Electrostatic Spray Head for Precise Can Rim Lubrication
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Solution Overview
Problem
Existing lubricant dispensing systems for beverage can necking machines lack consistency and adjustability, leading to uneven wax application, which can cause defects like galling, denting, or contamination, especially at high speeds.
Innovation Solution
An electrostatic spraying system with a heated tank, an electrostatic spray head, and a control unit that uses a capillary tube and high voltage electrode to apply a fine line of lubricant precisely, minimizing waste and ensuring accurate targeting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If roller applicator devices are used to apply wax to cans, then the wax application process can be automated, but the system produces inconsistent application quality and allows contamination of the wax vat with aluminum oxide particles
Solution Approach 1:
The patent replaces the mechanical roller applicator system with an electrostatic spray system. The spray nozzle generates an electrostatic charge on wax particles, which are then attracted to and deposited on the can surface through electrostatic attraction. This eliminates mechanical contact between rollers and wax, preventing aluminum oxide contamination while maintaining automated operation and improving application consistency.
Solution Approach 2:
The patent changes the physical state and electrical properties of the wax application process. By applying electrostatic charge to the wax particles and controlling the electrostatic field parameters, the system achieves precise control over wax deposition. This allows consistent application thickness and pattern while preventing contamination, as the electrostatic field can be precisely controlled without mechanical wear or particle contamination issues.
2Productivity
If roller applicator devices are used, then wax can be applied to moving cans, but the system lacks adjustability for high speed operations and produces uneven application
Solution Approach 1:
The patent introduces dynamic control capabilities through the electrostatic spray system. The system can rapidly adjust spray parameters including electrostatic charge level, spray pattern, and deposition rate in response to varying can speeds. This dynamic adaptability allows consistent quality application across a wide range of processing speeds, from slow to high speed operations, unlike fixed mechanical roller systems.
Solution Approach 2:
The patent incorporates feedback control mechanisms that monitor wax application quality and canifice parameters in real-time. Sensors detect application uniformity and provide feedback to the control system, which automatically adjusts electrostatic field parameters and spray characteristics to maintain consistent quality regardless of speed variations or material property changes.
3Reliability
If more wax is applied to ensure adequate lubrication, then galling is prevented, but over-lubrication causes contamination of the beverage product and creates dark marks on cans
Solution Approach 1:
The patent applies wax only to the specific local areas where lubrication is needed, such as the rim and flange areas of the can, rather than coating the entire can surface. The electrostatic spray system can be configured to target specific zones with precise spatial control, ensuring adequate lubrication at critical interfaces while preventing wax deposition on interior surfaces that would contact the beverage product or create visible dark marks.
Solution Approach 2:
The electrostatic spray system replaces mechanical roller contact, enabling precise control over wax deposition location and amount. The electrostatic field can be configured to attract charged wax particles only to grounded or oppositely charged target areas, providing exact placement control that prevents both insufficient lubrication and over-lubrication contamination.
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 provides uniform and efficient application of lubricants, preventing defects and contamination by ensuring precise control over the lubricant flow and distribution, even at high speeds.
Implementation Method 1
an electrostatic spray head that uses a capillary tube and high voltage electrode to apply a fine line of lubricant precisely
Implementation Method 2
electrostatically charged lubricant can be discharged
Data Source
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AI summary
A lubricant dispensing system having particular utility for applying a tightly controlled thin line of lubricant about the perimeter of cans as they are processed. The lubricant dispensing system includes an electrostatic spray head having a nozzle body that defines a lubricant receiving chamber for electrically charging lubricant therein and a capillary tube supported by the nozzle body having an inlet end communicating with the lubricant receiving chamber and an outlet that defines a discharge orifice of the electrostatic spray head. The capillary tube has a diameter between about 0.2 and 0.3 inches for directing electrostatically charged lubricant onto an item to be lubricated in a controlled thin line having a width no greater than 0.125 inches. The electrode is adjustably positionable relative to the capillary tube for selectively controlling the rate of discharging lubricant, and the electrode is configured for enhancing electrostatic charging of lubricant through the capillary tube.