USP_20100078496_Methods and systems for ultrasonic spray shaping (1063673)
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US 20100078496A1(19) United States(12) Patent Application Publication (10) Pub. No.: US 2010/0078496 A1Massimi(54)(43) Pub. Date:METHODS AND SYSTEMS FORULTRASONIC SPRAY SHAPING(75) Inventor:Apr. 1, 2010Publication Classi?cation(51)Benjamin Massimi, New PaltZ, NYInt. Cl.3053 17/06(200601)(Us)(52)US. Cl. ........................................ .. 239/4; 239/102.2Correspondence Address:BAKER & HOSTETLER LLPWASHINGTON SQUARE, SUITE 1100, 1050(57)CONNECTICUT AVE. N.W.WASHINGTON, DC 200365304 (Us)ABSTRACT____NeW and improved ultrasomc spray shaplng assemblies,components thereof, and methods for using the assemblies.(73) Assignee;s0n0_Tek Corporation, Milton,An ultrasonic spray shaping assembly includes jet block andNY (Us)impact jet components to receive and redirect a single gas12/569,169ultrasonic spray plume in a desired shape, particularly into astream, Whereby to use the single gas stream to shape an(21) Appl.
No.:_(22)desired Width of the plume. Modi?cations to the components,Flled?seP- 29’ 2009..Related U's' Apphcatlon Data(60)Provisional application NO_ 61/100,818, ?led on Sep29, 2008.such as relative positioning, can be used to alter the shape ofthe s ralume. The resent invention can be fabricated in acomgacil, plightweigh? design. It has many applications,including but not limited to, the deposition of ?ux onto aprinted circuit board.721420Patent Application PublicationApr. 1, 2010 Sheet 1 0f 4US 2010/0078496 A1Patent Application PublicationaApr. 1, 2010 Sheet 2 0f 4US 2010/0078496 A1Fig.2.._\4 lNI;/4.3"Patent Application PublicationApr. 1, 2010 Sheet 3 0f 4US 2010/0078496 A1Fig.3Patent Application PublicationApr. 1, 2010 Sheet 4 0f 4US 2010/0078496 A1Apr.
1,2010US 2010/0078496 A1METHODS AND SYSTEMS FORULTRASONIC SPRAY SHAPINGCLAIM FOR PRIORITY[0001]The present application is a non-provisional appligas stream and directing the gas stream relatively perpendicular to the ultrasonic spray to control a plume shape of theultrasonic spray.[0008] An additional embodiment is for a method for shaping the plume of an ultrasonic spray to deposit ?ux on aprinted circuit board. It comprises receiving a gas streamcation that claims priority to US.
Provisional Patent Application Ser. No. 61/1 00,81 8, ?led Sep. 29, 2008, the disclosureinput and a liquid ?ux stream input; converting the liquid ?uxof Which is hereby incorporated by reference in its entirety.directing the gas stream relatively perpendicular to the ultrastream to an ultrasonic ?ux spray; shaping the gas stream; andsonic ?ux spray to control a plume shape of the ultrasonic ?uxFIELD OF THE INVENTIONspray; and directing, using the assembly, the ultrasonic ?ux[0002] The present invention relates generally to the ?eld ofultrasonic spraying and more particularly to the ?eld of ultraspray onto a printed circuit board, Whereby to deposit the ?uxupon the printed circuit board.[0009] Another embodiment, a method for shaping thesonic noZZle plume spray shaping.plume of an ultrasonic spray to deposit material on a fuel cell,comprises receiving a gas stream input and a liquid phosphoBACKGROUND OF THE INVENTION[0003]Ultrasonic noZZles are knoWn to produce a loWvelocity atomized spray plume.
It is desirable to control thedeposition of the micron siZed atomiZed drops in the sprayplume produced by the ultrasonic noZZle. Due to the smallsiZe and thus light Weight of the atomiZed drops, the sprayplume from an ultrasonic noZZle is easily disturbed by aircurrents in the coating facility. If the atomiZed drops in theplume are not directed to a desired location in some manner,many or all of the drops[0004]One current method of shaping the plume producedby an ultrasonic noZZle consists of tWo streams of gas shearing the plume in order to produce a spray angle and direct theatomiZed liquid droplets to the substrate. In some embodiments one of the tWo gas streams, or a third gas stream, is usedto redirect the entrained droplets perpendicular to the originaldirection of the shearing gas streams.
The interaction of tWoand sometimes three separate gas streams often causes thepattern deposited on the substrate to exhibit non-uniformity.The use of multiple gas streams to shape the ultrasonic sprayplume requires precise control of each stream to produce auniform spray pattern.[0005] The present inventors have identi?ed signi?cantde?ciencies associated With the existing processes.
The use ofmultiple, precisely controlled gas streams to shape and/ordirect the ultrasonic spray plume raises issues associated Withthe dif?culty of controlling the various gas streams and hencethe spray plume. While it is possible to shear the atomiZedliquid off the tip of the ultrasonic noZZle using a sheet of gasas produced by an air knife to direct the atomiZed droplets,this Will not provide an acceptable pattern Width. The patternWidth Will be only slightly greater than the original ultrasonicspray plume.SUMMARY OF THE INVENTION[0006] At least in consideration of the above discussion, itWould be advantageous to overcomes the shortcomings of theprior art by using a single gas stream to entrain the atomiZeddrops of the ultrasonic spray plume in such a Way as to spreadthem at an angle, Which Will produce a spray pattern that isWider than the original ultrasonic spray plume.[0007] The present invention is for an apparatus for shapingthe plume of an ultrasonic spray.
It has a body including a gasstream input and a liquid stream input; an ultrasonic noZZleric doping material stream input; converting the liquid phosphoric doping material stream to an ultrasonic phosphoricdoping material spray; shaping the gas stream; and directingthe gas stream relatively perpendicular to the ultrasonic phosphoric doping material spray to control a plume shape of theultrasonic phosphoric doping material spray; and directing,using the assembly, the ultrasonic phosphoric doping material spray onto a fuel cell ?rst surface, Whereby to deposit thephosphoric doping material upon the fuel cell ?rst surface.[001 0] In still another embodiment, a means for shaping theplume of an ultrasonic spray to deposit a material on a surface,comprises receiving means for a gas stream input and a liquidstream input; and means for converting the liquid stream to anultrasonic spray; and means for shaping the gas stream; andmeans for directing the gas stream relatively perpendicular tothe ultrasonic spray to control a plume shape of the ultrasonicspray; and means for directing, using the assembly, the ultrasonic spray onto a surface, Whereby to deposit the liquidstream upon the surface.[0011]There has thus been outlined, rather broadly, certainembodiments of the invention in order that the detaileddescription thereof herein may be better understood, and inorder that the present contribution to the art may be betterappreciated.
There are, of course, additional embodiments ofthe invention that Will be described beloW and Which Willform the subject matter of the claims appended hereto.[0012] In this respect, before explaining at least oneembodiment of the invention in detail, it is to be understoodthat the invention is not limited in its application to the detailsof construction and to the arrangements of the components setforth in the folloWing description or illustrated in the draWings. The invention is capable of embodiments in addition tothose described and of being practiced and carried out invarious Ways. Also, it is to be understood that the phraseologyand terminology employed herein, as Well as the abstract, arefor the purpose of description and should not be regarded aslimiting.[0013] As such, those skilled in the art Will appreciate thatthe conception upon Which this disclosure is based mayreadily be utiliZed as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention.
It is important, therefore, thatthe claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope ofthe present invention.connected to the body for receiving the liquid stream andBRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is a diagrammatic vieW of an assembly forconverting the liquid stream to an ultrasonic spray; and an[0014]assembly connected to the body for receiving and shaping thecontrolling the shape of an ultrasonic spray plume.Apr. 1,2010US 2010/0078496 A1[0015]FIGS. 2 and 3 are diagrammatic vieWs of the assembly of FIG.
1 including exemplary dimensional markings.[0016] FIGS. 4 and 5 are three dimensional top and frontalvieWs of an embodiment of the assembly in operation.DETAILED DESCRIPTIONStructure of the Spray Shaping Assembly[0017]The invention Will noW be described With referenceto the draWing ?gures, in Which like reference numerals referto like parts throughout. An impact spray shaping assembly20 of the Figure addresses the issues mentioned above. Theimpact spray shaping assembly consists of four main components: an impact jet 10, a jet block 11, spray shaping gassupply ?tting 12 and the ultrasonic noZZle 14.
Liquid is supplied to the ultrasonic noZZle through the liquid supply ?tting13. The jet block 11 Was designed to hold the ultrasonicnoZZle 14 and the impact jet 10 in the required orientation inrelation to each other. The jet block 11 also provides themeans for air to be supplied to the impact jet 10 through thespray shaping gas supply ?tting 12.[0018] The impact jet 10 is a ?at fan hydraulic noZZle, forexample a K type noZZle. The jet 10 is typically used inWashing applications requiring a high impact force. Typicalspray angles are available from 15° to 50° for the spoonshaped de?ecting face design.
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