Insect Coil Dosing via Capillary Droplet Placement
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Solution Overview
Problem
Conventional insect coils face challenges in precisely applying an extra dose of active insecticide during manufacturing, especially in high-speed automated processes, due to variations in coil shape and size, leading to errors in dose location and increased defective coils.
Innovation Solution
The method involves applying the extra dose of active insecticide as a small, concentrated droplet using a dosing port located above the desired location on the coil as it is ejected from the die, ensuring precise orientation and minimizing interference with the coil's burning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If mechanical orientating devices are used to position coils for dosing, then automated dosing can be achieved, but orientation errors occur due to coil shape variations leading to incorrect dose placement
Solution Approach 1:
The coil is oriented during the cutting process itself, before dosing occurs. The die is designed with the coil orientation built-in, so that when the coil is cut from the sheet material, it is already in the correct orientation for dosing. This eliminates the need for separate mechanical orientating devices that are prone to errors due to coil shape variations.
2Ease of manufacture
If a large amount of liquid is used in the extra dose, then the active ingredient is more easily applied, but dose migration and dilution increase reducing effectiveness
Solution Approach 1:
The patent changes the physical state and concentration parameters of the active ingredient application. Instead of using large amounts of liquid, the invention applies a small amount of liquid containing a high concentration of active ingredient. This is achieved by dissolving the active ingredient in a minimal amount of solvent or using a concentrated solution, thereby maintaining ease of application while preventing dose migration and dilution.
3Ease of operation
If the dosing mechanism interacts with the coil shape for orientation, then automated positioning is possible, but errors occur due to variations in coil size and shape after drying
Solution Approach 1:
The orientation is determined and fixed during the cutting process, before any drying or shape variations occur. The die design incorporates the orientation information directly into the cutting pattern, so the coil is oriented correctly as it is being formed. This preliminary orientation action eliminates the need for subsequent positioning based on the dried coil shape, avoiding errors from size and shape variations.
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
This approach allows for precise and consistent application of the extra dose, reducing defective coils and maintaining the coil's performance by ensuring accurate dose placement and minimizing dilution, resulting in a more effective insect control product.
Implementation Method 1
The droplet is allowed to touch the top surface of the coil and is pulled downwardly onto the top surface of the coil by capillary action as the coil moves away from the die.
Data Source
AI summary
A method of manufacturing an insect coil includes the steps of feeding a sheet of dough material which includes an active insect control ingredient dispersed therein in a first direction, cutting the sheet of dough material with a die to form an insect coil, ejecting the insect coil from the die, and applying an extra dose of active to a specific location on the coil while the coil is being ejected from the die. Preferably, the extra dose of active is applied as a droplet using capillary forces that develop between the upper surface of the insect coil and the droplet itself and is forced through a tube located above the desired location. The insect coil may be tip treated only or may be zone treated at a plurality of spaced locations.