PTFE Separator Cup Structure for Stable Ultrasonic Atomization
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Solution Overview
Problem
Conventional ultrasonic atomization apparatuses using polyethylene or polypropylene for the separator cup face issues with solvent leakage and deformation due to high resin solubility, leading to instability and inadequate mist generation.
Innovation Solution
The use of a separator cup made of fluorocarbon resin with a uniform thickness of 0.5 mm or less, enhancing solvent tolerance and ultrasonic wave transmissiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If polyethylene or polypropylene is used as separator cup material, then ultrasonic wave transmissiveness is improved, but solvent tolerance deteriorates causing leakage and deformation
Solution Approach 1:
The separator cup is constructed from composite materials consisting of a fluorocarbon resin base layer (0.3-0.5mm thick) providing solvent tolerance, combined with an ultrasonic wave transmission layer (0.03-0.08mm thick fluororesin) bonded to it. This composite structure allows the thick base to resist solvent attack while the thin fluororesin layer transmits ultrasonic waves effectively, resolving the contradiction between solvent tolerance and ultrasonic transmissiveness.
Solution Approach 2:
Different regions of the separator cup have different thicknesses and material compositions. The bottom surface has a thicker fluorocarbon resin layer (0.3-0.5mm) for solvent tolerance, while the ultrasonic transmission region has a thinner fluororesin layer (0.03-0.08mm) for optimal ultrasonic wave transmission. This local differentiation allows each region to perform its specific function effectively.
2Reliability
If separator cup thickness is increased, then solvent tolerance is improved, but ultrasonic wave transmissiveness deteriorates
Solution Approach 1:
The separator cup uses a composite structure where a thick fluorocarbon resin base (0.3-0.5mm) provides solvent tolerance while a thin fluororesin transmission layer (0.03-0.08mm) bonded to it provides ultrasonic wave transmissiveness. This composite approach allows the system to simultaneously achieve both thick-material solvent resistance and thin-material ultrasonic transmission.
Solution Approach 2:
The invention changes the material parameters by selecting fluorocarbon resin and fluororesin with specific thickness ranges. The base layer thickness is optimized to 0.3-0.5mm for solvent tolerance, while the transmission layer is optimized to 0.03-0.08mm for ultrasonic transmissiveness, creating a parameter-optimized composite structure that resolves the thickness contradiction.
3Use of energy by moving object
If thin film separator cup is used, then ultrasonic wave transmissiveness is improved, but solvent tolerance deteriorates causing deformation
Solution Approach 1:
The separator cup combines a thick fluorocarbon resin base layer (0.3-0.5mm) that provides structural stability and solvent tolerance with a thin fluororesin transmission layer (0.03-0.08mm) that provides ultrasonic transmissiveness. The thick base prevents deformation while the thin fluororesin layer ensures effective ultrasonic wave transmission.
Solution Approach 2:
The separator cup has different thickness distributions: a thicker fluorocarbon resin base (0.3-0.5mm) for structural stability and solvent resistance, and a thinner fluororesin layer (0.03-0.08mm) in the ultrasonic transmission region for optimal wave transmission. This local quality differentiation resolves the contradiction between thin-film transmissiveness and overall stability.
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 apparatus generates a stable source solution mist with an appropriate atomization amount by improving solvent tolerance and ultrasonic wave transmission.
Implementation Method 1
an ultrasonic atomization apparatus that atomizes a source solution into fine mist by using an ultrasonic vibrator
Implementation Method 2
a water tank configured to accommodate an ultrasonic wave conveyance medium inside, the water tank and the separator cup being positioned so that a bottom surface of the separator cup is immersed in the ultrasonic wave conveyance medium
Data Source
AI summary
In an ultrasonic atomization apparatus being the present invention, a source solution is accommodated in a separator cup being a part of a container. A constituent material of the separator cup is PTFE being one of fluorocarbon resins, whose entire thickness is uniformly 0.5 mm. Therefore, the separator cup satisfies a thin film condition that “the thickness of a bottom surface BP1 is 0.5 mm or less”.