Double-Jet Nozzle Body Laser Machining for Bore Alignment
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Solution Overview
Problem
The production of double jet nozzle bodies with small nozzle bores is challenging due to the complexity and cost associated with aligning thin-walled sections during laser drilling, leading to functional restrictions and high cycle times.
Innovation Solution
The method involves creating an inflow or funnel between nozzle geometries and a fluid chamber using laser processing, allowing for precise alignment and connection of nozzle geometries, which simplifies the production process and reduces costs by overcoming the limitations of additive manufacturing and injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser drilling is used to create small nozzle bores in thin-walled sections, then manufacturing precision is improved, but device complexity and alignment requirements increase
Solution Approach 1:
The patent merges multiple nozzle bores into a single integrated component by creating thin-walled sections that connect multiple nozzle geometries. The laser processing method enables precise creation of these thin walls and internal channels in one operation, eliminating the need for separate alignment and assembly steps for multiple components.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with laser-based processing. Instead of using mechanical fixtures and alignment tools to position multiple components, the invention uses laser technology to directly create precisely aligned nozzle bores and thin-walled structures within a single blank, substituting mechanical alignment with optical processing precision.
2Manufacturing precision
If multiple laser drilling operations are performed to create nozzle bores with intersecting axes, then manufacturing precision is improved, but productivity decreases due to repeated alignment
Solution Approach 1:
The patent applies preliminary action by pre-forming the nozzle body blank with basic geometry through injection molding or additive manufacturing before laser processing. This preliminary shaping creates a stable base that facilitates subsequent laser drilling operations, allowing multiple nozzle bores to be created efficiently without requiring repeated complex alignment procedures.
Solution Approach 2:
The invention combines multiple laser drilling operations into a single integrated process by designing the nozzle body as a unified structure with thin-walled sections. This merging allows all nozzle bores to be created in one laser processing run rather than requiring separate operations with repeated alignment, thereby improving productivity while maintaining precision.
3Manufacturing precision
If thin-walled sections are used to support multiple nozzle geometries, then manufacturing precision is improved, but ease of manufacture worsens due to physical limitations of injection molding and additive manufacturing
Solution Approach 1:
The patent replaces the limitations of traditional manufacturing methods (injection molding and additive manufacturing) with laser processing technology. While injection molding and additive manufacturing struggle to create thin-walled sections with precise geometries, the laser processing method can directly ablate and shape materials to create these delicate structures with high precision, overcoming the physical constraints of conventional methods.
Solution Approach 2:
The invention changes the manufacturing parameters by transitioning from bulk material removal or layer-by-layer construction to precise laser ablation. This parameter change enables the creation of thin-walled sections with wall thicknesses that would be impossible or extremely difficult to achieve through traditional injection molding or additive manufacturing, while maintaining structural integrity and precise nozzle geometry positioning.
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 approach enables cost-effective production of double jet nozzle bodies with precise alignment and efficient fluid connection, reducing production time and costs while allowing for flexible design options through laser ablation and 3D laser ablation techniques.
Implementation Method 1
Laser processing allows the thin web to be made correspondingly thin, thus overcoming the physical limitations of additive manufacturing or plastic injection molding
Data Source
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Figure 5~6
AI summary
The present invention relates to a method for manufacturing a double-jet nozzle body (3) from a nozzle body blank (1) produced by injection molding or additive manufacturing, wherein the double-jet nozzle body (3) has at least two nozzle geometries (5), each of which has an axis, the at least two axes extending in a discharge direction and intersecting at a point outside the nozzle geometries (5), and wherein the nozzle body blank (1) is subsequently processed into the double-jet nozzle body (3) by laser processing. The object of the present invention is to make the manufacturing process cost-effective.For this purpose, an inflow (2) is produced by laser processing, which is arranged between a nozzle geometry (5) and a fluid chamber (6), and/or a funnel (4) is produced by laser processing, which is arranged between the nozzle geometry (5) and the inflow (2).