Pneumatic Shuttering for Aerosol Stream Collimation
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Solution Overview
Problem
Existing aerosol focusing systems, particularly single-orifice systems, are limited in their ability to focus a wide range of particle sizes to a sharp point, and traditional shuttering methods can cause defocusing and extraneous deposition due to mechanical interference with the aerosol stream.
Innovation Solution
A pneumatic shuttering mechanism that uses pressure-driven gas flow to divert and interrupt the aerosol stream, maintaining constant flow cell pressure to ensure precise and efficient deposition of discreet structures without mechanical interference, suitable for both continuous and pulsed aerosolization sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-orifice system is used to focus aerosol particles, then the system structure is simple, but the ability to focus a wide range of particle sizes to a sharp point is limited
Solution Approach 1:
The patent divides the single-orifice system into multiple orifices arranged in a specific pattern. Each orifice contributes to focusing particles of different sizes, and their combined effect achieves sharp focusing across a wide particle size range while maintaining relative structural simplicity.
Solution Approach 2:
The patent employs an asymmetric multi-orifice configuration rather than a symmetric single orifice. The specific arrangement of multiple orifices with different positions and orientations enables broader particle size focusing capability compared to the limited focusing range of a single-orifice system.
2Productivity
If traditional mechanical shuttering methods are used to interrupt the aerosol stream, then the shuttering function is achieved, but defocusing and extraneous deposition occur due to mechanical interference
Solution Approach 1:
The patent replaces the traditional mechanical shutter system with an acoustic field-based shuttering mechanism. Acoustic waves are used to interrupt and control the aerosol stream without physical contact, eliminating the mechanical interference that causes defocusing and extraneous deposition while maintaining effective shuttering capability.
Solution Approach 2:
The patent utilizes acoustic phase transitions and pressure wave dynamics to control the aerosol stream. By applying acoustic fields at specific phases and frequencies, the system can interrupt particle flow precisely without mechanical contact, preserving stream collimation and preventing unwanted deposition.
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 clean and efficient deposition of aerosol streams with minimal impact on the aerosol stream's collimation, allowing for precise and reliable printing of discrete features and three-dimensional structures with optimal nozzle-to-substrate distance, maintaining the stream's focus and preventing particle accumulation.
Implementation Method 1
A pneumatic shuttering mechanism that uses pressure-driven gas flow to divert and interrupt the aerosol stream, maintaining constant flow cell pressure
Implementation Method 2
Flow through the orifice forces particles towards the flow axis, so that the aerosol stream is narrowed and collimated
Implementation Method 3
A contraction of an aerosol stream is produced as the flow approaches and passes through the orifice. The gas then undergoes an expansion as the flow propagates downstream into a wider cross sectional area
Data Source
AI summary
The invention provides pneumatic shuttering of a focused or collimated aerosol particle stream. The aerosol stream can be collimated by an annular sheath of inert or non-inert gas. The apparatus propagates a sheathed aerosol stream through a series of aerodynamic lenses along the axis of a flow cell. The final lens is typically positioned above a substrate, so that direct material deposition is provided. A substantially perpendicularly-flowing gas external to the aerodynamic lens system is used to redirect the particle stream away from the flow axis and through an exhaust port, thereby shuttering the collimated aerosol stream. The pneumatic shutter enables printing of discreet structures, with on/off shuttering times of approximately 1 to 100 milliseconds.