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Aurizon’s rotary ultrasonic devices are high-power systems that use a voltage source applied to piezo-ceramic converters that vibrate at ultrasonic frequencies. Our unique and patented rotary horns convert this vibration into radial motion, where the expansion and contraction of the rotary disk occurs uniformly around its circumference.
When coupled with a rotary anvil, the two components form an in-running nip that effectively and efficiently delivers energy to the materials passing through. This energy, delivered through high-frequency compression-relaxation of the material, produces a hysteretic loss in the material, causing it to melt from the inside out.
The above animations illustrate the exaggerated motion of Aurizon’s rigid cantilevered horn design vibrating radially vs. a typical stationary “blade” horn vibrating extensionally. A key advantage of the rotary horn is the ability to achieve very high amplitudes and operate in contact with other surfaces (e.g. patterned steel anvils) without catastrophic failure of the horn or converter. Other advantages include:
Key benefits of rotary ultrasonic technology vs. stationary “blade” ultrasonic systems
- Enables faster processing speeds
- Effective at processing discontinuous products or webs
- More energy efficient
- Excellent for processing lofty webs or materials
- Can operate in contact mode to generate forces required for high speed bonding of lightweight materials
- Able to withstand metal-to-metal contact without catastrophic damage
Key benefits of rotary ultrasonic technology vs. heat sealing
- Very effective at sealing through contaminants including solids, liquids and powders
- Low temperature sealing is safer and requires much less energy
- Enables faster sealing capability, as heat is generated in the materials from the inside out
- No risk of product damage due to heat
- Offers high degree of process control and consistency
- More durable; requires less maintenance
- Instantaneous on/off requires no prolonged start/stop sequence
Key benefits of rotary ultrasonic technology vs. adhesives
- Cleaner processing; requires no cleanup of messy adhesives
- Offers greater process uptime due to fewer process disruptions
- Lower cost to operate; no costly adhesives to purchase
- More energy efficient; no heating of materials required
Aurizon’s ultrasonic nozzle technology is best described as an ultrasonically assisted pressure nozzle. It utilizes a specially designed and patented ultrasonic device that is inserted into a chamber through which liquid flows. The nodal plane of the device (point of no axial or radial vibration) acts as the closure point to the chamber, so it vibrates freely about this nodal plane at its resonant frequency (e.g., 20 or 40 kHz).
The tip of the device is strategically located inside the chamber directly above the exit orifice(s). It vibrates in an extensional mode, oscillating toward and away from the orifice. As the ultrasonic device vibrates and extends toward the orifice, it acts as a mini-pump by accelerating the liquid out of the orifice. Conversely, as it retracts away from the orifice, the liquid decelerates. These pulses cause differential velocities in the flow of liquid exiting the chamber, where the higher-velocity pulse collides with the lower-velocity pulse ahead of it, causing the liquid jet or plume to break apart and result in greater plume expansion and volume.
- Enables the effective atomization of high-viscosity liquids (e.g., 20,000 cps).
- Can increase the flow of viscous liquids through a nozzle.
- Capable of a wide range of flow rates (g/min. up to several kg/min.) with a single system.
- High degree of flexibility in system design.
- Provides ability to mix inputs directly in the nozzle
- Enables improved atomization, particularly with difficult to spray materials.
- Can “tune” droplet characteristics (e.g., SMD) by adjusting amplitude.
- Offers potential to spray at lower input temperatures and pressures.
- Can be controlled to provide instantaneous on/off activation for intermittent flow applications.
- Provides instantaneous on/off heating of liquid when system is activated.
- Improved atomization of liquids with no change in system conditions (e.g., temperature and/or pressure).
- Increased process efficiency through effective atomization of higher solids or higher viscosity formulations.
- No need for secondary atomizing fluid (e.g., steam or compressed air).
- Improved drying efficiency in spraying or spray-drying applications.
- Elimination or reduction in nozzle clogging.
- Enables new formulation options that utilize materials that are difficult to atomize.
- Potential for improved process control.
- Reduced energy requirements in existing systems (e.g., reduces heating demand for drying).
Comparison to Other Ultrasonic Nozzle Systems
The magnitude and efficiency with which the energy is delivered to the liquid being atomized is much greater with Aurizon’s nozzle systems than other ultrasonic “nebulizers”. With conventional ultrasonic nebulizers, the ultrasonic vibration is typically applied to a housing through which liquid is flowing or a liquid stream is “shaken” off the end of a vibrating tip or plate. In either case, these systems are generally limited to low-viscosity liquids and effective atomization at relatively low flow rates (e.g., g/min.).
Alternatively, Aurizon’s ultrasonic nozzle systems are designed so that the energy emitted by the vibrating device is applied directly to the liquid being atomized at the exit point of the nozzle orifice. This extremely efficient delivery of energy causes effective atomization and/or increased flow of high-viscosity liquids. These systems can be customized to provide optimum droplet size and distribution for a variety of applications and flow rates.
- Heating package (up to three zones) to maintain temperature control for applications where products require heating for effective processing.
- Fluid column extensions to enable nozzle insertion into a process or change the direction of the spray perpendicular to the system mounting surface.
- Protective shrouding to enclose the ultrasonic stack components and protect them from falling product or applications where contamination from/to the process must be avoided.
- Custom housing and horn designs to enable unique process requirements like multiple liquid inlets, higher pressures (>2000 PSI/136 Bar), or other specialized fittings.
- System integration or stand-alone ultrasonic controls for maximum process control and integration flexibility.