Stepped Orifice Nebulizer Plate for Vibration Efficiency
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Solution Overview
Problem
Conventional nebulization devices with metal spray orifice plates face issues such as poor chemical resistance, embrittlement, and reduced nebulization efficiency due to fixed nebulization hole distances and vulnerability to high-frequency vibrations, leading to ineffective energy transfer and nebulization performance.
Innovation Solution
A nebulization device with a spray orifice plate featuring a plurality of stepped orifices, including at least one through hole and recess for liquid storage, supported by an energy transfer element made of metal and a macromolecular polymer spray orifice plate, which enhances nebulization efficiency by allowing flexible design and improved energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal spray orifice plate is used, then the structural strength and rigidity are improved, but the chemical resistance and fatigue resistance deteriorate
Solution Approach 1:
The patent uses a metal support plate combined with a polymer coating layer to create a composite structure. The metal plate provides structural strength and rigidity, while the polymer coating provides chemical resistance and prevents metal fatigue, thus resolving the contradiction between strength and reliability.
Solution Approach 2:
The polymer coating layer acts as a sacrificial protective layer that can be replaced when degraded, protecting the expensive metal substrate from chemical corrosion and fatigue, thereby extending the overall system reliability while maintaining structural integrity.
2Ease of manufacture
If conventional nebulization holes are used, then the manufacturing process is simple, but the nebulization efficiency deteriorates due to fixed hole distances
Solution Approach 1:
The nebulization holes are segmented into multiple levels with different depths and diameters. This segmentation allows optimization of liquid flow paths and spray patterns at each level, improving nebulization efficiency while maintaining manufacturability through standard drilling and machining processes.
Solution Approach 2:
The invention transitions from a single-plane nebulization hole arrangement to a multi-level three-dimensional configuration. By distributing holes across different depths and radial positions, the design optimizes liquid distribution and spray characteristics without significantly complicating the manufacturing process.
3Productivity
If high-frequency vibrations are applied, then the nebulization effect is improved, but the metal plate becomes embrittled and fatigued
Solution Approach 1:
The composite structure of metal substrate and polymer coating allows the system to withstand high-frequency vibrations better. The polymer layer absorbs some vibration energy and prevents stress concentration in the metal, reducing fatigue while maintaining the nebulization performance enabled by high-frequency operation.
Solution Approach 2:
The polymer coating layer serves as a pre-applied cushioning layer that protects the metal structure from vibration-induced fatigue and embrittlement. This protective layer is designed to absorb and distribute mechanical stresses before they can damage the metal substrate, thereby extending service life.
4Reliability
If a macromolecular polymer spray orifice plate is used, then the chemical resistance and fatigue resistance are improved, but the rigidity and energy transfer efficiency deteriorate
Solution Approach 1:
The patent creates a composite structure where the metal support plate provides the necessary rigidity and structural strength, while the polymer coating layer provides chemical resistance and fatigue protection. This division of functional responsibilities resolves the contradiction between reliability and strength.
Solution Approach 2:
The metal support plate serves multiple functions: providing structural rigidity, supporting the polymer coating, and enabling energy transfer for vibration. The polymer coating simultaneously provides chemical resistance, fatigue protection, and contributes to the nebulization surface, making the composite structure universally functional.
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 stepped orifice design improves nebulization effect by temporarily storing and vibrating liquid, leading to enhanced nebulization performance and increased availability of the device, while the macromolecular polymer material addresses the issues of metal fatigue and corrosion.
Implementation Method 1
the driving element is provided with power, high-frequency vibration waves are produced, so that the first penetrating orifice plate is deformed and bent by resonance
Implementation Method 2
the first penetrating orifice plate is deformed and bent by resonance to break down the molecular structure of a liquid
Data Source
AI summary
Disclosed is a nebulization device with a spray orifice plate including an energy transfer element, a spray orifice plate and a driving element. The energy transfer element has at least one first penetrating hole for inputting a liquid from a side and the spray orifice plate is installed on at least one side of the energy transfer element for sealing the first penetrating hole, and the energy transfer element supports the spray orifice plate, and the spray orifice plate has at least one stepped orifice formed at a position corresponding to the first penetrating hole and serves as a transportation channel of the liquid, so that the liquid can be temporarily stored in the stepped orifice and sprayed out through the through hole after vibration and nebulization in order to improve the nebulization effect significantly.