Spray Head Orifice Analysis Using Compressed Gas Impact Visualization

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Solution Overview

Problem

Existing methods for testing pharmaceutical fluid product spraying devices are destructive, require human verification, and cannot efficiently assess the geometry and symmetry of the spray, limiting their ability to test 100% of devices without slowing down production.

Innovation Solution

A non-destructive analysis process using a spray head with a spray orifice, a reception surface with sensors, and a flow of compressed gas to visualize and analyze the impact zone, determining compliance with predetermined specifications regarding geometry and symmetry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional laboratory testing of assembled spray devices is performed, then spray properties can be verified against specifications, but the testing process is destructive and requires human verification

Engineering Contradiction:

Improvespray property verificationVSAvoidhuman verification requirement

Core Design Contradiction:

Measurement precisionVSExtent of automation

Solution Approach 1:

The patent replaces manual visual inspection and subjective human verification with an automated optical measurement system. A camera captures images of the spray pattern, and image processing algorithms automatically analyze the spray geometry, symmetry, and properties against predefined specifications, eliminating the need for human operators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention creates a visual copy (image) of the spray pattern using a camera, which then serves as the object of analysis. This digital representation allows for automated measurement and comparison with specifications without requiring physical handling or subjective human assessment of the actual spray.

Inventive Principle:

Principle #26Copying

2Reliability

If 100% of spray devices are tested, then compliance with specifications can be ensured, but production speed is significantly slowed down

Engineering Contradiction:

Improvecompliance assuranceVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The testing system is designed to operate continuously at the production line without interrupting the flow of devices. The spray device is tested while moving through the production process, allowing 100% inspection to occur simultaneously with production rather than as a separate batch process.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The entire measurement and analysis process is optimized to occur in a fraction of a second. The camera captures the spray pattern instantaneously, and the image processing algorithm rapidly compares the captured image against specifications, enabling each device to be tested and cleared in under 1 second, maintaining production throughput.

Inventive Principle:

Principle #21Skipping (Rushing through)

3Adaptability or versatility

If a strioscopic bench is used to visualize compressed air flow, then spray vs jet distinction is possible, but the equipment becomes complex and expensive

Engineering Contradiction:

Improvespray characterization capabilityVSAvoidstrioscopic bench requirement

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts only the essential measurement function from the complex strioscopic bench. Instead of using elaborate optical arrangements and specialized equipment, it employs a simple camera to capture the spray pattern, combined with basic image processing software to extract spray characteristics. This retains the ability to distinguish spray from jet while eliminating the need for complex dedicated testing equipment.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enables automated, non-destructive testing of 100% of spraying devices, ensuring compliance with specifications while maintaining production efficiency and reducing costs.

Implementation Method 1

passing a stream of compressed gas through said spray orifice of said spray head, sending said stream of compressed gas onto said receiving surface, visualizing the impact zone of said stream of compressed gas on said receiving surface by means of said sensors

Methodology Applied

Scientific EffectSensor detection:

Data Source

PatentEP4337392B1Method and device for analysing a device for spraying a pharmaceutical fluid product

Publication Date: 2025.05.14 APTAR FRANCE SAS

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AI summary

A method for analysing a device for spraying a pharmaceutical fluid product, comprising the following steps: - providing a spray head (1) of a device for spraying a pharmaceutical fluid product, the spray head (1) comprising a spray orifice (2), - providing a receiving surface (10) comprising a plurality of sensors (20), - passing a flow of compressed gas (F) through the spray orifice (2) of the spray head (1), - sending the flow of compressed gas (F) onto the receiving surface (10), - visualizing the impact zone of the flow of compressed gas (F) on the receiving surface (10) by means of the sensors (20), and - analysing the visualization of the impact zone to determine whether the impact zone is compliant or non-compliant with predetermined specifications, the receiving surface (10) being at least partially spherical in shape.