Nozzle Unit Assembly With Elastic Channel Expansion
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Solution Overview
Problem
Existing methods for producing nozzle units in liquid dispensers face challenges in achieving high reliability and reproducibility in discharge characteristics, particularly in maintaining the integrity and positioning of nozzle plate arrangements during assembly.
Innovation Solution
A method involving an assembly tool that elastically expands the nozzle channel to insert a nozzle plate assembly, using a tool with an oversized outer contour to ensure secure fitting and positioning, optionally with an auxiliary tool for precise alignment, and potentially followed by thermal treatment to enhance tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the nozzle plate arrangement is inserted into the nozzle channel without elastic expansion, then the assembly process is simpler, but the positional stability and tightness of the nozzle plate arrangement deteriorates
Solution Approach 1:
The patent changes the physical state of the nozzle channel wall from rigid to elastic by applying radial outward force, temporarily altering its dimensional parameters to enable insertion, then allowing it to return to its original state to secure the nozzle plate arrangement with high positional stability
Solution Approach 2:
The assembly tool is designed with an outer contour that is oversized relative to the nozzle channel, allowing it to preliminarily expand the nozzle channel wall before the nozzle plate arrangement is fully inserted, ensuring proper positioning and tightness from the outset
2Reliability
If thermal post-treatment is applied to enhance tightness, then the tightness of the nozzle plate arrangement improves, but the process complexity and energy consumption increase
Solution Approach 1:
The patent replaces thermal post-treatment processes with a purely mechanical assembly method using elastic expansion, achieving the same tightness enhancement through mechanical force rather than thermal energy, thereby simplifying the overall process
Solution Approach 2:
The nozzle channel wall's elastic properties enable it to self-secure the nozzle plate arrangement after insertion, with the material's natural elastic recovery providing the tightening force without requiring additional thermal or chemical treatment steps
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
Ensures high positional stability and tightness of the nozzle plate arrangement without thermal post-treatment, maintaining discharge reliability and preventing contamination, even under mechanical stress.
Implementation Method 1
the assembly tool (200) is inserted into the nozzle channel (30) from the inlet side in the joining direction (2), essentially following the nozzle plate assembly (50). As the assembly tool (200) is progressively inserted into the nozzle channel (30) in the joining direction (2), the assembly tool (200) increasingly comes into contact with the nozzle channel wall (31) and partially expands it elastically with its outer contour (202).
Data Source
Figure 1
Figure 2~4
Figure 4A~4D
AI summary
The invention relates to two sub-methods which are used together in particular in order to produce a nozzle unit for a liquid dispenser and nozzle units which have the features that can be achieved using said methods. The methods include a step of adding a nozzle plate (51) into a nozzle channel (30) of a plastic carrier (20) of a nozzle unit (10). The process of adding the nozzle plate is carried out using an assembly tool (200) that has an outer contour (202) by means of which the nozzle channel (30) can be elastically expanded. After inserting the nozzle plate (51), the assembly tool (200) is inserted into the nozzle channel (30), where the assembly tool then expands the nozzle channel (30), thus moving the nozzle plate (51) into its final position. The nozzle plate (51) remains there after the assembly tool (200) is removed. The methods also include a step of attaching a filter (80) to the plastic carrier (20). In a preparation step, a flat filter material (180) is positioned on the end face (20A) of the plastic carrier (20). Only after the filter material has been positioned and preferably after a thermal connection of the filter material to the end face (20A) has been established, a separation process is carried out in a subsequent method step, by means of which the filter material (180) is cut so as to surround the end face (20A) such that the flat filter (80) that has been positioned on the end face (20A) and has been circumferentially cut in situ remains.