Removable Nozzle Filling Head for Cleaner PU Spray Can Filling
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Solution Overview
Problem
The existing methods for filling polyurethane foam into spray cans face challenges such as uncontrolled turbulence and splashing of liquids, leading to soiling and increased maintenance costs due to nozzle blockages and erosion, which complicates the replacement process.
Innovation Solution
A filling station and method utilizing a removable nozzle design for the outer head, allowing easy replacement and maintenance, with features like laminar flow channels and an obturator to minimize turbulence and soiling, and manufactured using additive manufacturing for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a fixed nozzle design is used in the filling head, then the initial filling process can be performed, but the nozzle becomes difficult to replace when blocked or eroded, increasing maintenance time and costs
Solution Approach 1:
The filling head is divided into separable components: the outer head and the nozzle are distinct parts that can be detached from each other. The nozzle is inserted into the outer head and secured by friction and pressure from the filling medium, allowing it to be removed and replaced independently without replacing the entire filling head assembly.
Solution Approach 2:
The nozzle transitions from a static, permanently fixed component to a dynamic, replaceable component. The design allows the nozzle to be inserted, secured during operation through friction and pressure, and then removed when needed for maintenance or replacement, enabling adaptive maintenance scheduling.
2Reliability
If the nozzle is tightly secured in the outer head to prevent leakage, then filling reliability improves, but the nozzle becomes difficult to remove for replacement
Solution Approach 1:
The connection between nozzle and outer head is dynamic rather than static. During filling operation, the nozzle is tightly secured through friction and pressure effects, providing reliable sealing. During maintenance, the same friction and pressure mechanisms can be reversed or overcome to allow easy removal, enabling the system to adapt between operational and maintenance states.
Solution Approach 2:
The filling medium itself contributes to securing the nozzle in place through friction and pressure effects during operation. The system uses the operational conditions (filling pressure and flow) to automatically maintain the nozzle's secure position without additional fastening mechanisms.
3Productivity
If conventional filling methods are used without removable nozzles, then the initial setup is simpler, but maintenance costs and downtime increase due to difficult nozzle replacement
Solution Approach 1:
The filling head is segmented into the outer head and the nozzle as separate components. This segmentation increases manufacturing complexity slightly but enables rapid nozzle replacement during maintenance, significantly improving overall productivity by reducing downtime. The modular design allows the nozzle to be quickly swapped without replacing the entire filling head.
Solution Approach 2:
The nozzle is designed as a consumable or replaceable component that can be discarded after a certain period of use or when blocked/eroded, and recovered (removed) easily from the outer head. This approach prioritizes quick replacement over permanent installation, enabling maintenance teams to rapidly swap nozzles and minimize production interruptions.
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
Facilitates quick and cost-effective nozzle replacement, reduces soiling and maintenance efforts, and enhances production efficiency by ensuring laminar flow and minimizing downtime.
Implementation Method 1
the nozzle (1) is provided with a pattern of small channels for guiding the liquid through the nozzle in a laminar flow
Implementation Method 2
The filling head (3) comprises an obturator (4) for closing off the liquid supply
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
Described is a filling station for filling liquids for a polyurethane (PU) foam composition into a spray can whereby at least one filling head (3) of the filling station is provided with an unscrewable outer head (2) having a removable nozzle (1) therein. Further described is a method for the filling, by means of the filling station, of at least one liquid for a polyurethane (PU) foam composition into a spray can whereby at least one liquid filling is introduced into the spray can through the filling head (3) provided with the unscrewable outer head (2) with removable nozzle (1).