Apparatus and method for emulsifying a pressurized multi-component liquid

A method of ultrasonically emulsifying a pressurized multi-component liquid, the method comprising:

• supplying a multi-component liquid at a pressure of at least 100 psig to a die assembly comprising:
• a die housing further comprising:
• a die tip;
• a chamber adapted to receive a pressurized multi-component liquid;
• an inlet adapted to supply the chamber with the pressurized multi-component liquid;
• and
• a vestibular portion and an exit orifice defined by walls of the die tip adapted to receive the pressurized multi-component liquid from the chamber and pass the liquid out of the die housing under pressure along a first axis;
• and
• an ultrasonic horn having a first end and a second end and adapted, upon excitation by ultrasonic energy, to have a node and a longitudinal mechanical excitation axis, the horn being located in the chamber in a manner such that the first end of the horn is located outside of the chamber and the second end of the horn is located within the chamber and is in close proximity to the exit orifice but is not located within the die tip;
• exciting the ultrasonic horn to apply ultrasonic energy to a portion of the pressurized multi-component liquid within the chamber and without applying ultrasonic energy to the die tip while the exit orifice receives pressurized multi-component liquid from the chamber, and
• passing the pressurized liquid out of the exit orifice in the die tip under pressure so that the multi-component liquid is emulsified.