Two-Piece Foam Nozzle Spreader Tip for Durable Uniform Flow
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Solution Overview
Problem
The existing Bernz-O-Matic Model TX1527 Flame Spreader Tip is prone to damage due to its thin wall thickness and lacks sufficient holding ability, leading to inconsistent foam patterns and the need for frequent tape application, and is no longer available for replacement.
Innovation Solution
A monolithic spreader tip made of brass or stainless steel with a two-part design, featuring specific geometric shapes and screw holes, ensuring robust attachment and uniform foam flow without the need for additional securing tape, and allowing for easy cleaning and reproduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a thin-walled press-formed tip (0.047" wall thickness) is used to achieve a flat horizontal V pattern, then the foam pattern quality is improved, but the tip becomes susceptible to damage and requires frequent replacement
Solution Approach 1:
The tip is divided into two separate halves that are machined independently and then assembled together using set screws. This segmentation allows each half to be structurally robust while maintaining the precise internal geometry needed for foam pattern quality. The two-piece construction eliminates the fragility of thin-walled single-piece tips.
Solution Approach 2:
The wall thickness parameter is changed from thin (0.047") to thick (至少13mm), fundamentally altering the structural properties of the tip. This parameter change transforms the tip from a fragile component to a durable one, while the precise internal hollow space geometry maintains the required foam pattern quality.
2Strength
If a tight-fitting tip design is used to secure attachment, then the holding ability is improved, but the thin-walled tip lacks sufficient holding ability and requires aluminum tape to prevent detachment
Solution Approach 1:
The two-piece design with external set screw attachment points provides mechanical fastening capability that overcomes the insufficient holding ability of tight-fitting single-piece designs. The set screws create positive mechanical engagement without requiring thin walls or additional tapes.
Solution Approach 2:
The mechanical fastening system using set screws and threaded holes replaces the inadequate friction-based holding of tight-fitting designs and eliminates the need for aluminum tape. This provides reliable attachment while maintaining ease of operation through standardized fastening mechanisms.
3Ease of manufacture
If a single-piece press-formed tip is used, then the manufacturing process is simplified, but the tip cannot be easily cleaned or maintained
Solution Approach 1:
Dividing the tip into two separable halves creates internal access pathways for cleaning while maintaining manufacturing feasibility through standard machining processes. Each half can be independently manufactured with precise geometry, and the assembly provides maintenance accessibility.
4Reliability
If a robust thick-walled tip design is used, then the tip durability is improved, but the foam pattern consistency deteriorates
Solution Approach 1:
The tip design applies different quality requirements to different regions: the external walls are thick and robust for durability, while the internal hollow space geometry is precisely controlled for foam pattern consistency. This local differentiation resolves the contradiction between durability and precision.
Solution Approach 2:
The two-piece construction allows the external structure to be robust while the internal flow passages maintain precise geometry. The assembly of two machined halves provides both structural integrity and flow precision.
Data Source
AI summary
Disclosed herein is an article used as a foam nozzle spreader tip. The article is brass or stainless steel and has a first surface, a hollow space removed from the first surface, first and second screw holes through the article and the first surface but not touching the hollow space, and a third screw hole through the article touching the hollow space. The hollow space has a half-cylinder region and a rounded trapezoidal prism region.