Diverging Nozzle Layout for Uniform Foam Panel Lamination
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Solution Overview
Problem
Existing laminated panel production processes face challenges in achieving uniform distribution of foam formulation across the panel width, maintaining consistent foam quality at varying flow rates and rheologies, and minimizing fouling within the distribution system, leading to product defects.
Innovation Solution
A distribution system with diverging nozzles that dispense reactive foam formulation in diverging jets, ensuring uniform layer formation by adjusting flow paths and nozzle angles to maintain consistent foam properties across a wide range of conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional nozzle is used to apply foaming reaction mixture, then the application process is simple, but the foam expands beyond the desired area causing poor application results
Solution Approach 1:
The nozzle is divided into multiple segments including a body portion, a flared portion with progressively increasing diameter, and a rim portion. This segmentation allows each section to control a specific aspect of the foam flow and expansion, confining the foam within the desired application area while maintaining a manageable structural complexity through modular design.
Solution Approach 2:
The nozzle design incorporates a flared portion that expands in the radial dimension, creating a diverging flow pattern. This dimensional change from a narrow inlet to a wider outlet controls the foam expansion direction and confines it to the substrate surface, improving application precision without requiring complex mechanical constraints.
2Shape
If a non-diverging nozzle is used, then the nozzle structure is simple, but the foam does not expand properly causing poor application results
Solution Approach 1:
The nozzle incorporates a flared portion that creates a dynamically expanding flow path. As the foaming reaction mixture passes through the diverging geometry, the foam naturally expands and divers in the desired direction. This dynamic expansion control achieves proper foam shape without requiring complex movable or adjustable mechanisms.
3Manufacturing precision
If the nozzle rim is positioned too far from the substrate, then the nozzle is easier to operate, but the foam expands beyond the desired area
Solution Approach 1:
The nozzle incorporates a flared portion with a curved, diverging geometry that naturally directs the foam flow toward the substrate. This curved path compensates for variations in nozzle-to-substrate distance, allowing the foam to confine to the desired area even when the nozzle is positioned at varying distances, thereby improving ease of operation while maintaining precision.
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 system achieves highly uniform laminated panel production across varying flow rates and foam rheologies, reducing fouling and ensuring consistent panel quality by maintaining uniform foam distribution and curing.
Implementation Method 1
a foaming reaction mixture is applied to a substrate in a lamination process
Implementation Method 2
The foamable composition is supplied through a diverging nozzle, similar to those used in aircraft jet engines
Data Source
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AI summary
An apparatus for dispensing a reactive foam formulation to produce laminated panels includes a mixhead, a distribution system that defines multiple flowpaths for the reactive foam to outlets fitted with nozzles. The nozzles have multiple, spaced-apart outlets arranged at angles to each other to distribute the foam formulation evenly onto a moving bottom facing layer.