to be satisfied in different locations.
3Adaptability or versatility
If the membrane unit is designed with multiple separate components, then each component can be optimized independently, but the integration scale and cost-effectiveness are reduced
Solution Approach 1:
The rigid substrate and flexible substrate are merged into a single integrated substrate structure, reducing the number of separate components while maintaining the ability to optimize different regions independently. This integration improves manufacturing efficiency and cost-effectiveness without sacrificing design flexibility.
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 solution enables reproducible nebulization, easy attachment, and increased integration of the membrane unit, enhancing the aerosol generator's performance and manufacturing efficiency.
Implementation Method 1
a membrane unit for an aerosol generator... wherein a liquid is nebulized/aerosolized by means of the membrane unit
Implementation Method 2
the flexible substrate is adhered to the rigid one
Data Source
Figure 1~2
Figure 3A~3E
Figure 4a~4b
AI summary
The present disclosure relates to a membrane unit for an aerosol generator comprising a rigid substrate (11); a flexible circuit (50) having a conductive circuit pattern (52) formed on a flexible substrate (51); a membrane (100) supported by the flexible substrate (51) and having a plurality of through holes (121); and an oscillator (120) configured to vibrate the membrane (100), wherein the oscillator (120) is electrically interconnected with the conductive circuit pattern (52) of the flexible circuit (50), wherein the flexible circuit (50) comprises a membrane supporting portion (55) supporting the membrane (100), the membrane supporting portion (55) preferably having an annular shape, wherein the membrane supporting portion (55) is suspended via at least three spokes (56) to a surrounding portion (53).