Rectangular Spray Nozzle With Convex Shoulders
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Solution Overview
Problem
Conventional spray nozzles generate conical or flat fan-shaped spray jets, leading to inconsistent and uneven coverage on surfaces, particularly on planar shapes like shower walls, as they struggle to reach corners without overspraying.
Innovation Solution
A nozzle design featuring an actuator with a nozzle insert that includes a transition chamber with convex shoulders and converging planar walls, directing fluid flow to produce a wider discharge angle, resulting in a rectangular or oval spray pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conical spray jet is used, then the spray can be generated easily, but the coverage on surfaces is inconsistent and uneven
Solution Approach 1:
The spray jet is segmented into multiple sub-streams by the array of obstructions (ridges, ribs, or protrusions) within the nozzle. Each obstruction creates individual spray sub-streams that collectively form a broader, more uniform coverage pattern, resolving the contradiction between easy spray generation and coverage uniformity.
Solution Approach 2:
Different regions of the spray jet are given different characteristics through the obstructions. The obstructions are strategically positioned to create varying spray patterns in different zones, ensuring uniform coverage across the entire surface area while maintaining ease of operation.
2Device complexity
If a conical-shaped spray jet is used, then the spray structure is simple, but it cannot reach corners without overspraying adjacent surfaces
Solution Approach 1:
The single conical spray jet is divided into multiple directed sub-streams by the obstruction array. These segmented streams can be oriented to reach into corners and crevices while the overall nozzle structure remains simple and unchanged, improving corner coverage without increasing device complexity.
Solution Approach 2:
The spray pattern is extended from a two-dimensional conical projection to a three-dimensional distributed pattern by introducing obstructions that create vertical and lateral spray components. This dimensional enhancement allows the spray to reach corners and uneven surfaces more effectively while maintaining structural simplicity.
3Ease of operation
If a fan-shaped spray jet is used, then corners can be reached more reliably, but the product is not distributed uniformly across the spray pattern
Solution Approach 1:
The fan-shaped spray is segmented into multiple controlled sub-streams by the obstructions. Each obstruction directs a portion of the spray at specific angles, ensuring both corner coverage and uniform product distribution across the entire spray pattern by preventing any single region from receiving excessive product.
4Area of stationary object
If a fan-shaped spray jet is used, then the spray pattern is broader, but excessive user movement is required to cover the entire surface
Solution Approach 1:
The spray is segmented into multiple overlapping sub-streams that collectively cover a broader area from a single nozzle position. This segmentation allows the entire surface to be covered more quickly with minimal user movement, as the distributed spray pattern eliminates gaps and reduces the need for repeated passes.
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 design achieves consistent and uniform coverage across surfaces, including corners, with a reduced need for user movement, by generating a spray pattern that is more evenly distributed and effectively reaches the entire surface area.
Implementation Method 1
An insert has an inlet end coupled to the actuator outlet end and defines an insert passage in fluid communication with the outlet chamber. The insert further defines a transition chamber disposed downstream of the inlet passage and includes opposed first and second convex shoulders, opposed first and second planar walls extending between the first and second convex shoulders, and a nozzle outlet disposed downstream of the first and second convex shoulders.
Data Source
AI summary
A nozzle is provided for dispensing a liquid from a container in a desirable, nearly rectangular spray pattern. The nozzle includes an actuator having an inlet end adapted to receive liquid from the container and an outlet end, the actuator outlet end defining an outlet chamber. An insert is coupled to the actuator outlet end and defines an insert passage in fluid communication with the outlet chamber. The insert includes at least a first convex shoulder disposed downstream of the outlet chamber, and a nozzle outlet disposed downstream of the first convex shoulder. The convex shoulder may have a radius of curvature and side walls may be provided at an angle of convergence. The radius of curvature and the angle of convergence may be provided within certain ranges to obtain the desired spray pattern at the desired flow rate using typical aerosol can pressures.