Airless Spray Nozzle Coating Process for Container Interiors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for coating the inside of containers, especially at the shoulder or neck portion, are incomplete, leading to difficulties in evacuating viscous products, and there is a risk of oxidation when using pressurized air with traditional coating techniques.
Innovation Solution
A process involving a rotating container with an airless spray nozzle assembly that moves along the vertical axis, applying edible oil at controlled pressures and angles to ensure complete and uniform coating, utilizing centrifugal force for better coverage and avoiding air introduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional spray coating with pressurized air is used, then coating application is simplified, but oxidation risk increases and coating completeness deteriorates
Solution Approach 1:
The patent replaces air-based spray systems with an inert or oxygen-free atmosphere during the coating process. This eliminates oxygen exposure that causes oxidation of the coating material and product, while maintaining effective spray coating capabilities through modified nozzle designs that operate without requiring pressurized air.
2Device complexity
If traditional spray coating is used, then equipment complexity is reduced, but coating completeness especially at shoulder and neck portions deteriorates
Solution Approach 1:
The patent introduces dynamic elements to the coating system, including rotating the container during coating application and moving the spray nozzle along the container interior. These dynamic movements ensure comprehensive coverage of all surfaces including difficult-to-reach areas like the shoulder and neck portions, while maintaining relatively simple equipment through straightforward mechanical motions.
Solution Approach 2:
The patent adds rotational motion as a new dimension to the coating process. By rotating the container while applying spray coating, the system achieves three-dimensional coverage of the interior surfaces, ensuring complete coating of all areas including the shoulder and neck portions that are difficult to reach with static nozzle positioning.
3Manufacturing precision
If container rotation is added to improve coating uniformity, then coating quality improves, but process complexity increases
Solution Approach 1:
The patent implements container rotation as a dynamic element that continuously moves the container interior surfaces during coating application. This rotational motion ensures uniform coating distribution across all surfaces by constantly presenting fresh surfaces to the spray nozzle, achieving high coating quality through relatively simple rotational mechanics.
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
This method achieves a substantially complete and uniform coating, enabling efficient evacuation of viscous products with minimal residual waste and preventing oxidation, resulting in improved product removal and reduced waste.
Implementation Method 1
The action of centrifugal force from container 10 rotation is believed, without being bound by theory, to contribute to achieving a uniform coating by causing the oil layer to flatten out.
Implementation Method 2
lowering an airless spray nozzle assembly 21 along the vertical axis 17 of the container 10 into the cavity through the opening end; the spray nozzle assembly 21 having at least two nozzles 20
Data Source
Figure 1
Figure 2A~2D
Figure 3A~3B
AI summary
A process for coating inside a container includes rotating the container about its imaginary vertical axis while simultaneously lowering airless spray nozzles along the vertical axis of the`container into the cavity through the opening end and moving the nozzles back up and out of the container. Spray nozzles are used to apply a liquid coating at a spray pressure of about 100 to about 800 psi (6.89 to 55.16 bar)and at an angle of about 0 to about 120 degrees relative to the vertical axis, simultaneously with nozzle movement, to at least a portion of the inner surface while the container is rotating and the nozzles are moving along the vertical axis. The container is thereby coated on its inner surface to form an internally coated container.