Dual-Spray Nozzle for Reactive Mixture Application
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Solution Overview
Problem
Existing methods for applying plastic materials to fibre-reinforced products using round spray jets result in inefficient coverage of large surface areas, leading to increased cycle times, material loss, and environmental contamination due to the limited spray angle and generation of spray mist.
Innovation Solution
A device and method utilizing a spraying device capable of generating both planar, fan-shaped and round spray jets, allowing for staged application of a reactive mixture to a substrate, where the planar jet covers large areas efficiently and the round jet provides localized reinforcement with optional fibre addition, reducing cycle time and material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If round spray jets are used for applying plastic material, then the spray application can be performed with a simple nozzle design, but the spray angle is limited resulting in very long cycle times for large surface areas
Solution Approach 1:
The spray nozzle is designed to perform multiple functions: it can generate both round spray jets for localized application and fan-shaped spray jets for large surface coverage. This multi-functionality allows the same device to adapt to different application requirements, achieving high productivity for large surfaces while maintaining the option for precise localized spraying, thereby resolving the contradiction between coverage speed and device complexity.
2Productivity
If the spray angle is increased to cover large surface areas, then the coverage speed improves, but spray mist increases leading to material loss and environmental contamination
Solution Approach 1:
The invention applies different spray jet qualities to different spatial requirements: fan-shaped spray jets with large spray angles are used for large surface areas to achieve high coverage efficiency, while round spray jets with smaller spray angles are used for localized application to minimize spray mist and material loss. This local differentiation of spray characteristics resolves the contradiction between coverage efficiency and material loss.
3Manufacturing precision
If round spray jets are used for localized reinforcement, then precise material application is achieved, but the cycle time increases when covering large surface areas
Solution Approach 1:
The spray nozzle system is designed to dynamically switch between different spray jet modes (round and fan-shaped) based on the application requirements. This dynamic adaptability allows the system to use fan-shaped jets for rapid large-area coverage and round jets for precise localized reinforcement, thereby minimizing overall cycle time while maintaining manufacturing precision where needed.
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 dual-spray jet approach enables rapid and accurate application of materials over large surfaces with minimal overspray, allowing for efficient coverage and localized reinforcement, thereby reducing cycle times and environmental impact while maintaining high material utilization.
Implementation Method 1
a spraying device (10), which is able to generate a planar, fan-shaped spray jet (18), and an essentially round spray jet (17)
Implementation Method 2
in the first stage a first application of material with a reactive mixture takes place with the planar, fan-shaped spray jet (18) onto the substrate (41), and subsequently in a further stage a further application of material with a reactive mixture takes place with the round spray jet (17)
Data Source
AI summary
A device and method for applying a reactive mixture comprised of at least two components to a substrate (41) having a spraying device (10) capable of generating a planar, fan-shaped spray jet (18) and a round spray jet (17), and having a means for moving the spraying device relative to the substrate, wherein the spraying device is moved over the substrate in at least two stages, wherein in the first stage, a first application of material (42) is performed with reactive mixture, using the planar, fan-shaped spray jet, on the substrate, and in a further stage a second application of material (43a-c) is subsequently performed with reactive mixture, using the round spray jet, on at least a section of the material applied to the substrate in the first application of material.