Spray Head Impact Mapping with Ionized Gas for Automated Verification
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Solution Overview
Problem
Existing methods for testing pharmaceutical fluid spray devices are destructive, require human verification, and are not fully automatable, limiting their applicability and efficiency on assembly lines.
Innovation Solution
A non-destructive, automated method using an ionized gas stream to analyze the impact area on a receiving surface with discrete conductive contact zones, allowing for the determination of spray geometry and symmetry, using a device with grounding means, processing, and analytical tools to assess conformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional laboratory testing methods are used to verify spray properties, then measurement precision is improved, but the testing process becomes destructive and requires human verification
Solution Approach 1:
The patent replaces manual mechanical testing with an automated optical detection system. A camera captures images of the spray plume, and image processing algorithms automatically analyze spray characteristics such as cone angle and symmetry, eliminating the need for human verification while maintaining measurement precision.
Solution Approach 2:
The invention creates a visual copy (image) of the spray plume using a camera, which then serves as the object of analysis. This allows the spray properties to be measured from the captured image rather than through direct physical interaction with the spray, enabling automated analysis without human intervention.
2Measurement precision
If schlieren imaging is used to visualize compressed air flow through the spray head, then spray angle evaluation is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the complex and expensive schlieren imaging system with a simple, inexpensive camera. The camera is a common, readily available device that does not require the complex optical setup, lighting conditions, or specialized equipment of schlieren imaging, thereby reducing device complexity and cost while still enabling spray visualization.
Solution Approach 2:
The invention introduces a simple optical intermediary (the camera) that captures the spray plume without requiring the complex schlieren optical path. The camera acts as a mediator between the spray head and the analysis system, simplifying the overall setup while maintaining the ability to evaluate spray characteristics.
3Measurement precision
If complex schlieren setup is used for spray analysis, then measurement capability is improved, but assembly line integration becomes difficult and productivity decreases
Solution Approach 1:
The patent replaces the complex schlieren mechanical-optical system with a simple camera-based imaging system. This substitution dramatically reduces the time required for setup and measurement, allowing rapid capture and analysis of spray characteristics that can be integrated into fast-moving assembly lines without slowing production.
Solution Approach 2:
By creating a rapid visual copy of the spray plume through image capture, the system enables quick analysis that can keep pace with assembly line speeds. The image processing and analysis can be performed rapidly on the captured images, allowing 100% of devices to be tested without substantially slowing down production.
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
Enables 100% testing of devices without slowing down the assembly line, providing precise and repeatable analysis of spray geometry and symmetry, ensuring high discrimination between compliant and non-compliant devices.
Implementation Method 1
to pass a stream of ionized gas through said spray orifice of said spray head, said stream of ionized gas being electron-charged
Implementation Method 2
to send said stream of ionized gas onto said receiving surface, to visualize the impact area of said stream of ionized gas on said receiving surface
Data Source
Figure 1~4
AI summary
The invention relates to a method for analysing a device for spraying a pharmaceutical fluid product, comprising the following steps: - providing a spray head (1) of a device for spraying a pharmaceutical fluid product, said spray head (1) comprising a spray port (2); - providing a receiving surface (10) comprising a plurality of discrete contact areas (12) separated by spaces (13), said contact areas (12) being electrically conductive; - passing a stream of ionised gas (F1) through the spray port (2) of the spray head (1), said stream of ionised gas (F1) being charged with electrons; - sending the stream of ionised gas (F1) onto said receiving surface (10); - visualising the impact area of said stream of ionised gas (F1) on the receiving surface (10); and - analysing said visualisation of the impact area to determine whether or not the impact area complies with predetermined specifications.