Ultrasonic Atomizer Thermal Management for Aseptic Sterilization
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Solution Overview
Problem
Ultrasonic atomizers used in pharmaceutical production face challenges in maintaining a constant temperature for the ultrasonic vibration generating unit during high-temperature sterilization processes, which can lead to deterioration and contamination risks.
Innovation Solution
An ultrasonic atomizer design incorporating a thermoelectric element and cooling system, including a heat exchange unit with a Peltier element and a cooling air management system, to maintain a stable temperature around the ultrasonic vibration generating unit, even under high-temperature conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ultrasonic atomizer is sterilized in a high-pressure steam sterilizer, then the sterilization effectiveness is improved, but the ultrasonic vibration generating unit deteriorates due to high temperature exposure
Solution Approach 1:
The invention divides the sterilization process into two separate stages: first, the ultrasonic atomizer is sterilized in a high-pressure steam sterilizer to ensure sterilization effectiveness; second, the spray dryer is sterilized in a high-temperature dry heat sterilizer without the ultrasonic atomizer present, preventing temperature damage. This segmentation of the sterilization process resolves the contradiction between achieving effective sterilization and protecting the ultrasonic vibration generating unit from thermal deterioration.
2Reliability
If the spray dryer is sterilized through high-temperature dry heat sterilization with the ultrasonic atomizer mounted, then the sterilization completeness is improved, but the ultrasonic element deteriorates due to high temperature
Solution Approach 1:
The ultrasonic atomizer is sterilized in advance using high-pressure steam sterilization before being mounted in the spray dryer. This preliminary sterilization action ensures that the ultrasonic atomizer is already sterile when installed, allowing the subsequent high-temperature dry heat sterilization of the spray dryer to proceed without the ultrasonic atomizer present, thus preventing temperature damage while maintaining sterilization completeness.
Solution Approach 2:
The ultrasonic atomizer is extracted or removed from the spray dryer before the high-temperature dry heat sterilization process. This extraction prevents the ultrasonic element from being exposed to damaging high temperatures during the sterilization of the spray dryer, while the sterilization completeness is maintained through the preliminary sterilization of the ultrasonic atomizer.
3Reliability
If separate sterilization of the ultrasonic atomizer and spray dryer is performed, then the individual sterilization effectiveness is improved, but the contamination risk increases during mounting
Solution Approach 1:
The ultrasonic atomizer is sterilized in advance and then mounted in the spray dryer before the spray dryer undergoes high-temperature dry heat sterilization. This preliminary mounting action, combined with the preliminary sterilization of the ultrasonic atomizer, reduces the contamination risk during the sterilization process while maintaining individual sterilization effectiveness.
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
This design effectively protects the ultrasonic vibration generating unit from high temperatures, ensuring stable operation and preventing contamination, allowing for continuous, unaltered spraying of materials over extended periods.
Implementation Method 1
a heat exchange unit which includes: a thermoelectric element which absorbs heat at a heat absorbing surface that abuts the heating chamber, and radiates heat through a heat radiating surface that abuts the cooling chamber
Implementation Method 2
The ultrasonic atomizer is an apparatus that converts electrical energy into vibrational energy and provides a spray material with ultrasonic vibration having an output frequency, thereby spraying the spray material
Data Source
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AI summary
An ultrasonic atomizer capable of maintaining a constant temperature of an ultrasonic vibration generating unit by decreasing a temperature at the periphery of the ultrasonic vibration generating unit even under an environment in which the ultrasonic vibration generating unit is exposed to a high temperature is provided. The ultrasonic atomizer includes: an ultrasonic vibration generating unit which generates ultrasonic waves and atomizes a spray material; a nozzle unit which includes a spray flow path in which the spray material moves along a central axis that penetrates a center of the ultrasonic vibration generating unit, and includes a nozzle tip which is supplied with the spray material from one end of the spray flow path, and sprays the spray material from the other end of the spray flow path; a housing which surrounds the ultrasonic vibration generating unit and has a plurality of heat exchange chambers therein; and a heat exchange unit which surrounds the ultrasonic vibration generating unit, includes a separation wall which divides the heat exchange unit into the plurality of heat exchange chambers, and cools heat generated from the ultrasonic vibration generating unit, in which the plurality of heat exchange chambers include: a heating chamber which is positioned in the housing at the periphery of the ultrasonic vibration generating unit, and includes a heating space; and a cooling chamber which surrounds the heating chamber, and includes a cooling space by being isolated with the heat exchange unit abutting the heating chamber between the cooling chamber and the heating chamber.