Glass Object Spray Coating With Turn Nozzle Overspray Redirection

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Solution Overview

Problem

Conventional spray coating methods for glass pharmaceutical packaging face challenges in achieving uniformity and avoiding defects due to overlapping sprays and complex geometries, leading to mechanical issues and product sterility risks.

Innovation Solution

A spray coating apparatus with a turn nozzle assembly that redirects overspray using a pressurized gas to coat non-line of sight areas, utilizing a single atomizer and a turn nozzle to distribute droplets effectively on glass objects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple spray nozzles are used to coat different areas of glass objects, then coverage is improved, but overlapping sprays cause visible defects and thickness variation

Engineering Contradiction:

Improvecoating uniformityVSAvoidoverlapping spray defects

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a temporal dimension to the coating process by rotating the spray nozzle assembly around the glass object. This allows a single nozzle to sequentially coat different surfaces (side walls, heel, footprint) that would otherwise require multiple simultaneously positioned nozzles, eliminating overlapping spray defects while achieving complete coverage.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Loss of substance

If spray coating is used to apply coating material, then material waste is reduced, but uniformity and accuracy of droplet distribution is difficult to control

Engineering Contradiction:

Improvecoating material wasteVSAvoiddroplet distribution uniformity

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The spray nozzle assembly is made dynamic through rotation around the glass object. This rotational movement allows precise control of droplet distribution by adjusting rotation speed, nozzle positioning, and spray timing to match the object's geometry, achieving uniform coating while minimizing material waste.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If dip coating is used to coat glass objects, then coating application is simplified, but material waste increases and product appearance varies

Engineering Contradiction:

Improvecoating process simplicityVSAvoidcoating material waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent replaces the dip coating mechanical system (submerging objects in coating material) with a spray coating system that delivers coating material through aerosolized droplets. This substitution maintains ease of manufacture through automated nozzle rotation while dramatically reducing material waste and improving appearance uniformity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Quantity of substance

If thicker application of coating material is used, then coverage is improved, but film mobility increases causing thickness and appearance variability

Engineering Contradiction:

Improvecoating material amountVSAvoidfilm thickness control

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The rotational spray coating system applies coating material continuously as the nozzle moves around the glass object, ensuring even distribution before the material can become mobile. This continuous action maintains adequate coverage while preventing film mobility issues that occur with thick batch applications.

Inventive Principle:

Principle #20Continuity of useful 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 apparatus ensures uniform coating on glass objects by redirecting overspray, reducing material waste, and minimizing defects, thereby enhancing mechanical performance and product quality.

Implementation Method 1

A turn nozzle assembly includes a turn nozzle that is fluidly connected to a pressurized gas source. The turn nozzle is arranged and configured to direct pressurized gas in a second direction different than the first direction toward the non-line of sight area of the glass package to redirect the coating material onto the non-line of sight area.

Methodology Applied

Scientific EffectPressurized gas flow: Jet

Data Source

PatentUS12434253B2Spray coating apparatuses with turn nozzle assemblies and methods of coating glass objects

Publication Date: 2025.10.07 CORNING INC

AI summary

A spray coating apparatus that applies a coating material onto outer surfaces of glass objects includes a coating material source that includes a coating material. A spray nozzle assembly includes a spray nozzle fluidly connected to the coating material source. The spray nozzle is arranged and configured to direct the coating material in a first direction toward the glass object and provide an overspray amount of the coating material by the glass object such that the overspray amount bypasses a non-line of sight area of the glass object. A turn nozzle assembly includes a turn nozzle fluidly connected to a pressurized gas source. The turn nozzle is arranged and configured to direct pressurized gas in a second direction different than the first direction toward the non-line of sight area of the glass package to redirect the coating material onto the non-line of sight area.