Actuator Breakup Wedge for Spray Atomization
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Solution Overview
Problem
Conventional actuators for dispensing liquid products as a spray require complex flow-modifying inserts to achieve fine mist atomization, increasing manufacturing costs due to the need for multiple components.
Innovation Solution
An actuator design featuring a single-component cap with an axial feed channel and breakup wedge, where the breakup wedge splits the feed channel into sub-channels that collide in the spray channel, creating turbulent flow for atomization without additional components, reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flow-modifying insert is used to achieve fine mist atomization, then the atomization quality is improved, but the device complexity and manufacturing cost increase due to requiring multiple components
Solution Approach 1:
The patent combines the flow-modifying insert functionality directly into the actuator cap body by integrating a breakup wedge structure. The breakup wedge is formed as an integral part of the injection-molded actuator cap, eliminating the need for a separate flow-modifying insert component. This merging of functions maintains the fine mist atomization capability while reducing device complexity from multiple components to a single integrated component.
Solution Approach 2:
The actuator cap is designed to perform multiple functions: it serves as the structural housing, the actuation mechanism holder, and the flow-modifying element through the integrated breakup wedge. This multi-functional design eliminates the need for separate specialized components, reducing assembly steps and manufacturing complexity while maintaining effective atomization.
2Manufacturing precision
If a flow-modifying insert is used to create turbulent flow for atomization, then the spray quality is improved, but the ease of manufacture deteriorates due to requiring assembly of multiple components
Solution Approach 1:
The breakup wedge is injection molded as an integral part of the actuator cap body, eliminating the need for separate assembly steps. The single-shot or multi-shot injection molding process creates the complex internal flow channels and breakup wedge structure in one manufacturing operation, significantly simplifying production compared to assembling multiple separate components.
Solution Approach 2:
The feed channel is segmented by the breakup wedge into multiple sub-channels that redirect liquid flows. This segmentation is achieved through the injection molded geometry rather than separate parts, allowing complex flow patterns to be created within a single monolithic component that requires no assembly.
3Ease of manufacture
If a single-component actuator cap is used, then the ease of manufacture is improved, but the atomization capability deteriorates without a flow-modifying insert
Solution Approach 1:
The actuator cap features localized flow modification through the breakup wedge structure that is injection molded into specific regions of the cap body. The internal geometry includes strategically positioned flow redirection channels and the breakup wedge that create turbulent flow and enhance atomization at critical locations, achieving effective spray quality within a single-component design.
Solution Approach 2:
The breakup wedge creates three-dimensional flow redistribution within the liquid path, redirecting flows from multiple directions into the spray channel. This spatial arrangement of flow paths within the injection molded structure generates the necessary turbulence and atomization without requiring separate mechanical components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The actuator achieves efficient atomization of liquid products into a fine mist without a flow-modifying insert, optimizing the degree of atomization and simplifying the manufacturing process by forming a single component through injection molding.
Implementation Method 1
The sub flows subsequently collide in the inlet portion of the spray channel causing a turbulent flow of the liquid product in the inlet portion of the spray channel
Implementation Method 2
By 'turbulent flow' is meant flow accompanied by sufficient forces to cause atomization of the liquid product as it traverses, and exits from, the outlet portion of the spray channel
Data Source
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AI summary
The invention relates to an actuator for dispensing the liquid contents of a container in the form of a spray. The actuator comprises an actuator cap, an axial spray channel with an orifice for spraying the contents of the container, and an axial feed channel for connection a container outlet to the spray channel. A breakup wedge is provided in the feed channel such that it splits the feed channel into two sub channels, each connected via a side inlet opening with an inlet portion of the spray channel. Thus, in use, a flow of content is split into two sub flows by the breakup wedge, which sub flows subsequently collide in the inlet portion of the spray channel causing a turbulent flow of the liquid product in the inlet portion of the spray channel, which turbulent flow is guided by the spray channel towards and out of the dispensing opening.