Ultrasonic Liquid Atomization in Vacuum Coating Systems
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Solution Overview
Problem
Existing vacuum systems for applying liquids to objects in high vacuum environments face challenges such as liquid evaporation and contamination risks due to the formation of droplets on needle tips and the introduction of unnecessary components into the vacuum chamber.
Innovation Solution
A vacuum system comprising a first module for generating vacuum, a second module with a user chamber and an injection chamber for applying liquids under controlled conditions, and a third module for preparing and supplying the liquid, utilizing a sealed linear movement system to maintain high vacuum and precise control over the needle-to-object distance, minimizing contamination and ensuring purity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a needle is positioned above the object to apply liquid in a vacuum chamber, then liquid can be injected onto the object, but a droplet may form on the needle tip and fall onto the object in an undispersed form causing contamination
Solution Approach 1:
The patent replaces the mechanical needle-based injection system with an ultrasonic atomization system. The ultrasonic transducer vibrates at high frequency to atomize the liquid into fine droplets, eliminating the need for a mechanical needle that forms large undispersed droplets. This substitution of mechanical injection with ultrasonic vibration-based atomization resolves the contamination issue while maintaining ease of operation.
Solution Approach 2:
The patent employs ultrasonic vibration of the liquid surface in the reservoir to atomize the liquid. The ultrasonic transducer creates high-frequency vibrations that break the liquid into fine aerosol droplets, preventing the formation of large undispersed droplets that would contaminate the object. This mechanical vibration principle directly addresses the harmful effect of undispersed droplet contamination.
2Manufacturing precision
If adjustment system components are installed in the vacuum chamber to control needle-to-object distance, then precise control is achieved, but contamination risk increases from mechanical components exposed to vacuum and sprayed substance
Solution Approach 1:
The patent extracts the liquid preparation and injection control mechanisms from the vacuum chamber environment. The liquid reservoir and ultrasonic transducer are positioned outside the vacuum chamber, connected only by a sealed conduit. This extraction eliminates the need for mechanical adjustment components inside the vacuum chamber, thereby removing the source of contamination while maintaining precise control over the atomization process.
Solution Approach 2:
The patent introduces a sealed conduit as an intermediary between the liquid reservoir (outside vacuum) and the injection point (inside vacuum). This intermediary allows precise control of liquid delivery without requiring mechanical components to be exposed to the vacuum environment, thus preventing contamination from adjustment system components while maintaining manufacturing precision.
3Ease of operation
If liquids are introduced into high vacuum environment, then liquid can be applied to object, but liquid begins to boil and evaporate dynamically throughout its volume causing loss of substance
Solution Approach 1:
The patent uses ultrasonic vibration to atomize the liquid into extremely fine droplets before introduction into the vacuum chamber. This pre-atomization through mechanical vibration dramatically increases the surface area to volume ratio, allowing controlled evaporation rather than uncontrolled boiling. The liquid is applied as a fine aerosol that evaporates uniformly and controllably, preventing the dynamic boiling and substance loss that occurs with bulk liquid introduction.
Solution Approach 2:
The patent changes the physical parameters of the liquid by transforming it from bulk liquid form to fine aerosol droplets through ultrasonic atomization. This parameter change in droplet size and distribution allows the liquid to behave differently in vacuum - evaporating uniformly and controllably rather than boiling dynamically. The parameter change from bulk liquid to aerosol prevents substance loss while maintaining ease of application.
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 system enables the application of very thin, uniform liquid layers with precise control, maintaining high vacuum conditions and preventing exposure to air or contaminants, ensuring effective and clean coating processes.
Implementation Method 1
a first module for generating a vacuum; a second module with a user chamber and an injection chamber for applying the liquid to the object under vacuum conditions
Implementation Method 2
The injection needle passes through the sealed linear movement system to inject the liquid prepared in the third module, so that the injection needle protrudes from the linear movement system into the interior of the injection chamber
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A vacuum system for applying a liquid to an object, the vacuum system comprising: a first module (A) for generating a vacuum; a second module (B) with a user chamber (8) and an injection chamber (9) for applying the liquid to the object under vacuum conditions; and a third module (C) comprising a set of components for preparing the liquid and supplying the liquid to an injection needle (11). The first module (A) is tightly connected to the second module (B) and the second module (B) is tightly connected to the third module (C). The second module (B) is connected to the third module (C) via a sealed linear movement system (13). The injection needle (11) passes through the sealed linear movement system (13) to inject the liquid prepared in the third module (C), so that the injection needle (11) protrudes from the linear movement system (13) into the interior of the injection chamber (9) in the second module (B) and is movable in the horizontal axis relative to the object (10) located in the second module (B) onto which the liquid from the injection needle (11) is to be sprayed.