Spray Nozzle With Separating Wall For Uniform Atomization
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Solution Overview
Problem
Conventional spray nozzles face challenges in achieving high flow rates while minimizing overspray, especially when targeting large surface areas, and are often costly and inefficient in design.
Innovation Solution
A spray nozzle design featuring a separating wall that divides the material flow into two passages, combined with separate gas supply channels, enhances mixing by reducing the material's cross-section and increasing air interaction, allowing for higher velocity and reduced air pressure requirements, and includes a tapered outlet for uniform cone spray distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional spray nozzle design is used, then manufacturing cost is reduced, but overspray increases and high flow rate spraying capability is lost
Solution Approach 1:
The material flow is divided into two separate passages by a separating wall within the nozzle body. This segmentation allows the material stream to be split and recombined, creating turbulence and improving atomization efficiency. The separated flows mix more effectively with pressurized gas, enabling high flow rates while reducing overspray through better material utilization.
Solution Approach 2:
The separating wall introduces a spatial dimension to the flow path by creating distinct upper and lower passages. This dimensional separation allows pressurized gas to interact with material from multiple directions, enhancing mixing and atomization. The three-dimensional flow structure improves spray pattern control and reduces lateral dispersion that causes overspray.
2Productivity
If conventional spray nozzle design is used, then device complexity is reduced, but spray uniformity on large surfaces deteriorates
Solution Approach 1:
The internal nozzle structure is segmented into distinct functional zones: a separating wall creating two passages, a mixing section for gas-material interaction, and a tapered outlet. This segmentation allows each zone to perform its specific function optimally, ensuring uniform spray distribution across large surfaces while maintaining a manageable structural complexity through modular design.
Solution Approach 2:
Different sections of the nozzle have optimized local geometries: the separating wall creates specific flow patterns in the passages, the mixing section provides a defined interaction zone with pressurized gas, and the tapered outlet ensures uniform exit flow. Each local structure is tailored to its specific function, achieving overall spray uniformity through localized optimizations rather than uniform design throughout.
3Productivity
If material flow cross-section is reduced, then gas mixing efficiency is improved, but flow resistance increases
Solution Approach 1:
The flow path is segmented into two separate passages that run parallel through the nozzle body. This segmentation allows material to maintain higher velocity through narrower channels while the total cross-sectional area remains sufficient to minimize pressure loss. The segmented structure increases the perimeter-to-area ratio, enhancing gas-material contact surface area and mixing efficiency without significantly increasing flow resistance.
Solution Approach 2:
Pressurized gas is introduced through dedicated channels that intersect with the material passages in the mixing section. This pneumatic approach uses gas pressure to drive mixing and atomization, allowing efficient mixing at reduced material pressure losses. The gas flow dynamically interacts with the material stream, providing mixing force without requiring excessive material pressure.
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 design enables efficient, high-flow rate spraying with minimal overspray, facilitating uniform application on large surfaces with reduced air pressure needs and improved directional control.
Implementation Method 1
The inlet comprises a separating wall configured to divide a flow of material to be sprayed into two separate flow passages prior to entry into the mixing section
Implementation Method 2
a mixing section, an inlet for the material... The mixing section is in fluid communication with the outlet... The buffer space is in fluid communication with the mixing section via two or more separate gas supply channels
Data Source
AI summary
A spray nozzle for spraying material includes an outlet, a mixing section, an inlet for the material, and a buffer space for pressurized gas. The mixing section is in fluid communication with the outlet. The inlet is in fluid communication with the mixing section. The buffer space is in fluid communication with the mixing section via two or more separate gas supply channels. The inlet comprises a separating wall configured to divide a flow of material to be sprayed into two separate flow passages prior to entry into the mixing section.