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 during high-temperature sterilization processes, leading to potential damage and contamination risks due to the exposure of the ultrasonic vibration generating unit to high temperatures.
Innovation Solution
An ultrasonic atomizer design incorporating a heat exchange unit with a vortex flow forming system and thermal insulation to maintain a constant temperature around the ultrasonic vibration generating unit, utilizing a cooling air discharge system and thermal insulators to prevent heat transfer and maintain stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ultrasonic atomizer is sterilized using high-temperature dry heat sterilization method, then the sterilization effectiveness is improved, but the ultrasonic vibration generating unit deteriorates due to high temperature exposure
Solution Approach 1:
The housing is divided into a high-temperature resistant portion and a low-temperature portion, with the ultrasonic vibration generating unit positioned in the low-temperature zone. This segmentation allows different parts of the device to experience different temperature conditions during sterilization, protecting the temperature-sensitive ultrasonic element while maintaining sterilization effectiveness in the spray chamber.
Solution Approach 2:
The housing acts as an intermediary barrier between the high-temperature sterilization environment and the ultrasonic vibration generating unit. By positioning the ultrasonic element in a protected zone within the housing, the intermediary structure prevents direct thermal exposure while allowing the overall device to undergo sterilization.
2Reliability
If the ultrasonic atomizer is sterilized using high-pressure steam sterilizer, then the sterilization effectiveness is improved, but the risk of contamination increases due to separate sterilization and mounting processes
Solution Approach 1:
The design merges the ultrasonic atomizer with the spray dryer housing such that the entire integrated device can undergo sterilization as a single unit. The housing structure is designed to allow sterilization agents to reach all necessary surfaces while protecting the ultrasonic element, eliminating the need for separate sterilization and mounting steps that create contamination risks.
Solution Approach 2:
The housing serves multiple functions: it protects the ultrasonic vibration generating unit from high temperatures, provides structural support, and acts as a sterilization barrier. This multi-functionality allows the device to maintain both the ultrasonic element and the spray chamber in a sterile state simultaneously.
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 design effectively protects the ultrasonic vibration generating unit from high temperatures, ensuring stable operation and preventing contamination, allowing for continuous and efficient spraying of pharmaceutical materials without changes in characteristics over time.
Implementation Method 1
a heat exchange unit, and a housing. The heat exchange unit surrounds the ultrasonic vibration generating unit (102), thereby cooling heat generated from the ultrasonic vibration generating unit (102)
Implementation Method 2
a vortex flow forming unit (120) which is positioned in the housing (100) at a periphery of the ultrasonic vibration generating unit (102), thereby forming a vortex tube
Implementation Method 3
a thermal insulation portion which insulates a peripheral portion of the ultrasonic vibration generating unit (102)
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 atomize 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 heat exchange unit which surrounds the ultrasonic vibration generating unit and cools heat generated from the ultrasonic vibration generating unit; and a housing which surrounds the ultrasonic vibration generating unit and the heat exchange unit, and has plurality of heat exchange chambers therein, in which the a plurality of heat exchange chambers include: a vortex chamber which is positioned in the housing at the periphery of the ultrasonic vibration generating unit and guides a vortex flow; and a thermal insulation chamber which surrounds the vortex chamber and has a separation wall which abuts the vortex chamber, and includes an internal thermal insulation space.