Spray Cap With Segmented Slits and Non-Return Valve
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Solution Overview
Problem
Conventional spray containers with single spray orifices require high manufacturing costs, result in uneven liquid coverage, and slow container retraction due to small orifice diameter, necessitating multiple squeezes and inefficient air intake.
Innovation Solution
A one-piece polymeric spray cap with multiple spray slits and a non-return valve for rapid air intake, allowing for even coverage and quick container retraction, manufactured through injection molding for reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single spray orifice is used, then the manufacturing cost is reduced (one-piece moulding), but the liquid coverage becomes uneven and the spray area is limited
Solution Approach 1:
The single spray orifice is segmented into multiple spray slits (at least two) formed in the cap plate. This segmentation allows the liquid stream to be divided into multiple smaller streams, creating more uniform coverage across the spray area while still using a one-piece molded cap structure.
Solution Approach 2:
The spray output is transformed from a single circular orifice to elongated slits with significant length. This dimensional change from point-like orifices to line-like slits increases the effective spray area and improves coverage uniformity while maintaining the simplicity of one-piece manufacturing.
2Device complexity
If a single spray orifice is used, then the cap structure is simple, but the container retraction speed is slow due to restricted air intake
Solution Approach 1:
The single air intake orifice is segmented into multiple spray slits that also function as air intake paths. This segmentation provides multiple parallel air flow paths, significantly increasing the total air intake area and enabling faster container retraction while maintaining a simple cap structure.
Solution Approach 2:
The spray slits serve dual functions: they act as spray outlets for liquid dispensing and simultaneously serve as air intake pathways during container retraction. This multi-functionality eliminates the need for separate air intake orifices, maintaining structural simplicity while improving retraction speed.
3Manufacturing precision
If multiple spray orifices are used to improve coverage, then the liquid coverage becomes more uniform, but the manufacturing cost increases due to multiple components
Solution Approach 1:
Multiple spray orifices are merged into a single cap plate structure formed by one-piece injection molding. The cap plate integrates multiple spray slits and air intake pathways into a single molded component, eliminating the need for separate nozzle assemblies and reducing manufacturing complexity while achieving uniform coverage.
Solution Approach 2:
The spray features are transformed from small circular orifices to elongated slits with significant length in the cap plate. This dimensional change increases the effective spray perimeter and coverage area while maintaining manageable dimensions for single-step injection molding manufacturing.
4Stress or pressure
If the spray orifice diameter is reduced to increase spray pressure, then the spray atomisation improves, but the air intake speed during retraction decreases
Solution Approach 1:
The total spray pressure requirement is segmented across multiple parallel slits rather than concentrated in a single small orifice. Each slit can be optimized for adequate pressure drop and atomisation, while the collective array of slits provides sufficient total flow area for both spray dispensing and air intake during retraction.
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 provides even liquid coverage over a larger area with fewer squeezes and rapid container retraction, enhancing user experience and manufacturing efficiency.
Implementation Method 1
a non-return valve arranged to permit air to flow through it in one direction which, in use, is towards the interior of the spray container but substantially to prevent the flow of air through it in the opposite direction
Implementation Method 2
The combination of the high pressure and the small diameter of the spray orifice results in the jet of liquid passing through the spray orifice being discharged from it in spray or atomised form
Implementation Method 3
by squeezing the wall of the receptacle, which must therefore be of flexible, resilient material
Data Source
AI summary
A spray cap for a spray container constitutes a one-piece moulding of polymeric material and includes a cap plate in which a plurality of spray slits is formed. Integral with the cap plate is a non-return valve arranged to permit air to flow through it in one direction which, in use, is towards the interior of the spray container but substantially to prevent flow of air through it in the opposite direction.