Spray Nozzle Assembly for Small Droplets of Viscous Liquids
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Solution Overview
Problem
Existing liquid dispensing systems struggle to reliably and rapidly dispense precisely controlled small droplets of highly viscous liquids, often resulting in splattering due to clogging from solids and limitations in air-operated piston operation.
Innovation Solution
A modular liquid dispensing system with spray nozzles featuring larger inlet passages to reduce clogging, air-actuated pistons with return springs optimized for rapid operation, and solenoid valves to control piston movement and nozzle operation, enabling precise control over droplet size and rapid dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If smaller nozzle passages are used to control droplet size, then droplet control precision is improved, but the nozzle becomes susceptible to clogging from solids in the liquid
Solution Approach 1:
The nozzle is divided into separate functional sections: a larger inlet passage (first passage) that receives liquid with solids, and a smaller outlet passage (second passage) that controls droplet size. This segmentation allows each section to perform its specific function optimally without compromising the other.
Solution Approach 2:
A piston assembly acts as an intermediary component between the inlet and outlet passages. The piston rapidly opens and closes to control liquid flow, enabling precise droplet dispensing while the larger inlet passage prevents clogging by allowing solids to pass through freely.
2Productivity
If rapid piston operation is used to increase dispensing speed, then productivity is improved, but the compressibility of controlling air limits piston speed
Solution Approach 1:
The piston operates through periodic rapid opening and closing cycles controlled by alternating air pressure application. This periodic action enables high-speed repetitive dispensing operations, achieving productivity improvements while maintaining reliable control through the cyclic nature of the operation.
3Device complexity
If spring return mechanism is used for air-operated piston, then device simplicity is improved, but spring return force resists rapid piston closure
Solution Approach 1:
The system applies preliminary air pressure to actively drive the piston closed, counteracting the resistive force of the return spring. This preliminary anti-action allows the spring return mechanism to remain simple while achieving rapid piston closure through the dominant air pressure force during the closing stroke.
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 system effectively dispenses precisely controlled small droplets of highly viscous liquids without splattering, operates more rapidly, and is less susceptible to clogging, while maintaining a simple design for economical manufacture and efficient usage.
Implementation Method 1
solenoid valves to control piston movement and nozzle operation
Implementation Method 2
air-actuated pistons with return springs optimized for rapid operation
Data Source
AI summary
A modular liquid distribution system in which each module has a module body, a spray nozzle, and a cyclically operable piston for controlling the dispensing of high viscous liquids from the spray nozzle. Each spray nozzle has a nozzle body with a liquid inlet and a tear dropped shaped pintle which together with the nozzle body defines an expansion chamber that reduces velocity of the liquid sufficient to be dispensed in small droplet form without splattering. In one embodiment, the nozzle body has a discharge orifice sized smaller than the outer diameter of the expansion chamber for accelerating liquid flow upon discharge sufficient to enhance consistent and repeatable breaks in the cyclically controlled fluid flow stream for enabling the discharge of smaller and more consistent volumes.