Supersonic Atomizer De Laval Gap Droplet Size

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Solution Overview

Problem

Existing atomization technologies are complex, costly, and limited in scalability and effectiveness for producing fine droplets, particularly for liquids containing solids, and are not suitable for continuous operation or pharmaceutical applications.

Innovation Solution

A supersonic atomizer with an annular de Laval gap around the central axis accelerates gas to supersonic speed, generating shockwaves that effectively atomize liquids into droplets of less than 10 micrometers, using a compact and flexible design with minimal moving parts and energy input.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If ultrasonic gas jets and complex spray nozzle structure are used to achieve fine droplet atomization, then droplet size is reduced, but device complexity and production effort increase significantly

Engineering Contradiction:

Improvedroplet sizeVSAvoidspray nozzle structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the complex internal structure, separation tips, and multiple gas jet convergence points from the spray nozzle design. By using a simple straight liquid channel with a single gas outlet opening positioned downstream, the patent achieves fine droplet atomization without the complicated structures that previously were necessary

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of creating fine droplets through complex internal structures and multiple gas jets converging at a point, the invention inverts the approach by using a simple geometry with the gas outlet positioned downstream of the liquid outlet, allowing the gas flow to interact with the liquid jet in a straightforward manner to achieve atomization

Inventive Principle:

Principle #13The other way round (Inversion)

2Productivity

If narrow liquid channels are used in the spray nozzle, then liquid flow is controlled, but suitability for liquids containing solids deteriorates

Engineering Contradiction:

Improveliquid flow controlVSAvoidsuitability for liquids with solids

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The invention applies local quality by having different channel geometries in different sections: the liquid channel has a wider cross-section suitable for solids-containing liquids, while the gas channel has a narrower annular gap for precise gas flow control. This local differentiation allows each channel to be optimized for its specific function without compromising the other

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If separation tips and multiple gas jet convergence points are used, then atomization is achieved, but the number of parts and production effort increase

Engineering Contradiction:

Improveatomization qualityVSAvoidproduction effort

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The gas outlet opening serves multiple functions: it introduces the gas flow, positions the gas jet downstream of the liquid outlet, and creates the annular gap for gas flow control. This multi-functionality eliminates the need for separate separation tips and multiple gas jet nozzles, simplifying manufacturing while maintaining atomization quality

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Manufacturing precision

If high pressure homogenizers are used for nano-emulsion preparation, then droplet size in nanometer range is achieved, but shear forces on product and process complexity increase

Engineering Contradiction:

Improvedroplet sizeVSAvoidshear forces on product

Core Design Contradiction:

Manufacturing precisionVSForce

Solution Approach 1:

The invention replaces the high-pressure mechanical homogenization system with a gas-dynamic atomization system. Instead of using high pressure pumps and valves to force liquid through narrow gaps, the patent uses supersonic gas flows and shockwaves to atomize the liquid, significantly reducing mechanical shear forces on the product

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 atomizer achieves efficient and reliable atomization of liquids into fine droplets with minimal energy and maintenance, enabling continuous operation and homogeneous distribution, suitable for pharmaceutical applications and retrofitting existing systems.

Implementation Method 1

a gas channel with a de Laval gap running annularly around the central axis, which is arranged so as to accelerate the gas to supersonic speed

Methodology Applied

Scientific Effectde Laval nozzle effect: De Laval Nozzle

Implementation Method 2

acceleration of the gas to supersonic speed using a de Laval gap... generating shockwaves that effectively atomize liquids into droplets

Methodology Applied

Scientific EffectShockwave: Shock Wave

Data Source

PatentUS20240390928A1Supersonic atomiser

Publication Date: 2024.11.28 ELEMENT 6 GMBH

AI summary

Provided herein is a supersonic atomizer and a method for atomizing a liquid into fine droplets, in particular for homogenizing the liquid. The atomizer may include a central axis, an inner part with a liquid channel extending along the central axis and leading into a liquid-outlet opening, and an outer part with a gas channel leading into a gas-outlet opening. The gas channel may have a de Laval gap, running annularly around the central axis, for accelerating the gas to supersonic speed upstream of the gas-outlet opening.