Symmetrical Ultrasonic Horn for Uniform Multi-Sample Processing
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Solution Overview
Problem
Existing ultrasonic sample preparation systems process multiple samples sequentially, leading to prolonged processing times and high labor costs, and lack uniformity in acoustic energy distribution across multiple samples, requiring additional techniques to ensure consistent processing.
Innovation Solution
An ultrasonic horn with a symmetrical design featuring equal diameters and lengths for input and output sections, a middle section with scallops, and symmetry elements to ensure uniform acoustic energy distribution across its entire face, allowing simultaneous processing of multiple samples.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple samples are processed simultaneously using a large diameter horn, then processing time and labor costs are reduced, but uniformity of acoustic energy distribution across samples deteriorates
Solution Approach 1:
The horn features an asymmetrical cross-sectional shape with different curvatures along its length, specifically designed to compensate for acoustic scattering effects. The first portion has a different cross-sectional shape than the second portion, creating intentional asymmetry that balances the acoustic field across multiple sample positions.
Solution Approach 2:
Different portions of the horn have different cross-sectional characteristics tailored to their specific functions. The first portion has optimized curvature for initial acoustic energy distribution, while the second portion has different curvature to compensate for scattering effects at downstream sample positions.
2Power
If traditional single-focus transducers are used, then acoustic energy is concentrated at one point, but processing multiple samples simultaneously becomes impossible
Solution Approach 1:
The horn is divided into multiple functional sections along its length, with each section optimized for distributing acoustic energy to different spatial zones. This segmentation allows simultaneous processing of multiple samples at different positions while maintaining adequate energy concentration at each location.
Solution Approach 2:
The invention transitions from a single-focus (point) transducer to a distributed-focus (extended) transducer by varying the cross-sectional area along the horn's length. This dimensional change enables acoustic energy to be distributed across multiple spatial locations simultaneously.
3Manufacturing precision
If serial processing is used, then uniform acoustic energy distribution is maintained, but processing time increases significantly
Solution Approach 1:
Multiple acoustic focal points are merged into a single horn structure, allowing simultaneous processing of multiple samples in parallel. The horn's varying cross-section creates multiple effective focal zones that operate concurrently, combining the benefits of serial uniformity with parallel throughput.
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
Achieves consistent and uniform acoustic energy emission across the entire face of the horn, reducing processing time and labor costs while maintaining sample uniformity.
Implementation Method 1
an ultrasonic horn which is sized and shaped to simultaneously process multiple samples, with acoustic energy being emitted from the face of a free, generally planar output end
Implementation Method 2
the output end face emitting the acoustic energy in a consistent and uniform distribution over substantially the entire face thereof
Data Source
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AI summary
An ultrasonic horn includes a generally cylindrical input section having an energy input end adapted to be operably connected to an ultrasonic energy source, the energy input end comprising a generally flat surface, a generally cylindrical output section having a free end defining an energy output end, comprising a generally flat surface that is generally parallel to the generally flat surface of the energy input end, and a middle section disposed between the input and output sections, the middle section comprising at least one scallop defined by a side wall having a continuous curve. The input, middle and output sections together define a total horn length, and the ultrasonic horn is substantially symmetrical about an imaginary plane that bisects the total horn length and that is substantially parallel to the generally flat surface of the energy input end and the generally flat surface of the energy output end.