Ultrasonic Waveguide Agitating Members for Particle Dispersion
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Solution Overview
Problem
Conventional methods for mixing powders and particulates into cosmetic formulations are inefficient, leading to issues like dusting, clumping, poor hydration, human error in weighing, and batch-to-batch inconsistencies, which result in time and cost inefficiencies.
Innovation Solution
An ultrasonic mixing system that uses a treatment chamber with an elongate housing and an ultrasonic waveguide assembly to energize and mix particulates with formulations, enhancing cavitation and ensuring consistent mixing through precise control of particulate dispensing and formulation flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manual mixing methods are used, then the process is simple to operate, but mixing precision and consistency deteriorate due to human error and manual timing variations
Solution Approach 1:
The patent replaces manual mechanical mixing operations with an automated ultrasonic mixing system. The ultrasonic waveguide assembly generates high-frequency vibrations that automatically mix particulates into formulations, eliminating human error in weighing and timing while maintaining operational simplicity through automated control.
Solution Approach 2:
The patent changes the physical parameters of the mixing process by introducing ultrasonic vibration frequency and intensity as controllable parameters. The waveguide assembly operates at specific ultrasonic frequencies to optimize cavitation effects, transforming the mixing process from a manual mechanical operation to a controlled physical field process that improves consistency without proportionally increasing complexity.
2Manufacturing precision
If ultrasonic waveguide assembly is introduced to enhance mixing, then mixing precision and consistency improve, but device complexity increases
Solution Approach 1:
The patent segments the mixing system into distinct functional modules: the ultrasonic waveguide assembly, the formulation dispensing system, and the particulate dispensing system. This segmentation allows each component to be optimized independently and facilitates easier maintenance and operation, reducing the perceived complexity despite the advanced mixing capabilities.
Solution Approach 2:
The ultrasonic waveguide assembly serves multiple functions: it generates cavitation for enhanced mixing, provides ultrasonic vibration for particle dispersion, and can be adjusted for different formulation types. This multi-functionality reduces the need for separate equipment for different mixing tasks, thereby limiting the increase in overall system complexity.
3Productivity
If batch-type mixing processes are used, then the process is easy to operate, but productivity deteriorates due to lengthy heating and mixing times
Solution Approach 1:
The patent implements continuous ultrasonic mixing action through the waveguide assembly, which operates continuously as formulations and particulates flow through the treatment chamber. This eliminates the start-stop nature of batch processing and heating cycles, dramatically increasing mixing speed while maintaining operational simplicity through automated continuous flow control.
Solution Approach 2:
The patent replaces thermal heating methods with ultrasonic vibration-based mixing. The ultrasonic waveguide assembly generates cavitation and mechanical vibration that rapidly mixes particulates without requiring lengthy heating cycles, thereby increasing productivity while keeping the operational interface simple through automated flow and power control.
4Manufacturing precision
If manual ingredient addition is used, then the process is simple to operate, but manufacturing precision deteriorates due to weighing errors and incomplete transfers
Solution Approach 1:
The patent replaces manual weighing and transferring of ingredients with automated dispensing systems. The formulation and particulate dispensing systems use controlled flow mechanisms and ultrasonic assistance to accurately deliver precise amounts of materials into the treatment chamber, eliminating weighing errors and incomplete transfers while maintaining operational simplicity through automated control.
Solution Approach 2:
The dispensing systems are designed to automatically measure and deliver the correct amounts of formulations and particulates without requiring manual intervention for weighing or transfer. The systems self-regulate flow rates and volumes, ensuring consistent accuracy while reducing the operational complexity to simple start/stop controls.
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 effectively disperses particulates throughout formulations, improving mixing efficiency, reducing inconsistencies, and enhancing product quality by ensuring thorough and uniform incorporation of ingredients.
Implementation Method 1
the waveguide assembly comprises an elongate ultrasonic horn disposed at least in part intermediate the inlet port and the outlet port of the housing and having an outer surface located for contact with the formulation and particulates flowing within the housing from the inlet port to the outlet port. A plurality of discrete agitating members are in contact with and extend transversely outward from the outer surface of the horn intermediate the inlet port and the outlet port in longitudinally spaced relationship with each other. The agitating members and the horn are constructed and arranged for dynamic motion of the agitating members relative to the horn upon ultrasonic vibration of the horn at the predetermined frequency and to operate in an ultrasonic cavitation mode of the agitating members corresponding to the predetermined frequency and the formulation being mixed with particulates in the chamber.
Data Source
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AI summary
An ultrasonic mixing system having a particulate dispensing system to dispense particulates into a treatment chamber and the treatment chamber in which particulates can be mixed with one or more formulations is disclosed. Specifically, the treatment chamber has an elongate housing through which a formulation and particulates flow longitudinally from an inlet port to an outlet port thereof. An elongate ultrasonic waveguide assembly extends within the housing and is operable at a predetermined ultrasonic frequency to ultrasonically energize the formulation and particulates within the housing. An elongate ultrasonic horn of the waveguide assembly is disposed at least in part intermediate the inlet and outlet ports, and has a plurality of discrete agitating members in contact with and extending transversely outward from the horn intermediate the inlet and outlet ports in longitudinally spaced relationship with each other. The horn and agitating members are constructed and arranged for dynamic motion of the agitating members relative to the horn at the predetermined frequency and to operate in an ultrasonic cavitation mode of the agitating members corresponding to the predetermined frequency and the formulation and particulates being mixed in the chamber.