Overmoulded Micro-Nozzle Insert for High-Pressure Chip Sealing
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Solution Overview
Problem
Existing micro-fluidic nozzle systems face challenges in securely sealing cuboidal chips within aerosol systems due to their cylindrical or conical form factors and are prone to delamination under high operational pressures, compromising structural integrity.
Innovation Solution
An overmould casing is used to encase the fluidic chip, providing a tight seal and protection, while incorporating features like grooves, flanges, and elastomers to maintain structural integrity and isolate pressures, and a filter retaining wall to prevent hydraulic impulses from affecting the chip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cuboidal fluidic chip is used in an aerosol system, then the chip can be manufactured using standard microfabrication processes, but the chip cannot be securely sealed within the aerosol system due to form factor mismatch
Solution Approach 1:
The system is divided into separate functional components: the cuboidal fluidic chip and the cylindrical aerosol housing. The chip remains cuboidal for manufacturing purposes while the housing provides the cylindrical form factor needed for sealing and integration into the aerosol system.
Solution Approach 2:
A transition component or adapter is introduced between the cuboidal chip and cylindrical housing to bridge the form factor mismatch. This intermediary element enables secure sealing of the chip within the aerosol system while maintaining the manufacturing advantages of the cuboidal chip design.
2Speed
If high operational pressures are applied to achieve high-velocity aerosol delivery, then aerosol performance is improved, but the fragile chip becomes delaminated or damaged
Solution Approach 1:
The chip is encased in a protective housing structure before being subjected to high operational pressures. This pre-protective enclosure cushions the fragile chip against the damaging effects of high pressure while allowing the system to achieve the necessary high-velocity aerosol delivery.
Solution Approach 2:
A flexible or compliant sealing structure is used to encase the chip, allowing the structure to deform elastically under high pressure without transmitting damaging stress concentrations to the fragile chip. This flexible enclosure maintains sealing integrity while protecting the chip from pressure-induced damage.
3Strength
If the chip is encased in a protective housing, then structural integrity is improved, but the device complexity increases
Solution Approach 1:
Multiple functions are combined into the housing structure: protection of the chip, sealing of the aerosol system, and integration with the aerosol generator. By merging these functions into a single integrated housing, the design provides robust chip protection while minimizing the increase in overall device complexity.
Solution Approach 2:
The housing is designed to serve multiple purposes simultaneously: it acts as a protective enclosure for the chip, provides sealing surfaces for the aerosol system, and serves as a mounting structure for integration into the aerosol generator. This multi-functionality reduces the need for additional separate components.
Data Source
AI summary
An insert for a micro-nozzle (10), and a micro-nozzle (10) comprising such insert. The insert comprises a microfabricated fluidic chip (1) having an inlet, an outlet and one or more microfluidic channels connecting the inlet and outlet and an overmould casing (2) overmoulded around the fluidic chip (1) so as to substantially encase the fluidic chip (1), and comprising an inlet in fluid communication with the inlet of the chip and an outlet in fluid communication with the outlet of the chip.