ULV Fogger Recirculation System for Reliable Operation
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Solution Overview
Problem
Conventional foggers configured to generate ultra-low volume (ULV) fog are often expensive and prone to breakdown due to their delicate electrical systems, making them unreliable and costly for large-area applications.
Innovation Solution
A system comprising a holding tank, pump, nozzle, and fan with a recirculation line that maintains constant pressure by diverting liquid back to the tank when pressure exceeds a set value, eliminating the need for expensive and fragile electrical systems, and allowing for the production of ULV fog using a robust and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional foggers use delicate electrical systems (gas motors, compressors, rotary atomizers), then ULV fog generation capability is achieved, but reliability deteriorates and cost increases
Solution Approach 1:
The patent replaces the conventional electrical/mechanical system (gas motor, compressor, rotary atomizer) with a purely mechanical high-pressure pump system. The pump delivers liquid at pressures exceeding 1000 psi directly to a nozzle, eliminating all electrical components while maintaining ULV fog generation capability. This mechanical substitution resolves the contradiction by improving reliability through component reduction while achieving the same technical effect.
Solution Approach 2:
The invention extracts and removes the delicate electrical subsystems (gas motor, blower, compressor, electrical controls) from the fogger system, retaining only the essential mechanical components (pump, nozzle, tank, recirculation line). By taking out the problematic electrical elements and replacing them with a simple mechanical high-pressure delivery system, the patent achieves both simplicity and reliability.
2Manufacturing precision
If high pressure is used to generate ULV fog, then droplet size is reduced below 30 microns, but pressure control complexity increases
Solution Approach 1:
The system employs a self-regulating recirculation mechanism where excess liquid automatically flows back to the tank through a recirculation line when the pressure regulator maintains set pressure. This self-service pressure control eliminates the need for complex electronic pressure management systems, sensors, and controls, achieving precise droplet size control through passive mechanical means.
Solution Approach 2:
The pressure regulator provides automatic feedback control by maintaining a constant pressure differential across the nozzle. When pressure exceeds the set point, the recirculation line activates to divert excess flow back to the tank, creating a self-correcting system that maintains consistent ULV droplet generation without complex electronics.
3Stability of the object's composition
If recirculation line is added to maintain constant pressure, then pressure stability is improved, but device complexity increases
Solution Approach 1:
The recirculation line converts what would be wasted liquid (excess flow beyond what the nozzle can atomize at constant pressure) into a beneficial feature by routing it back to the tank. This transforms potential waste and pressure instability into a self-regulating mechanism that maintains constant pressure and extends operational time, justifying the minimal added complexity.
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 generates ULV fog with droplets less than 30 microns, ensuring reliable operation and reduced maintenance costs over conventional foggers, suitable for large-area applications.
Implementation Method 1
pumping the liquid to a pressure above 1000 psi
Implementation Method 2
a nozzle configured to emit a fog... Droplets of this size have been shown to have optimum drift
Implementation Method 3
a fan configured to push the fog through a tube
Implementation Method 4
a recirculation line allowing a portion of the liquid may be diverted to the holding tank... maintaining a constant pressure
Data Source
AI summary
Disclosed is a system that may include a holding tank configured to hold a liquid, a pump configured to receive the liquid from the holding tank, a nozzle configured to emit a fog, and a fan configured to push the fog through a tube. Disclosed also is a method of creating a fog by transferring a liquid from a holding tank to a pump, pumping the liquid to a pressure regulator, moving the liquid from the pressure regulator back to the holding tank when a pressure is above a first value and moving the liquid to a fogger when the pressure is below the first pressure.