Multi-Hole Nozzle for High-Speed Filling Foam Reduction
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Solution Overview
Problem
High flow rate bottle/container filling processes often result in foam generation, leading to liquid spillage and contamination issues due to the increased volume of foam, which negatively impacts product appearance and manufacturing efficiency.
Innovation Solution
A multi-hole nozzle with passageways of specific dimensions and geometries, manufactured using 3D printing technologies, is designed to minimize foam creation by facilitating laminar flow and reducing turbulence, thereby accommodating high flow rates without significant spillage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high fill rate is used to save time during bottle filling operation, then productivity is improved, but foam generation increases leading to spillage and contamination
Solution Approach 1:
The nozzle is divided into multiple separate passageways (typically 3-7 passages) instead of a single opening. Each passageway has specific dimensions (diameter 1-3mm, length 5mm-1.5m) that create individual laminar flow streams. This segmentation of the fluid flow path reduces turbulence and foam generation while maintaining high overall fill rates through parallel flow channels.
Solution Approach 2:
The patent specifies precise parameter ranges for the passageways including diameter (1-3mm), length (5mm-1.5m), and length-to-diameter ratio (5:1 to 1500:1). These parameter changes optimize the flow characteristics to promote laminar flow patterns that minimize foam creation. The specific dimensional parameters are critical to achieving the desired flow regime that reduces harmful foam generation.
2Productivity
If high fill rate is used to increase productivity, then output is improved, but liquid spillage outside the container increases causing contamination and maintenance issues
Solution Approach 1:
By segmenting the nozzle into multiple controlled passageways, each creating a separate laminar flow stream, the liquid is delivered in a more controlled manner. This prevents the turbulent splashing that causes spillage, thereby reducing liquid loss outside the container while maintaining high productivity through parallel flow channels.
Solution Approach 2:
The optimized parameters (diameter 1-3mm, length 5mm-1.5m, length-to-diameter ratio 5:1 to 1500:1) create flow conditions that minimize spillage. The long, narrow passageway geometry promotes laminar flow that is less prone to splashing and spillage, directly reducing liquid loss while preserving high fill rates.
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 nozzle effectively reduces foam generation and spillage, enabling faster fill rates with improved product quality and reduced maintenance costs by ensuring liquids are contained within the bottle/container, as demonstrated by experimental data showing 25% foam reduction and 20% increased fill rates.
Implementation Method 1
minimize foam creation by facilitating laminar flow and reducing turbulence
Data Source
AI summary
Techniques regarding multi-hole nozzle architectures and/or manufacturing methods are provided. For example, one or more embodiments described herein can comprise a multi-hole nozzle component for a filling machine, the multi-hole nozzle component having a periphery, an inlet side having a surface, and an outlet side having a surface. The nozzle component can further comprise a plurality of separate passageways extending through the nozzle component from adjacent its inlet side to its outlet side. Also, the passageways can form a plurality of openings in the surface of the outlet side of the nozzle component. Further, each of the separate passageways can have a diameter of from about 1 mm to about 3 mm and a length of from about 5 mm to about 1.5 m.