Dual-Axis Spray Applicator with Tilted Nozzles for Uniform Web Coating

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Solution Overview

Problem

Current fluid spraying technologies for materials like fabrics and papers struggle to achieve a uniform spray result, especially at higher web speeds, and there is a need for improved spray applicators that can maintain uniformity and reduce fluid volume usage.

Innovation Solution

A spray applicator design featuring two groups of spray nozzles arranged on different axes with varying tilt angles, providing overlapping spray zones and adjustable pulsing fluid control to adapt to web speeds, ensuring uniform coverage across the material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single row of spray nozzles is used, then the device complexity is low, but the spray uniformity deteriorates at higher web speeds

Engineering Contradiction:

Improvenozzle arrangementVSAvoidspray uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The spray system is segmented into multiple rows of nozzles (first row, second row, etc.) arranged along the web direction. Each row contributes to the overall spray pattern, allowing the system to maintain uniformity at higher web speeds by distributing the spraying action across multiple segments rather than relying on a single row.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The nozzle arrangement extends from a single line into a two-dimensional grid pattern with multiple rows spaced along the web direction and multiple nozzles across the width. This dimensional expansion allows the system to address both spray uniformity and web speed requirements simultaneously.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If spray nozzles are tilted with different inclination angles, then the spray pattern coverage is improved, but the device complexity increases

Engineering Contradiction:

Improvespray pattern uniformityVSAvoidnozzle configuration

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Different rows of nozzles are assigned different local qualities in terms of tilt angles. The first row has nozzles tilted at a first inclination angle, while the second row has nozzles tilted at a second inclination angle. This local differentiation optimizes the spray pattern coverage and overlap characteristics for each row's specific position in the web direction.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The nozzle rows are configured with asymmetric tilt angles relative to each other. Rather than all nozzles having the same orientation, the system employs deliberate asymmetry in the tilt angles between rows to achieve better spray pattern overlap and coverage distribution across the web surface.

Inventive Principle:

Principle #4Asymmetry

3Manufacturing precision

If multiple groups of spray nozzles are added, then the spray uniformity at high web speeds is improved, but the fluid volume requirement increases

Engineering Contradiction:

Improvespray uniformityVSAvoidfluid volume

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The spray system employs periodic pulsing action where nozzles are activated in a sequential or alternating pattern rather than continuously. This periodic activation allows multiple nozzle rows to contribute to spray uniformity while reducing the total fluid volume requirement by ensuring that not all nozzles are spraying simultaneously at full capacity.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system uses partial action by activating only certain nozzle rows at given time intervals or using a subset of nozzles within rows. This approach achieves the necessary spray uniformity through coordinated partial coverage from multiple rows rather than requiring all nozzles to operate at full capacity, thereby reducing overall fluid consumption.

Inventive Principle:

Principle #16Partial or excessive action

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 design achieves a more uniform and efficient spraying process by optimizing nozzle placement and tilting angles, reducing fluid volume requirements and maintaining uniformity at higher web speeds, surpassing the limitations of existing technologies.

Implementation Method 1

a first group of spray nozzles arranged along a first axis, and a second group of spray nozzles arranged along a second axis... Each spray nozzle has an elongated spray opening configured to spray fluid in a direction towards the web plane

Methodology Applied

Scientific EffectFluid Spray: Fluid Spray

Data Source

PatentUS11712709B2Spray applicator and spray unit

Publication Date: 2023.08.01 BW CONVERTING AB

AI summary

A spray applicator (1) for spraying a fluid onto a web (W) of material has a first group of spray nozzles (10A) arranged along a first axis (FA) and a second group of spray nozzles (11A) arranged along a second axis (SA). The first (FA) and second (SA) spray nozzle axes are arranged on the same side of a plane in which the web (W) is run. Each spray nozzle (10A, 11A) has an elongated spray opening configured to spray fluid in a direction towards the web (W). The first spray nozzle opening of the first group of spray nozzles (10A) has an inclination angle which differs from the second nozzle opening inclination angle of the second group of spray nozzles (11A).