Self-Cleaning Nozzle Porous Surface for Spray Contamination
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Solution Overview
Problem
Existing spray apparatuses for applying fluids to moving webs in papermaking processes face challenges in maintaining nozzle cleanliness, leading to deposition of contaminants that disrupt the spray pattern and clog nozzles, which limits machine speed and precision in material application.
Innovation Solution
A self-cleaning nozzle design featuring a porous surface surrounding the annular gas flow channel, with a radiused surface to decompress motive fluid and create a radially outward flow, preventing deposition of contaminants and ensuring uniform dispersion of process liquids onto the web.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If spray nozzles are used to apply process liquid directly onto the sheet, then application precision and control are improved, but nozzle contamination and clogging occur
Solution Approach 1:
The patent applies preliminary action by using the motive fluid flow to preemptively remove contaminants from the nozzle face before they can accumulate and disrupt spray pattern. The fluid flow continuously clears the discharge end area, preventing clogging before it occurs.
Solution Approach 2:
The nozzle assembly performs self-service by using its own motive fluid to clean its discharge end. The fluid that would otherwise be wasted is redirected through the discharge end to clean contaminants, allowing the nozzle to maintain itself without external intervention.
2Productivity
If machine speed is increased to improve productivity, then output increases, but spray pattern stability deteriorates
Solution Approach 1:
The self-cleaning capability allows the nozzle to maintain optimal spray pattern at higher speeds without requiring shutdowns for cleaning. The continuous clearance of contaminants ensures spray stability is maintained even as machine speed increases.
Solution Approach 2:
The patent ensures continuity of useful action by maintaining a clean discharge end continuously through the motive fluid flow. This prevents intermittent disruptions from clogging, allowing steady operation at high speeds without breaks for maintenance.
3Reliability
If nozzle discharge end is kept clean to prevent clogging, then spray quality is maintained, but device complexity increases
Solution Approach 1:
The motive fluid serves multiple functions: it disperses the process liquid onto the sheet and simultaneously cleans the discharge end by flowing through it. This multi-functionality eliminates the need for separate cleaning mechanisms, reducing overall device complexity.
Solution Approach 2:
The nozzle uses its own operating fluid to perform cleaning, eliminating the need for external cleaning systems. The motive fluid is simply redirected through the discharge end, adding minimal structural complexity while achieving effective self-cleaning.
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 self-cleaning nozzle minimizes the need for production line shutdowns and maintains consistent spray quality by preventing deposition of contaminants around the discharge end, allowing for higher machine speeds and precise control of material application.
Implementation Method 1
A porous surface is located on the face of a discharge end of the nozzle assembly and is in fluid communication with a preferably annular pathway. The porous surface is adapted to provide a low velocity fluid discharge of the pressurized fluid delivered to the annular pathway.
Implementation Method 2
A radiused surface is formed in the carrier body around the air discharge outlet where it acts to decompress a motive fluid so that it expands the flow outwardly to the porous surface.
Implementation Method 3
Motive fluid delivered to an annular flow channel at the nozzle face imparts a helical swirl to process liquid delivered via a central spray outlet, thereby dispersing and uniformly distributing it onto a web moving through the spray apparatus.
Data Source
Figure 1~3
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AI summary
A nozzle assembly with a self-cleaning face is provided, having a nozzle body with a liquid flow path defined therethrough with an inlet and a spray outlet. The nozzle body is mounted in a carrier body, and an annular gas flow channel is located about the nozzle body with a gas discharge outlet defined around the spray outlet. A porous surface is located about the annular gas flow channel at the gas discharge outlet. A radiused surface is formed in the carrier body at the air discharge outlet. A pathway is in communication with the porous surface and adapted to provide a low velocity fluid discharge from the porous surface. A spray device and method are also provided using the nozzle assembly with the self-cleaning face. An adaptor for retrofitting an existing nozzle is also provided.