USP_20100078496_Methods and systems for ultrasonic spray shaping (1063673), страница 2
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Impact spray shaping assemblies 20 of the present invention have been produced With jets10 at angles form 15° to 50°, With equal amounts of success,especially With ajet at 15°, 35° and 50°.[0019] FIG. 1 shoWs a reciprocating ?uxer operated of thepresent invention in Which the jet is 50°. The de?ection angleis related to the spray angle. For example, the 15°, 35° and 50°spray angles, the de?ection angles are 5°, 35° and 55°, respectively.
The de?ection angle and spray angle correlation maychange from manufacturer, depending on design. They aretypically referred to as noZZles, although referred to herein asa jet due to the use in this application and to avoid confusionWhen referencing the ultrasonic noZZle 14. They are typicallymanufactured in brass and 303 stainless steel or any othercorrosion resistant, non or loW reacting material. In thispresent embodiment there is used a 316istainless steel piecedue to the corrosive nature of ?uxes.[0020] In an additional embodiments, the jet can be Te?on(PTFE). This material has provided the same de?ection andspray angles as brass and 303 stainless steel.
The impact jet 10is available in many different siZes With different sprayangles, de?ection angles and ori?ce siZes. The impact jet 10used is selected based upon siZe, Weight and air ?oW speci?cations decided appropriate for the application, for examplethe ?uxer application described beloW.[0021] The main function of the jet block 11 is to supportimpact jet 10 and the ultrasonic noZZle atomiZing surface 14in the correct orientation in relation to each other. The correctorientation provides that the ultrasonic spray is sheared perpendicular to the atomiZing surface and that all of the atomiZed liquid drops are entrained in the ?at fan gas stream.
Thejet block 11 also can support the gas supply ?tting 12 andprovides a path for the gas to exit the gas supply ?tting 12 andenter the impact jet 10. The current jet block 11 design projet 10. Brackets can be designed and fabricated for any number of noZZles other than the one pictured in FIG. 20. Thedescribed jet block 11 is designed around the siZe of theultrasonic noZZle 14, the siZe of the impact jet 10 and the 55°de?ection angle of the impact jet 10 shoWn in FIGS. 2 and 3beloW. The jet block 11 is made, in the described embodiment, from Ertalyte Tex. due to the light Weight and corrosionresistance nature of the material and its suitability for the?uxing application described beloW.
Ertalyte is semi crystalline, un-reinforced, thermoplastic polyester based on polyethylterephthalate (PET-P). It’s has an excellent dimensionalstability together With superb Wear resistance, a loW co-e?icient of friction, high poWer, & resistance to fairly acidicsolutions. Ertalyte’s properties make it particularly suitablefor the construction of precision perfunctory parts Which arecapable of supporting high loads & enduring Wear circumstances.
Ertalyte PETP can be machined to accurate detail onnormal metal Working gear.[0022] Therefore, the jet block 11 can be produced fromany number of materials including aluminum, stainless steel,Delrin, Te?on, etc. The selected material desirably retainsdimensional stability and provides suitable corrosion resistance for the desired application.[0023]With reference noW to FIGS. 2 and 3, jet block 11 isdesigned, that is shaped, dimensioned and positioned, to support the impact jet 10 and the ultrasonic noZZle 14 atomiZingsurface in a particular relation to each other. The designreference in FIGS.
2 and 3 is based on an ultrasonic noZZle,Which can atomiZe ?oW rates from approximately 10 ml/minto 70 ml/min. The ultrasonic atomiZing surface diameter, i.e.the tip of noZZle 14, can range from 0.23 inches to 0.75 inches.For example, 0.46 inches is used in a described embodiment.The edge of the de?ection surface on the impact jet 10 can belocated from 0.03 inches to 0.75 inches.
For example, 0.14inches is used in a described embodiment and is measuredhoriZontally from the center of the atomiZing surface and 0.06inches to 0.63 inches. For example, 0.30 inches is used in adescribed embodiment and is measured vertically from theatomiZing surface. The provided dimensions are based on the50° impact jet 10 in system 20. The dimensions can be alteredbased on other impact jet designs available.
The gas suppliedto the impact jet 10 is betWeen 5 and 15 psi. The plumediameter When sheared by the impact gas stream is approximately equal to or less than the atomiZing surface diameter.The plume diameter depends on the ?oW rate and poWer beingsupplied to the ultrasonic noZZle. The pattern Width producedon the substrate can range from one inch to six inches,depending on liquid ?oW rate, gas pressure and height of theassembly from the substrate. For example, in one embodiment using components and materials as described above, the?oW rate is equal to 48 ml/min, the gas pressure is equal to 10psi, the height is equal to 6 inches from substrate, resultingpattern Width is equal to 3 inches.[0024] Ultrasonic noZZle 14 comprises any appropriateultrasonic noZZle, for example an appropriate 8700-seriesmodel of the type manufactured and sold by the Sono-TekCorporation.
The gas supply ?tting 12 and liquid supply?tting 13 comprise conventional components Well knoWn tothe reader.vides through-holes (not shoWn) in order to use a screW tothread into a ?at on the body of ultrasonic noZZle 14. The jetOperation of the Spray Shaping Assemblyblock 11 also has tWo locations in Which brackets (not shoWn)can be placed to orient the ultrasonic noZZle 14 atomiZingsurface in relation to the exit of the gas stream from the impact[0025] The assembly uses a single gas stream, Which isconverted into a ?at fan pattern, to entrain the drops in theultrasonic spray plume. The gas stream is created by the ?oWApr.
1,2010US 2010/0078496 A1of pressurized gas introduced into the assembly through thespray shaping gas supply ?tting 12. The gas is forced throughthe jet block 11 and introduced to the impact jet 10. The ?atfan spray angle is produced by the impact of the gas stream onthe de?ecting surface of the impact jet 10. The de?ectingsurface produces not only the spray angle and converts the gasbe large due to the difference in air velocity required to entrainultrasonic atomiZed drops versus the air velocity required toentrain air atomiZed drops.[0029] In an additional embodiment, the present inventioncan be used in solar cell manufacturing. The spraying apparatus and techniques taught by the present invention can bystream to a ?at fan pattern, but the orientation shears theused to solder bus ?ux silicon solar cells or depositing susultrasonic spray plume perpendicular to the ultrasonic noZZleatomiZing surface 14.
Through-holes on the jet block 11 andthreaded holes on the body of the ultrasonic noZZle 14 insurethat the atomiZing surface of the ultrasonic noZZle 14 is oriented correctly in relation to the Impact jet 10. The ultrasonicspray plume is entrained in the spray angle of the ?at fanpattern produced by the impact jet 10. Due to the entrainmentof the ultrasonic spray plume in the ?at fan, the pattern Widthdeposited on the substrate can be many times the diameter ofthe ultrasonic spray plume. The pattern Width deposited onthe substrate can be affected by several variables. Theypensions for transparent conductive oxide (TCO) layers inthin ?lm solar cell manufacturing.[0030] The present invention can do phosphoric doping andspray pyrolysis applications for production of fuel cells byapplying the material to a fuel cells ?rst surface.
The presentinvention can be used to coat Proton Exchange MembranesWith catalyst inks such as carbon black and other preciousmetal suspensions onto na?on membranes.[003 1] In another embodiment, the present invention can beutiliZed to coat baked goods. For example, the present invention could coat the top of a bread or Danish With a ultra?ne?oW rate, gas ?oW rate and pressure of gas stream impactingcoating of egg Wash to produce a shinny glaZed look on thetop of the bread or Danish. The present invention could alsocoat the bread With a micro ?ne coating of preservative to helpthe de?ecting surface and orientation of the impact jet 10 inkeep the bread fresh and keep the bread form groWing mold.relation to the ultrasonic noZZle atomiZing surface 14.[0026] With reference noW to FIGS.
4 and 5, FIG. 4 shoWsa top vieW of the described assembly 20 in operation, With theOther Features and Advantages of the Present Inventiongas stream 402 directed, by the described assembly, producnoZZle are ejected from the atomiZing surface at very-loWinclude: impact jet 10 spray angle, plume siZe due to liquid[0032] The atomiZed drops produced by the ultrasonicing a shaped gas stream 403 across the path of the ultrasonicvelocity. The atomiZed drops produced by an air atomiZingliquidplume 404.
FIG. 5 shoWs the resultant, desired, shaping502 of the ultrasonic plume 404.noZZle are ejected from the noZZle at very high velocity. Dueto the loW velocity of the ultrasonic atomized drops they canbe entrained by a loW velocity gas stream. The high velocitydrops produced by an air atomiZing noZZle must be entrainedby high velocity gas streams in order to change the direction[0027] The Impact Spray Shaping Assembly of the presentinvention produces a pattern Width many times the Width ofthe ultrasonic spray plume. The orientation of the Impact Jet10 and the atomiZing surface of the ultrasonic noZZle 14 inrelation to each other are unique, as described. Changes in theorientation of the components can be used to alter the patternWidth, as described.
The Impact Spray Shaping Assembly canbe assembled With light Weight, compact components in orderto be used in reciprocating spray ?uxing machines.of the drops and produce the desired spray pattern. In the priorart, the high velocity of the atomiZed drops and the sprayshaping gas streams associated With air atomiZing noZZles ledto clogged ori?ces and exhaust systems, loW transfer e?iciency, Wasted process chemicals and extended cleaning timeof the spray ?uxing machines.
Air atomiZing noZZles typiExemplary Uses of the Spray Shaping Assemblyused in ?uxing machines. The interaction of tWo high velocitycally used tWo gas streams to create the ?at fan spray pattern[0028] One intended use of the Impact Spray ShapingAssembly is in the printed circuit board (PCB) ?uxing industry.
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