Atomizer Nozzle Mould with Universal Flow Chamber Core
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Solution Overview
Problem
Existing moulds for producing atomizer nozzles are costly due to the need for expensive tools to produce flow chamber core mould parts, which are typically used for a single size of nozzle, limiting versatility and increasing production costs.
Innovation Solution
A mould design where the flow chamber core mould part has a smooth, continuous surface for mounting different mouthpiece core mould parts, allowing for precise configuration of the transition between the flow chamber and mouthpiece, enabling the production of various nozzle sizes using the same flow chamber core mould part, and incorporating features like encircling projections and latching mechanisms for reliable sealing and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flow chamber core mould part is designed for a single nozzle size, then manufacturing precision is improved, but adaptability deteriorates
Solution Approach 1:
The flow chamber core mould part is designed with a substantially smooth surface and continuous contours in the transition region, allowing it to serve as a universal base for multiple nozzle sizes. Different mouthpiece core mould parts can be mounted on this standardized flow chamber core mould part, enabling the same flow chamber core mould part to produce different nozzle sizes while maintaining high precision through the smooth surface that eliminates edges and grooves.
2Manufacturing precision
If expensive tools are used to produce flow chamber core mould parts, then manufacturing precision is improved, but production cost increases
Solution Approach 1:
By designing the flow chamber core mould part as a universal component that can accommodate different mouthpiece core mould parts, the expensive flow chamber core mould part is reused across multiple nozzle size productions. This universality amortizes the high tooling cost over a greater number of products, reducing the average production cost while maintaining the precision benefits of the smooth surface design.
Solution Approach 2:
The mould system is segmented into two functional parts: a standardized flow chamber core mould part and interchangeable mouthpiece core mould parts. This segmentation allows the expensive, precision-critical flow chamber portion to be produced once with high-precision tools, while less critical mouthpiece variations can be produced with simpler tools and then mounted on the standardized base.
3Ease of manufacture
If the flow chamber core mould part has edges or grooves in the transition region, then ease of manufacture is improved, but manufacturing precision deteriorates
Solution Approach 1:
The surface parameters of the flow chamber core mould part in the transition region are changed to substantially smooth surfaces without edges or grooves. This parameter change ensures that when different mouthpiece core mould parts are mounted on this surface, the transition between flow chamber and mouthpiece achieves high precision and smooth contours, eliminating the need for additional finishing work on the produced nozzles.
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 design reduces production costs by allowing the same flow chamber core mould part to be used for different nozzle sizes, minimizing finishing work and ensuring precise shaping of atomizer nozzles, especially those made of ceramic materials, while maintaining reliable sealing and alignment.
Implementation Method 1
which is then made to solidify, wherein the mould has at least one flow chamber core mould part for defining an inner wall of the flow chamber
Data Source
AI summary
A mold for producing atomizer nozzles, wherein a mouthpiece core mold part defines an inner wall of the mouthpiece, at least in the region of a transition between the mouthpiece and the flow chamber, and is of integral design, wherein the flow chamber core mold part has a substantially smooth surface and continuous contours in the region of the transition from the flow chamber to the mouthpiece, and wherein the mouthpiece core mold part is placed against the flow chamber core mold part at the transition between the flow chamber and the mouthpiece.