Multi-Stage Ultrasonic Atomizer for Viscous Fluids
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Solution Overview
Problem
Conventional spray drying methods face limitations in achieving high flow rates and consistent particle size, particularly for viscous substances, due to low flow rates and inability to generate uniform droplets.
Innovation Solution
A multi-stage ultrasonic atomizing spray dryer is employed, utilizing transducers in close proximity to the liquid feed opening to create a path for atomization flow, with controlled oscillation to produce uniform droplets, and featuring radial or slot jet nozzles for higher throughput and adjustable droplet size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional spray drying methods are used, then the process is simple to operate, but the flow rate is low and particle size consistency is poor
Solution Approach 1:
The atomization process is divided into multiple stages with multiple ultrasonic transducers operating at different positions. The first transducer creates initial droplets, and subsequent transducers further atomize the liquid stream, enabling both high throughput and consistent particle size distribution through sequential refinement
Solution Approach 2:
Ultrasonic transducers generate high-frequency mechanical vibrations that directly作用于 the liquid stream, breaking it into uniform droplets. The vibration frequency and amplitude are controlled to achieve consistent droplet sizes while maintaining high atomization efficiency and flow rate
2Adaptability or versatility
If conventional spray drying methods are used, then the device structure is simple, but the ability to handle viscous substances is limited
Solution Approach 1:
Multiple transducers are arranged in sequence along the liquid path, with each transducer handling a specific portion of the atomization process. This segmented approach allows the system to effectively process viscous materials by progressively breaking them down through multiple vibration stages
Solution Approach 2:
The system employs adjustable ultrasonic vibration parameters (frequency, amplitude, duration) that can be dynamically optimized for different liquid viscosities. This dynamic control enables the same device structure to adapt to various viscous substances without requiring structural modifications
3Manufacturing precision
If ultrasonic transducers are placed in close proximity to the liquid feed opening, then uniform droplets are produced, but the device complexity increases
Solution Approach 1:
Instead of using a single complex transducer system, multiple simpler transducers are arranged in sequence at different positions. Each transducer contributes to droplet formation independently, and their combined effect achieves superior uniformity while keeping individual component complexity low
Solution Approach 2:
The transducers are arranged along the length of the liquid stream rather than concentrating all atomization function at a single point. This spatial distribution along one dimension allows each transducer to work on a specific segment of the liquid, achieving uniform droplets without requiring complex single-point geometry
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 solution enables a high volume of consistent particle output with adjustable droplet size, effectively addressing the limitations of conventional spray drying for viscous materials by enhancing flow rates and particle uniformity.
Implementation Method 1
Piezoelectricity, the fundamental theory behind ultrasonics, describes the phenomenon the electric charge generation proportion to the applied mechanical stress and vice versa
Implementation Method 2
Vibrating plate transducers (usually in disc shape) are commonly used due to its superior performance. With this type of transducer immersed into a reservoir of water at a certain depth under the water surface, the alternative current (AC) signal is converted to mechanical vibration towards the water-air interface by creating a mist of water
Implementation Method 3
Ultrasonic atomization is based on the response of the liquid-air interface to incident oscillations by a transducer, which break the bulk liquid into fine droplets
Data Source
AI summary
An atomizing spray dryer employs one or more stages defined by ultrasonic transducers in close proximity to a liquid feed opening forming a path of an atomization flow for producing uniform droplets from a close tolerance with the transducer. The atomization flow exits a gap between the transducer and an outer edge of the opening, such that the passed liquid is responsive to an oscillation of the transducer for forming the droplets. A conical or other suitably shaped transducer engages a substantially round liquid feed opening. Subsequent stages may include a circular, ring, or other suitable shape aligned to receive the atomization flow from a circumference of the conical base, or may also take any suitable shape, preferably to receive droplets directed by the first stage.