Cold-Spray Nozzle With Variable Diameter Convergent and Divergent Parts
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Solution Overview
Problem
Conventional cold-spray nozzles have fixed opening profiles, requiring the cold-spray process to be stopped and the nozzle to be changed when different sizes are needed, which slows down manufacturing and limits the ability to adjust the spray pattern for solid powder materials.
Innovation Solution
A cold-spray nozzle with a variable diameter convergent and divergent part, along with a ring portion that controls the opening to the diffuser, allowing for adjustments during the manufacturing process to change the spray pattern without stopping the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional fixed opening profile nozzles are used, then the nozzle structure is simple and easy to manufacture, but the manufacturing process must be stopped to change nozzles when different spray patterns are needed, reducing productivity
Solution Approach 1:
The patent applies the dynamics principle by making the nozzle opening profile adjustable during operation. The convergent and divergent parts can be rotated relative to each other to change the opening profile dynamically, allowing different spray patterns without stopping the manufacturing process. This transforms a static nozzle into a dynamic one that can adapt to different requirements.
Solution Approach 2:
The nozzle is segmented into multiple rotatable parts including a convergent part, divergent part, and intermediate section with indexing features. These segmented components can be independently positioned to create different opening profiles, enabling versatility while maintaining manageable structural complexity through modular design.
2Adaptability or versatility
If multiple fixed nozzles are kept for different spray patterns, then the spray pattern flexibility is improved, but the device complexity and inventory requirements increase
Solution Approach 1:
The patent implements universality by designing a single nozzle assembly that can perform multiple functions through rotation. The same physical nozzle structure can produce different spray patterns by changing the relative orientation of its parts, eliminating the need for multiple specialized nozzles and simplifying the overall system while maintaining versatility.
Solution Approach 2:
The dynamic adjustability of the nozzle opening profile allows one nozzle to replace multiple fixed nozzles. By rotating the convergent and divergent parts to different positions, the same physical component adapts to different spray requirements, reducing inventory needs and system complexity.
3Manufacturing precision
If the nozzle opening profile is fixed, then the manufacturing process is simple and fast, but the ability to control resolution mid-print is limited
Solution Approach 1:
The patent enables dynamic resolution control by allowing rotation of the nozzle parts during the printing process. Different opening profiles can be selected mid-print to adjust the spray pattern and resolution requirements for different features of the part being manufactured, maintaining process continuity without nozzle changes.
Solution Approach 2:
The opening profile parameter of the nozzle can be changed during operation by rotating the convergent and divergent parts to different indexed positions. This parameter change allows adjustment of spray characteristics to match different manufacturing precision requirements for various features without interrupting the overall manufacturing process.
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
Enables continuous manufacturing with adjustable spray patterns, improving efficiency by allowing mid-print resolution control and eliminating the need for frequent nozzle changes, thereby enhancing the flexibility and speed of the cold-spray process.
Implementation Method 1
a pressurized gas feed coupled to the material hopper. The cold-spray nozzle is coupled to the pressurized gas feed and configured to receive material from the material hopper
Implementation Method 2
The material being deposited may be sprayed at a base material at a speed high enough to induce solid-state welding on impact
Implementation Method 3
The cold-spray nozzle includes a variable diameter convergent part and a variable diameter divergent part forming a diffuser
Implementation Method 4
a flow channel for accelerating an exhaust gas toward a mixer
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
Systems, apparatus, and method for manufacturing are disclosed. In an aspect, the apparatus may be a cold-spray nozzle. The cold-spray nozzle may include a variable diameter convergent part. The cold-spray nozzle may also include a variable diameter divergent part. The variable diameter divergent part may form a diffuser. Additionally, The cold-spray nozzle may include a ring portion. The ring portion may couple the variable diameter convergent part and the variable diameter divergent part. Additionally, the ring portion may control the opening to the diffuser.