Side-by-side spray and vacuum nozzle for fastener powder application
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Solution Overview
Problem
Existing unitary nozzles for applying thermoplastic powder to internally threaded fasteners, such as small closed-end nuts, are inadequate due to size constraints and porting limitations, which prevent sufficient powder flow and proper patch formation.
Innovation Solution
A combined spray and vacuum nozzle design with side-by-side powder supply and vacuum withdrawal passages allows for a smaller outside diameter, enabling effective powder application and collection within a closed-end fastener bore, ensuring sufficient powder flow without blocking the ports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If coaxial spray and vacuum passages are used in a unitary nozzle, then the nozzle structure is simplified, but the bore size constraints prevent sufficient powder flow
Solution Approach 1:
The patent transitions from a coaxial (one-dimensional radial arrangement) to a side-by-side (two-dimensional planar arrangement) configuration of spray and vacuum passages. This dimensional change allows both passages to be positioned laterally adjacent to each other rather than one inside the other, increasing the effective cross-sectional area for powder flow while maintaining a compact nozzle outer diameter suitable for small fastener bores.
2Length of moving object
If the nozzle outside diameter is reduced to fit small closed-end nuts, then access to the fastener bore is improved, but powder flow becomes insufficient and ports become blocked
Solution Approach 1:
By arranging spray and vacuum passages side-by-side in a planar configuration rather than coaxially, the patent increases the effective flow area without increasing the nozzle's outer diameter. This allows the nozzle to maintain a small size for accessing tight bore clearances while providing sufficient passage area for adequate powder flow rates.
Solution Approach 2:
The patent optimizes the local geometry of the passage cross-sections and orientations to maximize flow efficiency. The passages are configured with appropriate dimensions and angular orientations relative to the spray axis, allowing each passage to be sized optimally for its function while maintaining overall compact nozzle dimensions.
3Quantity of substance
If spray and vacuum ports are positioned to allow sufficient powder flow, then powder application is improved, but the nozzle diameter increases preventing entry into small fastener bores
Solution Approach 1:
The side-by-side arrangement of passages in lateral dimensions rather than radial dimensions allows both spray and vacuum ports to be adequately sized for sufficient powder flow while keeping the nozzle outer diameter small enough to enter tight fastener bores with appropriate clearance.
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
This design enables the formation of a retention patch inside a closed-end internally-threaded fastener by allowing sufficient powder flow and efficient overspray collection, overcoming previous size and porting limitations.
Implementation Method 1
a source of pressurized air and thermoplastic material that is fluidized so as to spray from the nozzle
Implementation Method 2
The sprayed powder that contacts the heated threads melts so as to adhere to the threads
Implementation Method 3
Excess powder that does not melt and adhere to the threads is typically withdrawn from the fastener using a vacuum nozzle that communicates with a powder collection system
Data Source
AI summary
A combined spray and vacuum nozzle includes a nozzle housing containing a powder supply passage and a vacuum withdrawal passage, where the powder supply passage and the vacuum withdrawal passage are arranged in a side-by-side relationship. The nozzle housing has a proximal end portion and a distal end portion. The distal end portion features a spray port in communication with the powder supply passage and a vacuum port in communication with the vacuum withdrawal passage. The spray port is positioned adjacent to the vacuum port. The proximal end portion of the nozzle housing adapted to communicate with a source of aspirated powder and a vacuum source so that the powder supply passage communicates with the source of aspirated powder and the vacuum withdrawal passage communicates with the vacuum source.