Ultrasonic Cleaning Tilted Bottom Surface Liquid Film
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Solution Overview
Problem
Conventional ultrasonic cleaning systems face challenges in efficiently cleaning large-sized objects with uniformity and reduced liquid consumption, as they require continuous large amounts of cleaning liquid to prevent heating and ensure effective ultrasonic wave propagation, and struggle with air bubbles entering the system, leading to reduced cleaning effectiveness and increased costs.
Innovation Solution
An ultrasonic cleaning apparatus with a tilted casing bottom surface and a liquid film forming mechanism that accelerates the flow speed of cleaning liquid, forming a continuous liquid film on the surface, which is then discharged to the object, allowing for efficient ultrasonic energy transfer and reduced liquid usage, while preventing heating without liquid and maintaining uniform cleaning across the object's width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional ultrasonic cleaning system uses continuous large amounts of cleaning liquid to prevent heating and ensure effective ultrasonic wave propagation, then the reliability of the cleaning system is improved, but the loss of substance (cleaning liquid consumption) increases
Solution Approach 1:
The patent applies hydraulic principles by using a liquid film forming mechanism that directs cleaning liquid to flow along the bottom surface of the casing. This creates a controlled liquid film that ensures continuous contact between the cleaning liquid and the ultrasonic transducer, preventing heating while using minimal liquid. The liquid film approach transforms the conventional bulk liquid consumption into a targeted film-based solution.
Solution Approach 2:
The patent changes the physical state and distribution of the cleaning liquid from bulk continuous flow to a controlled thin film flow along the bottom surface. By altering how the liquid is distributed (as a film rather than bulk), the system maintains effective ultrasonic wave propagation and prevents heating while dramatically reducing overall liquid consumption.
2Reliability
If air bubbles enter the cleaning liquid supply system, then the device complexity increases due to need for bubble removal mechanisms, but the reliability decreases due to reduced cleaning effectiveness and potential transducer damage
Solution Approach 1:
The patent implements preliminary action by incorporating an overflow rectifier that removes air bubbles from the cleaning liquid before it reaches the ultrasonic transducer. The bubble removal happens in advance through the overflow mechanism, preventing bubbles from entering the critical ultrasonic vibration zone and causing damage or reduced effectiveness.
Solution Approach 2:
The patent extracts harmful air bubbles from the cleaning liquid supply system using an overflow rectifier mechanism. The bubbles are separated and removed from the liquid flow path before the liquid contacts the ultrasonic transducer, eliminating the harmful effect of bubbles without requiring complex additional systems.
3Loss of substance
If the ultrasonic transducer operates without sufficient liquid contact, then the productivity increases by reducing liquid usage, but the temperature increases causing transducer breakdown
Solution Approach 1:
The patent uses hydraulic flow control to create a liquid film that continuously flows along the bottom surface of the casing where the ultrasonic transducer is located. This film-based approach ensures the transducer remains in contact with cooling liquid, preventing temperature rise and breakdown, while using far less liquid than conventional bulk flow systems.
4Manufacturing precision
If a tilted casing bottom surface is used to form a liquid film, then the manufacturing precision of uniform cleaning is improved, but the device complexity increases due to tilted structure and flow control mechanisms
Solution Approach 1:
The patent applies asymmetry by tilting the bottom surface of the casing at a specific angle (1° to 15°) relative to the horizontal plane. This asymmetric tilt creates a gravity-driven liquid film flow that ensures uniform distribution of cleaning liquid across the bottom surface, improving cleaning uniformity while using a relatively simple structural modification.
Solution Approach 2:
The tilted bottom surface creates a gravity-based flow system where the cleaning liquid naturally flows from the higher end to the lower end, forming a uniform film through gravitational potential energy conversion. This passive flow control mechanism achieves uniform liquid distribution without requiring complex active flow control systems.
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 effective cleaning of large objects with reduced liquid consumption, prevents heating issues, and maintains uniformity in cleaning, achieving stable ultrasonic vibration and high cleaning effectiveness while minimizing the risk of transducer breakdown.
Implementation Method 1
a bottom surface to which ultrasonic vibration is applied by an ultrasonic transducer
Implementation Method 2
a liquid film forming means that forms a liquid film on the bottom surface through flowing a cleaning liquid along the bottom surface
Data Source
AI summary
An ultrasonic cleaning apparatus capable of cleaning large-sized objects includes: a casing having a bottom surface that forms a tilted surface to oppose the object to be cleaned and having an ultrasonic transducer provided at an inner lower surface; a cleaning liquid supply device configured to supply cleaning liquid to a casing bottom surface; and a flow-speed accelerator that ejects the cleaning liquid by accelerating the flow speed of the cleaning liquid from the cleaning liquid supply device. The casing is formed by a main body including an upper plate, a projected part attached to a lower part of the upper plate, an outer lateral face extended from the projected part in a downward direction, and the bottom surface connected integrally at a lower end part of the outer lateral face. The bottom surface is formed to be tilted at a prescribed angle with respect to a horizontal plane.