Sono-tek Corporation

Bae Systems Information and Electronic Systems Integration Inc.

Harvey L Berger

Charles R Brandow

Alan Paul

William J Broe

Randy A Copeman

Allister McNeish

Mark Brown

Robb W Engle

Donald Frederick Mowbray

Carl Levine

Vincent D Whipple

Mark W Leiby

Matthew C Walls

James J Cerul

Robert J Russell

Edmund Popp

A Earle Ericson

An ultrasonic generator is provided. The ultrasonic generator includes an amplifier for outputting a drive signal to an ultrasonic atomizing nozzle, and a microcontroller, coupled to the amplifier, to control an output power of the amplifier. The microcontroller includes a load leveling operating mode in which the output power of the amplifier fluctuates to match changing load conditions of the ultrasonic atomizing nozzle.

Dynamic ultrasonic generator for ultrasonic spray systems

An ultrasonic nozzle configured to form relatively small drops of liquid at relatively high rates. The nozzle includes two horns, at least one of which includes a ceramic material. The nozzle also includes one or more transducers that cause mechanical motion in at least one of the horns. In addition, a method of forming micrometer-scaled drops of liquid at relatively high rates is provided.

Ultrasonic atomizing nozzle and method

The present invention relates to an apparatus and process for producing a thin organic film on a substrate using an ultrasonic nozzle to produce a cloud of micro-droplets in a vacuum chamber. The micro-droplets move turbulently within the vacuum chamber, isotropically impacting and adhering to the surface of the substrate. The resulting product has a smooth, continuous, conformal, and uniform organic thin film, when the critical process parameters of micro-droplet size, shot size, vacuum chamber pressure, and timing are well-controlled, and defects such as 'orange peel' effect and webbing are avoided. The apparatus includes an improved ultrasonic nozzle assembly that comprises vacuum sealing and a separate, independent passageway for introducing a directed purging gas.

Process for coating three-dimensional substrates with thin organic films and products

An axial flow tube ultrasonic atomizer in which the front horn section and axial flow section are of unitary construction. The device further comprises five sealing rings and two grooves cut into the unitary flow tube structure for receipt of the sealing rings. This structure results in better sealing and facilitates assembly.

Unitary axial flow tube ultrasonic atomizer with enhanced sealing

An ultrasonic atomizing transducer assembly includes cylindrical front atomizing and rear dummy sections clamped to a sandwich of an annular electrode between two annular piezoelectric disks by a central tubular bolt. Liquid to be atomized enters the rear of the transducer assembly through a feed tube forming a rearward extension of the central bolt and flows through an axial passage to exit onto an atomizing surface on the tip of an amplifying probe extending from the front end of the front cylindrical section. An annular sealing member disposed between a sealing surface at the front end of the bolt and the passage prevents liquid flowing through the passage from contacting the inner surfaces of the piezoelectric disks. To protect the outer surfaces of the piezoelectric disks, an enclosed shell surrounds and supports the transducer via O-rings loaded purely in radial compression.

Central bolt ultrasonic atomizer

An ultrasonic liquid atomizer particularly for high volume flow rates is disclosed. An enlarged tip with a plurality of orifices is provided to increase the flow rate. A gradual transition to the enlarged atomizer tip is provided to enhance performance. The atomizer provides a substantially cylindrical or slightly conical spray pattern and is particularly suited for use in a vertical orientation with the tip facing upwardly or in horizontal orientations. Titanium alloy bolts are used to clamp the front and rear sections of the atomizer together resulting in significant energy reduction and essentially eliminating bolt shearing.

High volume ultrasonic liquid atomizer

An ultrasonic liquid atomizer particularly for high volume flow rates is disclosed. An enlarged tip with a plurality of orifices is provided to increase the flow rate. A gradual transition to the enlarged atomizer tip can also be provided to enhance performance. A barrier disposed adjacent the atomizing surface of the atomizer tip enhances proper atomization of liquid, particularly when the enlarged atomizer tip is used, and particularly when such an atomizer is vertically oriented with the tip facing downwardly. A lip extending about the atomizer surface prevents unatomized liquid from leaving the atomizing surface in radial directions.

Ultrasonic liquid atomizer, particularly for high volume flow rates

An ultrasonic liquid atomizer is disclosed in which the liquid feed to the atomizing surface extends axially through the atomizer. This arrangement enables improved and simplified coupling of the liquid supply tube to the atomizer. In a disclosed embodiment, rear and front horn sections sandwich a driver, and an atomizing section is coupled to the front horn section. A passage axially extends through the rear section, the driver, the front section and the atomizing section to an atomizing surface. The driver includes piezoelectric elements of annular configuration. A tubular member or a liquid supply tube itself is received in the passage. In a preferred embodiment, the tubular member of the liquid supply tube includes a decoupling sleeve section and a stepped portion adapted to engage a stepped portion in the rear section upon coupling the tubular member or liquid supply tube to the atomizer to draw the front and rear sections together.

Ultrasonic liquid atomizer having an axially-extending liquid feed

An ultrasonic atomizer having a stepped amplifying section with a flanged atomizing tip. The face of the flange is frusto-conical for providing a cone-shaped spray pattern. The lengths of the amplifying section and flange tip portions are interrelated to provide optimum results.

Ultrasonic fuel atomizer

A transducer assembly includes a first half wavelength double-dummy section having a pair of quarter wavelength ultrasonic horns and a driving element sandwiched therebetween. A second half wavelength stepped amplifying section extends from one end of the first section and has a theoretical resonant frequency equal to the actual resonant frequency of the first section. When used as a liquid atomizer, the small diameter portion of the stepped amplifying section has a flanged tip to provide an atomizing surface of increased area. To maintain efficiency, the length of the small diameter portion of the second section with a flange should be less than its length without a flange. A decoupling sleeve within an axial liquid passageway eliminates premature atomization of the liquid before reaching the atomizing surface. In a fuel burner incorporating the atomizer, ignition electrode life is increased by locating the electrodes outside the normal flame envelope. During the ignition phase, drive power to the atomizer is increased to widen the spray envelope to the location of the electrodes. A variable orifice controls combustion air flow in accordance with fuel rate while maintaining constant blower speed. Either three-step or continuous fuel rate modulation saves fuel and reduces pollution.

Transducer assembly, ultrasonic atomizer and fuel burner

A transducer assembly includes a first half wavelength double-dummy section having a pair of quarter wavelength ultrasonic horns and a driving element sandwiched therebetween. A second half wavelength stepped amplifying section extends from one end of the first section and has a theoretical resonant frequency equal to the actual resonant frequency of the first section. When used as a liquid atomizer, the small diameter portion of the stepped amplifying section has a flanged tip to provide an atomizing surface of increased area. To maintain efficiency, the length of the small diameter portion of the second section with a flange should be less than its length without a flange. A decoupling sleeve within an axial liquid passageway eliminates premature atomization of the liquid before reaching the atomizing surface. In a fuel burner incorporating the atomizer, ignition electrode life is increased by locating the electrodes outside the normal flame envelope. During the ignition phase, drive power to the atomizer is increased to widen the spray envelope to the location of the electrodes. A variable orifice controls combustion air flow in accordance with fuel rate while maintaining constant lower speed. Either three-step or continuous fuel rate modulation saves fuel and reduces pollution.

Growing community of inventors

Poughkeepsie, NY, United States of America

Harvey L Berger