Focused ultrasonic atomizer

An atomizer device can include a container for storing liquid for atomization, the container defining a top portion and a bottom portion, the top portion defining a mist opening. An ultrasonic transducer can be located at the bottom portion of the container and configured to generate waves in the liquid. A sleeve can extend from the bottom portion toward the top portion of the container. The sleeve can be configured to direct the waves along a longitudinal axis of the sleeve. A float can be located within the sleeve and be configured to move along the longitudinal axis of the sleeve. The float can define a through hole, wherein the waves are concentrated toward a surface of the liquid by passing through the through hole.

TECHNICAL FIELD

The present disclosure relates to the field of atomizers, and more particularly to ultrasonic atomizers.

BACKGROUND

In daily life, essential oils are often used to improve the surrounding environment or to perform medical treatment, such as sterilization, disinfection or changing environmental odor, etc. When using the essential oils, an atomizer is often used to atomize the essential oils for facilitating diffusion of the essential oils into the environment.

SUMMARY

One aspect of the present disclosure relates to an atomizer device including a container for storing liquid for atomization, wherein the container can define a top portion and a bottom portion and the top portion can define a mist opening, an ultrasonic transducer located at the bottom portion of the container and configured to generate waves in the liquid, and a sleeve extending from the bottom portion toward the top portion of the container and having a longitudinal axis, with the sleeve being configured to direct the waves along the longitudinal axis.

In some embodiments, a float can be located within the sleeve and can be configured to move along the longitudinal axis of the sleeve. The float can define a through hole, wherein the waves can be concentrated toward a surface of the liquid by passing through the through hole. The atomizer device can further include a splash cover located at the top portion of the container and configured to prevent liquid from exiting the mist opening. The splash cover can be attached to at least one of the container or the sleeve.

In some embodiments, the ultrasonic transducer can configured to atomize liquid at a depth of about 55 mm, such as when operating at 24V. The sleeve can define slits configured to allow liquid to enter the sleeve. An output of atomized liquid can be substantially equal across a plurality of operating depths per unit time. The ultrasonic transducer can oscillate in the vertical direction. A liquid depth inside the sleeve can be the same as a liquid depth outside of the sleeve.

In some embodiments, the hole defined by the float tapers upward along the longitudinal axis. An outer diameter of the float can be less than inner diameter of sleeve. The mist opening, the splash cover, the float, and the ultrasonic transducer can be centered along the longitudinal axis of the sleeve. The splash cover can prevent the float from exiting the sleeve. The sleeve can partially constrain the waves from expanding beyond a predetermined radius from the longitudinal axis.

Another aspect of the disclosure relates to an ultrasonic atomizer including a container for storing liquid, a piezoelectric transducer configured to propagate vibrations in the liquid, and a guide wall positioned in the container and configured to constrain the vibrations.

In some embodiments, the atomizer further includes a cover configured to couple with the container to define an internal volume for storing the liquid, the cover defining an aperture for expelling atomized liquid, and a float defining a through hole configured to concentrate the vibrations toward a surface of the liquid, the float being constrained by the guide wall.

In some embodiments, the guide wall constrains the vibrations from expanding beyond a projection of the piezoelectric transducer. The piezoelectric transducer and the guide wall can be offset from a central axis of the container. The atomizer can further include a floating nozzle that defines a hole that opens at a surface of the liquid across a plurality of liquid depths.

The above summary of the present invention is not intended to describe each embodiment or every implementation of the present invention. The Figures and the detailed description that follow more particularly exemplify one or more preferred embodiments.

DETAILED DESCRIPTION

The working principle of ultrasonic atomization involves positioning a transducer at the bottom of the tank or container configured to hold liquid. A printed circuit board assembly can be communicatively coupled with the transducer and can apply electrical energy to the transducer. In response to the electrical energy, the transducer can oscillate to generate vibrations or waves in the liquid. In some embodiments, the transducer oscillates in the vertical direction, which in turn propagates waves in the vertical direction. Under the proper depth, the energy propagation produces a liquid column at the surface, and a large number of tiny tension waves occur at the top of the liquid column, greatly reducing surface tension. Once the amplitude of the capillary waves reaches a critical height, they become too tall to support themselves and tiny droplets fall off the tip of each wave into the air to form a mist, resulting in atomization of the liquid.

However, the energy produced by the transducer can be attenuated, absorbed, or diffused, resulting in variations in the energy transmitted to the liquid surface at different liquid depths, which affects the amount of atomization. Thus, traditional ultrasonic aromatherapy devices are limited in that the depth of the liquid is highly restricted to ensure proper performance of the device. For example, the liquid depth of a 24V ultrasonic aromatherapy machine usually cannot exceed around 38 mm, and the liquid depth of a 5V ultrasonic aromatherapy machine usually cannot exceed around 20 mm. Thus, conventional ultrasonic atomizers are restricted in the amount of liquid that is able to be contained in the device. Additionally, conventional atomizers experience a large variance in the amount of mist generated when the liquid depth is large versus when the liquid depth is small. The present disclosure introduces a device capable of overcoming the limitations and shortcomings of conventional ultrasonic atomizers. For instance, many of the complications that arise due to attenuation can be overcome by introducing one or more of the focusing or concentrating features as disclosed herein.

It will be appreciated that while the present disclosure focuses on essential oil atomizers, the components and principles discussed herein can be applied to a wide range of fields, such as spray painting, humidifiers, electronic cigarettes, fuel cells, wafers, solar panels, similar devices, and combinations thereof.

FIG. 1illustrates a cross-sectional side view of an ultrasonic atomizer100according to one embodiment. The atomizer100includes a tank or container104configured to hold liquid. As used herein “liquid” can refer to a wide variety of liquid substances that are capable of being atomized, such as essential oils, water, other aromatic fluids, and combinations thereof. The tank104can be positioned on a base112configured to house various operational components such as a fan132, electrical components, and a printed circuit board assembly. The fan132can be used to direct atomized mist or vapor away from the atomizer100and into the air. The atomizer100can further include a cover or lid108configured to couple with the tank104to form a volume within which the liquid is stored. The cover108can define a mist opening or aperture116. The opening116allows atomized mist to escape the internal volume defined by the tank104and cover108and enter into the outside environment. The atomizer100can include an ultrasonic transducer115. In some examples, the transducer115can be a piezoelectric transducer. The transducer115can be incorporated into a bottom of the tank104such that at least a portion of the transducer115is in contact with fluids held in the internal volume of the tank104. In some embodiments, the transducer115can comprise a protective layer or fluid-tight layer separating delicate components of the transducer115from the fluid while allowing vibrations generated by the transducer115to pass into the fluids of the tank104.

A printed circuit board assembly117can be communicatively coupled with the transducer115and can apply electrical energy to the transducer115. In response to the electrical energy, the transducer115can oscillate to generate vibrations or waves120in the liquid. In some embodiments, the transducer115oscillates in the vertical direction, which in turn, generates pulses or waves120that propagate in the vertical direction (i.e., from the bottom of the tank104toward the cover108). Under the proper liquid depth, and with the proper vibration strength and frequency, the vibrational waves can produce a liquid column124at the surface118, resulting in atomization of the liquid. In some embodiments, the atomizer100can be configured such that the ultrasonic transducer115is configured to atomize liquid at a depth of about 38 mm when operating at 24V. A depth indicator128can be attached or formed into the tank104to prevent overfilling the tank104. The depth indicator128can serve as a visual reference of the max fill line for the user. In some embodiments, the depth indicator128includes an overspill reservoir to prevent overfilling the tank104which can reduce the effectiveness of the atomization. For example, the atomizer100may only be able to atomize liquid when the liquid depth is no greater than a depth d1. A top-most position the depth indicator128in the tank104can be substantially equal to the top of the depth d1.

FIG. 2illustrates a side cross-sectional view of a focused ultrasonic atomizer200according to one embodiment. The atomizer200can be substantially similar to, and can include some or all of the features of, the atomizer100discussed above. For instance, the atomizer200can include a tank104, cover108, and base112.

In some embodiments, the atomizer200can include a guide, baffle, or sleeve236positioned in the tank104. The sleeve236can have an inner surface configured to come into contact with the waves120produced by the transducer115as they radiate through the fluid in the tank104. The sleeve236can be shaped and/or positioned to concentrate or reflect the waves120. For instance, the sleeve236can be configured to restrict or constrain the waves120such that the waves120are directed upward along the sleeve236toward the surface of the liquid. In this manner, the sleeve236at least partially constrains the propagation of the waves120from expanding beyond a predetermined radius from the longitudinal axis237, wherein the radius is defined by the inner radius of the sleeve236. In some embodiments, the sleeve236can completely constrain the waves120from propagating laterally beyond the inner radius of the sleeve236. In other words, the waves can be driven into the inner surface of the sleeve236and can be at least partially reflected or absorbed by the sleeve such that along at least a portion of the longitudinal length of the sleeve236, the waves do not significantly escape the sleeve236or pass unhindered into the remaining liquid in the tank104. In some embodiments, only a portion of the waves120are constrained by the sleeve236, while some of the waves120propagate beyond the internal radius of the sleeve236, for example, through slits238, as discussed below with reference toFIG. 3. As stated above, the energy produced by traditional ultrasonic atomizers can be attenuated, absorbed, or diffused, resulting in variations in the energy transmitted to the liquid surface at different liquid depths, which affects the amount of atomization. In some cases, when the liquid depth exceeds a maximum operating depth, the energy is attenuated to such a degree that the transducer is unable to atomize the liquid. To overcome these shortcomings, the sleeve236acts as a focusing barrier and prevents at least portions of the waves120from being dissipated or attenuated outside of the sleeve236. Thus, the sleeve236can reduce the attenuation of the vibrational energy during propagation through the liquid. This focusing or concentrating of the waves120can greatly amplify the amount of atomization because the sleeve236reduces attenuation and dispersion of the waves120throughout the tank104external to the sleeve236, thereby greatly amplifying the tension wave concentrated at the top of the water column124to increase the amount of atomization.

The sleeve236, as shown inFIGS. 2 and 3, can be a hollow tube. It will be understood that the sleeve236is not limited to the particular embodiment depicted in the figures. For example, the sleeve or guide236is not necessarily cylindrical and may be rectangular, hexagonal, elliptical, or may take on another shape. In some embodiments, the sleeve236can be referred to as a guide wall, working in combination with a sidewall of the tank104to direct propagation of the waves120. As shown inFIG. 3, the sleeve236can define one or more slits, gaps, holes, or other openings238to allow the liquid to enter the sleeve236through the slits238. As a result, the surface of the liquid level inside the sleeve236can be maintained at substantially the same level as outside the sleeve236within the tank104. In other words, the surface height of the liquid outside of the sleeve is the same as the surface height of the liquid inside of the sleeve236. As a result, the depth of the liquid within the sleeve236and the rest of the tank104remains consistent, and the fluid within the sleeve236does not run out before the rest of the tank104(or vice versa). In some embodiments, the sleeve236is stationary relative to the tank104and transducer115. For example, the sleeve236can be attached, either permanently or removably to a portion of the tank104. In some embodiments, the sleeve236can be securely attached to the transducer115which in turn is attached to the tank104and/or to the base112. In some embodiments, the position of the sleeve236remains the same, regardless of the liquid depth level. In some embodiments, the sleeve236can comprise a continuous inner surface about its circumference, wherein no slits238interrupt the inner surface, and, rather than having slits238, a plurality of apertures or channels are located at the base of the sleeve236to permit passage of fluid into the base of the inner chamber of the sleeve236. In this manner, the waves generated by the transducer115can be especially highly concentrated by the sleeve236since they can be substantially entirely contained within the central fluid column within the sleeve236.

In some embodiments, the atomizer200includes a float or nozzle240. The float240can be buoyant so that it floats on or near the surface118of the liquid. The float240can be positioned inside the sleeve236. For instance, the float240can have a periphery cross section that has the same cross-sectional shape as the internal walls of the sleeve236. In some embodiments, an outermost diameter of the float240is less than an innermost diameter of the sleeve236such that the float240can freely move along the longitudinal axis237of the sleeve. In other words, a slight gap can exist between the outer peripheral surface of the float240and the inner wall surface(s) of the sleeve236to ensure that the float240can move freely in the sleeve236along the longitudinal axis of the sleeve236. The float240can be configured to fit securely in the sleeve236such that the float240cannot travel in the horizontal direction. Accordingly, as the fluid level in the tank104changes, the float240can remain at the top surface of the fluid level over time.

As shown inFIG. 3, the transducer115, the sleeve236, and the float240can be centered along the longitudinal axis237. The sleeve236can define an internal volume within which the float240resides. In some embodiments, at least a portion of the float240can extend into one or more of the slits238to restrict rotation of the float240along the longitudinal axis237. In some embodiments, the float240can rotate within the sleeve236about the longitudinal axis237. The slits238can be wide enough to allow the liquid to freely enter the sleeve236, yet narrow enough such that the float240remains secured within the sleeve236. The slits238can also be configured to have opening widths that enable the fluid in the tank104to freely circulate around the tank104and interior of the sleeve236so that the fluid being atomized has a generally consistent mix ratio (e.g., when a mixture of water and oil are atomized).

The float240can include a through hole or aperture242that extends through the float240. The through hole242can be any shape, for example, the through hole242can be a circular or conical through hole in the middle of the float240for constraining and focusing waves of vibrational energy travelling through the liquid. In some embodiments, the through hole242is tapered upward (i.e, toward the cover108), such that a lower diameter of the through hole242is larger than an upper diameter of the through hole242. The tapered through hole242can be configured to concentrate or focus the waves120as they propagate upward through the float240. Thus, the waves can agitate the fluid at the surface118more powerfully than if there had been no float240.

The float240can be made of a buoyant material. For example, the float240can have a buoyancy sufficient to position a top surface of the float240substantially in plane or flush with the surface of the liquid (i.e., the float240can be substantially submerged while remaining near the surface of the liquid). In some examples, the float240can have a buoyancy sufficiently high to cause the float240to sit atop the surface118of the liquid (i.e., with a majority of the float240above the surface of the liquid). In any case, the buoyancy of the float240can enable the float240to remain at the surface118irrespective of the amount of liquid in the tank104. This property can help ensure more consistent atomization of the liquid, whether the tank is full or nearing empty.

In some embodiments, the longitudinal axis of the sleeve236is aligned with a center of the transducer115such that the through hole242in the float240and the center of the transducer115are on roughly the same axis (i.e., the longitudinal axis of the sleeve236).

The incorporation of the sleeve236and/or the float240can allow for an increase of at least 70% in the liquid depth. For instance, the ultrasonic transducer115can be configured to atomize liquid at a depth of about 55 mm when operating at 24V (as compared to a conventional ultrasonic atomizer, which can only effectively atomize up to 38 mm of liquid depth at 24V). Further, because the sleeve236and/or the float240cause an energy focusing effect, the atomizer can output atomized droplets at a much more consistent rate, even with drastic changes in the liquid depth. Thus, an output of atomized liquid can be substantially equal across a plurality of operating depths.

Due to the advantageous effects of the sleeve236and/or float240, the atomizer200has a greater maximum operating depth d2than the maximum operating depth d1of the atomizer100. Advantageously, this allows a user to beneficially operate the atomizer200with a greater amount of liquid in the tank104than would be possible in the atomizer100. Consequently, the atomizer200requires the tank104to be refilled less than the atomizer100, and an equal rate of atomization can be achieved for a longer duration. Further, such a configuration reduces energy demands of the transducer115by more efficiently transferring the vibrational energy to the surface118.

In some examples, the atomizer200includes a splash guard244positioned between the sleeve236and the cover108. The splash guard244can be configured to block liquid from exiting the opening116, while still allowing atomized mist to exit the opening116. In some embodiments, the splash guard244is attached to the cover108by means of any suitable attachment mechanism (e.g., fasteners, tabs, threads, etc.). In some embodiments, the splash guard244is integrally formed with the cover108. For instance, the splash guard244and the cover108can be formed from a single mold and as a single, integral piece. The splash guard244can prevent the float240from exiting the sleeve236. For instance, the splash guard244can be separated from the top of the sleeve236by a distance that is less than a height of the float240such that the float240comes into mechanical interference with the splash guard244before the float240is able to become dislodged from the sleeve236.

FIG. 4illustrates a cross-sectional side view of an atomizer300according to one embodiment. The atomizer300can be substantially similar to, and include some or all of the features of atomizers100and200discussed above. Certain components of the atomizer300have been removed for clarity. In some embodiments, the atomizer300can include a splash guard344that is substantially similar to the splash guard244in shape, but which is coupled or affixed to the sleeve336rather than the cover308. It will be understood that despite being affixed to the sleeve336, the splash guard344and sleeve336still permit atomized mist to escape the atomizer300while preventing liquid from splashing out of the opening116. For example, the mist and vapor can exit the sleeve336between slits in the sleeve336or through openings (not shown) formed between the sleeve336and the splash guard344. In some examples, the splash guard344can be attached to both the sleeve336and the cover308.

FIG. 4further illustrates a float340. The float340can be substantially similar to the float240with the exception that the float340defines a cylindrical through hole342rather than the conical though hole242illustrated inFIG. 2. In this manner, less energy can be concentrated toward the top end of the float340as compared to float240. The inner diameter and cross-section of the through holes242,342can also be modified to control the rate of atomization through the float, such as by increasing the inner diameter of the through holes342to allow more dispersed energy to pass through the float.

As illustrated inFIGS. 2-4, the mist opening116, the splash guard244, the float240, and the ultrasonic transducer115can each be centered and aligned along the longitudinal axis237of the sleeve236, and further, in some embodiments, can be centered along a central axis of the tank104. However, it will be understood that other configurations are also possible. For instance, in some embodiments, the splash guard244and/or the mist opening116can be offset from the longitudinal axis237of the sleeve236.

FIG. 5illustrates a diagrammatic side cross-section view of an atomizer400including an off-axis, asymmetrical atomization assembly. The atomizer400can be substantially similar to, and include many of the parts of atomizers100,200, and300configured to perform their respective functions. Thus, certain components of the atomizer400have been removed for clarity inFIG. 5. In some embodiments, at least one of the transducer115, the sleeve236, the float240, the splash guard244, or the mist opening116can be offset from a central axis450bisecting the tank104. Because of the isolated atomization region created by the sleeve236, the transducer115can still effectively atomize the liquid despite being off-axis. This can remain true even when the sleeve is substantially proximate a sidewall of the tank104. An asymmetrically-located atomization column (including at least sleeve236, float240, and cover244) can enable the atomizer400to have different aesthetic designs, to incorporate multiple atomization columns (e.g., one on the left side and one on the right side of the tank104), to make it easier for the user to fill the tank (e.g., because most of the tank is empty), and to make it easier to repair or replace parts of the atomizer400(e.g., because parts can be located near outer surfaces of the container for easier access).

It is noted that when a component is referred to as being “fixed to,” “installed on,” “arranged on” or “disposed on” another component, it can be directly or indirectly fixed on another component. When a component is referred to as being “connected to” another component, it can be directly or indirectly connected to the other component.

In addition, the terms “first” and “second” are for illustrative purposes only and should not be construed as indicating or implying a relative importance or indicating the quantity of technical features. Therefore, a feature that is qualified as “first” and “second” may expressly or implicitly include one or more of such a feature. In the description of the present invention, “multiple” means two or more, unless otherwise specifically defined.

Unless specified otherwise, it should be understood that, “length”, “width”, “upper”, “lower”, “front”, “back”, “left” and “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside” and other terms indicating the orientation or positional relationship are used to refer to orientation or positional relationship shown in the drawings, only for the purpose of facilitating and simplifying the description of the invention, instead of indicating or implying that the indicated device or component must have a specific orientation and constructed and operated in a particular orientation, and therefore cannot be construed as limiting.

In the description of the present invention, it should be noted that the terms “install,” “connected,” and “connect” should be interpreted broadly unless specifically defined or limited otherwise. For example, the components may be fixedly connected or they may be detachable connected, or integral connected. The connection can be mechanical or electrical. The connection can be direct or indirect (connected through an intermediary). It can also be the internal communication of two components or the interaction between two components. Those of ordinary skill in the art can understand the specific meanings of the above terms in the present disclosure according to specific circumstances.

The present description provides examples, and is not limiting of the scope, applicability, or configuration set forth in the claims. Thus, it will be understood that changes may be made in the function and arrangement of elements discussed without departing from the spirit and scope of the disclosure, and various embodiments may omit, substitute, or add other procedures or components as appropriate. For instance, the methods described may be performed in an order different from that described, and various steps may be added, omitted, or combined. Also, features described with respect to certain embodiments may be combined in other embodiments.

Various inventions have been described herein with reference to certain specific embodiments and examples. However, they will be recognized by those skilled in the art that many variations are possible without departing from the scope and spirit of the inventions disclosed herein, in that those inventions set forth in the claims below are intended to cover all variations and modifications of the inventions disclosed without departing from the spirit of the inventions. The terms “including:” and “having” come as used in the specification and claims shall have the same meaning as the term “comprising.”