3D-Printed Spray Head With Integrated Nozzles for Tight Die Spaces
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Solution Overview
Problem
Existing spray heads for cooling lubrication in forming machines have limited variability due to their narrow construction and separate feed channels, which restricts their use in smaller spaces and flexibility in die cooling applications.
Innovation Solution
A spray head with a one-piece two-substance nozzle and integrated feed channel configuration, allowing for compact and individually controllable nozzles, which eliminates seals and enables versatile use by incorporating a DE LAVAL or convergent-divergent type nozzle for intense atomization and a porous housing with drip points for fluid management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a multi-layer plate arrangement with separate feed channels is used, then the spray head can be introduced into smaller free spaces between dies, but the variability of use is limited
Solution Approach 1:
The patent merges separate feed channels and valve components into a single integrated body. The body houses multiple internal channels for spray medium and spray air, along with membrane valves, eliminating the need for separate plate layers and external channel connections. This integration maintains compact dimensions while enabling greater design flexibility and adaptability for different die configurations.
2Ease of manufacture
If separate feed channels and valve components are used, then the spray head can be constructed in a modular manner, but the construction becomes more complex and requires seals
Solution Approach 1:
The patent combines multiple separate components (feed channels, membrane valves, housing) into a single monolithic body. This eliminates the interfaces between components that would require seals and complex assembly procedures. The integrated design simplifies manufacturing while reducing structural complexity, as the body can be produced as one piece without requiring multiple sealed connections.
3Volume of moving object
If a compact spray head design is used, then it can fit into smaller spaces between dies, but the individual controllability of nozzles is reduced
Solution Approach 1:
The patent segments the internal flow paths within the integrated body, providing separate feed channels for spray medium and spray air that can be independently controlled. Membrane valves are incorporated within the body to enable individual control of each nozzle while maintaining the compact integrated structure. This segmentation allows independent operation of nozzles without requiring a larger overall design.
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 a highly versatile and compact spray head that can be adapted for various die cooling applications, ensuring effective cooling lubrication with minimal space requirements and preventing fluid accumulation, thus enhancing the flexibility and efficiency of the spray head's operation.
Implementation Method 1
which atomizes a mixture of spray medium and spray air onto the die for cooling lubrication
Implementation Method 2
by means of 3D printing, in particular by means of metallic 3D printing
Data Source
AI summary
A spray head for supplying at least one die of a forming machine with lubricating coolant, the forming machine including a lower die and an upper die, is preferably produced by rapid manufacturing and is designed as a single piece to a large extent. The use of rapid manufacturing allows the production of the most varied configurations, such as stabilizing honey-comb structures or drip points, which allow a more advantageous design of the spray head. The spray head carries at least one two-substance nozzle connected with at least one feed channel. The nozzle body of the nozzle and the channel wall of the feed channel are configured in one piece with one another or the channel wall of the feed channel and a spray head foot carrying a supply connector connected with the feed channel are configured in one piece with one another.