Rotating Disc Liquid Applicator for Uniform Substrate Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devices for applying liquids to moving substrates, such as water to fabrics, face challenges in achieving homogeneous distribution and are prone to nozzle clogging due to small orifice diameters, leading to inconsistent liquid quantity across the substrate.
Innovation Solution
A device utilizing rotating discs with larger orifice diameters and hydrostatic pressure to ensure consistent liquid distribution, where each rotor is fed by a container with constant pressure, and the liquid height is adjusted to regulate the volume flow, eliminating the need for nozzles and reducing clogging risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If nozzles with small orifice diameters are used to apply liquid, then the liquid application precision is improved, but the reliability deteriorates due to frequent clogging
Solution Approach 1:
The invention changes the critical parameter from orifice diameter to liquid height in the supply container. By using larger diameter holes (0.5-2 cm) instead of small orifices (0.5-1 mm) and controlling liquid flow through hydrostatic pressure (liquid height 1-10 cm), the system achieves both precision and reliability. The formula Q = φεA√(2gH) shows that flow rate can be precisely controlled by adjusting H (liquid height) while using much larger A (hole area), eliminating clogging issues.
2Reliability
If rotating discs with larger orifice diameters are used, then the reliability is improved by reducing clogging, but the manufacturing precision deteriorates due to inconsistent liquid distribution
Solution Approach 1:
The invention creates equipotential conditions by providing identical supply containers for each rotor, all filled to the same liquid height H. This ensures equal hydrostatic pressure (P = ρgH) at each rotor inlet, guaranteeing uniform liquid distribution across all rotors. The containers act as pressure equalizing reservoirs, eliminating distribution inconsistencies while allowing large orifice diameters for reliability.
Solution Approach 2:
The invention replaces the mechanical nozzle system (requiring precise small orifices) with a hydrostatic pressure system. Instead of relying on mechanically precision-formed small holes, the system uses gravity-driven flow from elevated containers, where flow rate is controlled by liquid height rather than orifice geometry. This substitution eliminates the precision-manufacturing bottleneck while maintaining distribution uniformity.
3Manufacturing precision
If nozzles with small orifices are used, then the liquid distribution control is improved, but the device complexity increases due to clogging risks and maintenance requirements
Solution Approach 1:
The invention extracts and eliminates the nozzle component entirely from the system. By removing nozzles with their small, clog-prone orifices, the system simplifies the liquid delivery mechanism to basic containers with large holes. This extraction eliminates the primary source of complexity (clogging and maintenance) while retaining distribution control through the simpler hydrostatic pressure mechanism.
Solution Approach 2:
The supply containers with large holes represent a simple, inexpensive, and maintenance-free alternative to complex nozzle systems. The containers can be simple geometric shapes with drilled holes, requiring no precision manufacturing or maintenance. Even if the containers need replacement, their simplicity makes them far less complex than nozzle systems requiring cleaning, calibration, and replacement of clogged orifices.
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 solution achieves uniform liquid distribution across the substrate, ensuring consistent quantity along the entire length and reducing the likelihood of rotor obstruction, resulting in a more reliable and cost-effective device for applying liquids to moving substrates.
Implementation Method 1
Each rotor is fed by a container ensuring a constant and identical hydrostatic pressure for each rotor
Implementation Method 2
These devices use rotating discs to project the fluid, the liquid being projected by centrifugal force
Implementation Method 3
The spraying of a very small quantity of liquid is obtained by decreasing the height of the liquid in the supply containers of the rotors
Data Source
Figure 1
Figure 2~5
Figure 3
AI summary
The invention relates to a device for applying a liquid, in particular water, onto a moving substrate, comprising a series of rotors attached on a carrier beam (26). Said rotors include rotary discs (7, 8) that spray the liquid onto said substrate through openings formed in a plate (21) arranged between said discs and the substrate. Each rotor comprises liquid supply means (25, 27) for the discs. The device comprises a casing (20) in which the carrier beam and the rotors are arranged. Each rotor comprises a vertical axle (17) on which two flexible and planar discs (7, 8) are mounted, which disks rotate in opposite directions. The rotors are mounted on the beam as a series of identical groups that include three rotors (17, 17', 17''), the arrangement being such that there are always two discs rotating in opposite directions and partially overlapping.