Particle Generating Apparatus Using Drop Solidification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for generating particles, such as sputtering or electric arcs, are complex and cost-intensive, especially for producing small-sized or nano particles.
Innovation Solution
A method and apparatus that form drops from a flowable medium and solidify them on a particle forming surface, using techniques like atomization and ultrasonic treatment to control drop size and solidification, with a particle forming surface adapted to prevent drop collisions and enhance spherical particle formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sputtering or electric arc methods are used to generate particles, then particles can be produced, but the process becomes complex and cost-intensive
Solution Approach 1:
The patent changes the fundamental parameter of particle generation from plasma-based processes (sputtering, electric arc) to a thermal solidification process. By controlling the cooling rate and solidification conditions on the particle forming surface, precise particle size control is achieved while dramatically simplifying the overall process complexity and reducing operational costs
Solution Approach 2:
The patent replaces complex plasma generation and control systems with a simpler thermal field approach. Instead of using electric arcs or sputtering equipment, the invention uses a heated particle forming surface to melt and rapidly solidify droplets, substituting mechanical/electrical complexity with controlled thermal processing
2Quantity of substance
If sputtering or electric arc methods are used to generate particles, then particles can be produced, but operational costs increase
Solution Approach 1:
The particle forming surface is designed to be self-heating through the accumulation of molten material, reducing or eliminating the need for external heating energy input. The system uses the heat from the molten droplets themselves to maintain the particle forming surface temperature, significantly reducing operational energy costs while maintaining continuous particle production
Solution Approach 2:
The patent utilizes the phase transition from liquid to solid during rapid cooling on the particle forming surface. This phase change releases latent heat that contributes to maintaining the particle forming surface temperature, reducing external energy requirements. The controlled solidification process efficiently converts thermal energy into particle formation without requiring continuous high-energy input
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
This approach simplifies and cost-reduces particle generation, allowing for precise control of particle size and shape, including the production of small-sized and spherical particles, while minimizing complexity and operational costs.
Implementation Method 1
forming drops from the flowable medium
Implementation Method 2
solidifying the drops, thereby forming the particles
Data Source
AI summary
A method and an apparatus for generating particles are provided. The method may be a method for generating particles from a flowable medium, the method involving forming drops from the flowable medium, arranging the drops on a particle forming surface and solidifying the drops, thereby forming the particles. The apparatus may be an apparatus for generating particles from a flowable medium with a drop generator and a particle forming surface, the drop generator being formed to arrange drops on the particle forming surface and the particle forming surface may be adapted to contact the drops when the particles are being formed.