Single-Piece Nebuliser Outlet for Reproducible Spray Distribution
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Solution Overview
Problem
Conventional nebulisers for ion sources exhibit variability in performance due to manufacturing imperfections and misalignment of liquid and gas capillaries, leading to inconsistent spray distribution and ionization efficiency.
Innovation Solution
A nebuliser outlet is designed as a single integrated component with precisely controlled spatial parameters, utilizing additive manufacturing techniques like Selective Laser Melting (SLM) to ensure consistent capillary alignment and gas flow, reducing variability and manufacturing imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional multi-component nebulisers are assembled from separate liquid and gas capillaries, then ease of manufacture is improved, but manufacturing precision deteriorates due to alignment errors and assembly variability
Solution Approach 1:
The patent merges the liquid capillary and gas capillary into a single integrated nebuliser outlet component. This eliminates the alignment errors and assembly variability inherent in multi-component designs while maintaining manufacturability through advanced fabrication techniques.
Solution Approach 2:
The patent replaces traditional mechanical assembly processes with additive manufacturing (3D printing) technology. This substitution enables the creation of complex integrated geometries with precise spatial relationships between channels that would be difficult or impossible to achieve through conventional machining and assembly.
2Manufacturing precision
If additive manufacturing is used to create the nebuliser outlet, then manufacturing precision is improved, but ease of manufacture deteriorates due to specialized process requirements
Solution Approach 1:
The patent changes the manufacturing parameters and processes from conventional machining to additive manufacturing. This enables the fabrication of complex internal geometries with precise control over channel dimensions, wall thicknesses, and spatial relationships, achieving manufacturing precision that outweighs the learning curve of the new process.
3Adaptability or versatility
If separate capillaries are used in the nebuliser, then adaptability is improved, but reliability deteriorates due to performance variability between installations
Solution Approach 1:
By combining the liquid and gas capillaries into a single integrated component, the patent eliminates the variability introduced by repeated assembly and disassembly of separate parts. The fixed spatial relationships within the integrated design ensure consistent performance across multiple installations while maintaining the ability to adapt the overall nebuliser system configuration.
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 solution significantly reduces variation in nebuliser performance across multiple uses and installations, achieving consistent and reproducible spray distribution and ionization efficiency.
Implementation Method 1
A flow of liquid supplied to the liquid capillary is nebulised by a nebulising gas flow supplied to the gas capillary
Implementation Method 2
gas received by the nebuliser outlet will pass to the outlet end via the one or more second channels, and will nebulise liquid emitted from the capillary
Data Source
AI summary
A nebuliser outlet comprises an inlet end and an outlet end, a first channel and one or more second channels arranged between the inlet end and the outlet end. The first channel is configured to receive a capillary, and the one or more second channels are configured to pass gas to the outlet end. The nebuliser outlet is a single integrated component.