Laser-Finished Nozzle Body for Small Bore and Complex Geometry
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Solution Overview
Problem
Existing methods for producing nozzle bodies, such as injection molding and 3D printing, are limited in design freedom, particularly in creating complex geometries and small nozzle diameters.
Innovation Solution
The nozzle body blank is partially processed using laser processing to achieve a wide range of geometries, including small nozzle diameters and complex features, thereby overcoming the limitations of injection molding and 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used to produce nozzle bodies, then mass production capability is improved, but design freedom and ability to create complex geometries deteriorates
Solution Approach 1:
The production process is segmented into two stages: injection molding for the basic nozzle body structure (high productivity) and subsequent laser processing for creating complex geometries and nozzle bores (high adaptability). This segmentation allows each process to optimize for its strength, resolving the contradiction between mass production capability and design freedom.
2Productivity
If injection molding is used to produce nozzle bodies, then manufacturing efficiency is improved, but ability to create small nozzle diameters and undercuts deteriorates
Solution Approach 1:
The mechanical injection molding process is supplemented with laser processing (optical/thermal system) to create precise nozzle bores with diameters below 300 μm. The laser replaces the limitation of mechanical mold constraints, enabling precise small-diameter nozzles while maintaining the efficiency of injection molding for the overall structure.
3Adaptability or versatility
If 3D printing is used to produce nozzle bodies, then design freedom is improved, but manufacturing precision and surface quality deteriorates
Solution Approach 1:
The invention merges 3D printing (for design freedom and complex geometries) with laser processing (for precision and surface quality). The laser processing step corrects and enhances the surface quality of 3D printed parts, combining the advantages of both methods to resolve the contradiction between design freedom and manufacturing precision.
4Adaptability or versatility
If laser processing is used to create complex nozzle geometries, then design freedom is improved, but production time increases
Solution Approach 1:
The injection molding process creates the preliminary nozzle body structure with basic geometry, and then laser processing adds the complex features. This preliminary action approach allows the majority of the structure to be produced efficiently by injection molding, while only the complex geometries require time-consuming laser processing, thus minimizing overall production time while maintaining design freedom.
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 a high degree of design freedom, enabling the creation of nozzle bodies with precise control over nozzle geometry and size, which is essential for efficient liquid fog formation.
Implementation Method 1
Laser processing preferably involves laser ablation, laser drilling, and/or 3D laser ablation. Laser ablation refers to the removal of material from a surface by bombarding it with a pulsed laser.
Implementation Method 2
The laser or laser radiation causes rapid heating and, consequently, the formation of a plasma on the surface of the workpiece.
Implementation Method 3
the nozzle body has a hollow cone geometry. With a hollow cone nozzle, the liquid to be atomized is set into a rotating motion. This results in a fine liquid mist.
Data Source
Figure 1~5
AI summary
The present invention relates to a method for manufacturing a nozzle body (4) from a nozzle body blank (1) produced by injection molding or a 3D printing process. The aim of the present invention is to achieve a high degree of design freedom for the nozzle body. For this purpose, the nozzle body blank (1) is subsequently processed, at least partially, by laser processing to form the nozzle body (4).