Multi-element Ultrasonic Atomizer Parallel Processing
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Solution Overview
Problem
Conventional ultrasonic atomizers are limited by their ability to process only one liquid sample at a time, requiring increased labor and unable to efficiently atomize large quantities of liquids while consuming high electric power.
Innovation Solution
A multi-element ultrasonic atomizer with a power generator, converter, and multiple atomizing probes made of titanium alloy, where the converter converts electrical oscillations into mechanical vibrations transmitted to the probes, allowing simultaneous processing of multiple liquid samples with reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple nozzles are used to increase atomizing capacity, then the mass output and productivity are improved, but the device complexity increases
Solution Approach 1:
Multiple atomizing probes are coupled to a single ultrasonic horn, merging the vibration source into one component while maintaining multiple processing points. This allows increased productivity through parallel processing of multiple liquid samples while avoiding the complexity of multiple independent ultrasonic generators and control systems.
Solution Approach 2:
The single ultrasonic horn serves multiple atomizing probes simultaneously, making the vibration generation system universal. One horn provides ultrasonic vibrations to all coupled probes, enabling the system to process multiple liquid samples in parallel with a single vibration source, thus improving productivity without proportionally increasing device complexity.
2Device complexity
If a single probe is used, then the device complexity is reduced, but the productivity and mass output are limited
Solution Approach 1:
The atomizing function is segmented into multiple probes that can process different liquid samples simultaneously. Each probe maintains its own liquid passage and atomizing tip, allowing independent processing of multiple samples while sharing the common ultrasonic horn, thus increasing productivity without requiring fully independent systems for each probe.
Solution Approach 2:
The system transitions from single-point atomization to multi-point atomization by coupling multiple probes to one horn. This dimensional expansion from one probe to multiple probes allows parallel processing of multiple liquid samples, dramatically increasing mass output and productivity while maintaining a single vibration source.
3Productivity
If conventional spray nozzles are used to increase liquid flow, then the mass output is improved, but the energy consumption and power requirements increase
Solution Approach 1:
The system uses ultrasonic mechanical vibrations at the atomizing tips to break liquid into droplets, replacing the need for high-velocity motion and high power consumption conventional spray nozzles. The ultrasonic vibrations efficiently atomize liquid with minimal power consumption while maintaining high mass output through multiple probes processing simultaneously.
Solution Approach 2:
The conventional mechanical spray nozzle system relying on high fluid pressure and high-velocity motion is replaced with an ultrasonic atomization system. The ultrasonic horn and probes convert electrical energy to mechanical vibrations that directly atomize liquid at the tip, eliminating the need for high-pressure pumps and high-velocity flow systems, thus reducing overall energy consumption while maintaining productivity.
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 efficient atomization of multiple liquid samples simultaneously with reduced electric power consumption, producing a low-velocity mist with droplet sizes between 60 microns to 100 microns, suitable for various industrial applications.
Implementation Method 1
A power supply supplies electrical energy to the transducer and causes it to oscillate at a certain ultrasonic frequency. This electrical oscillation passes to some type of converter, such as piezoelectric material, and is then converted into mechanical vibrations in the ultrasonic range.
Implementation Method 2
The resulting intensive mechanical vibrations produce a field of waves on the surface of a liquid, causing the velocity of the liquid particles in the waves to become so high that it overcomes the effects of gravity and surface tension forces and causes small particles to detach from the liquid surface into the air.
Data Source
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AI summary
A multi-element ultrasonic atomizer and method for atomizing liquids is described, having a power generator, a converter, an ultrasonic horn coupled to the converter, and at least two atomizing probes coupled to the ultrasound horn, each atomizing probe including at least one liquid passage extending longitudinally along the atomizing probe and terminating at an atomizing tip at a distal end of the atomizing probe. The atomizing probes are made to vibrate at same frequency. A liquid is delivered to an atomizing surface through the liquid passage and through an opening at the atomizing tip.