Spray Tip Assembly Using Brazed Pre-Orifice Insert Alignment
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Solution Overview
Problem
The existing spray tip assembly process for fluid applicators is inefficient due to the need for outside diameter grinding of pre-orifice inserts, which results in significant scrap and alignment issues, affecting the desired spray pattern.
Innovation Solution
A spray tip assembly process that eliminates the need for outside diameter grinding by using a slip fit with a filler metal in a brazing process, where pre-orifice inserts are press fit into the stem and secured using silver brazing filler metal or other bonding agents, allowing for improved alignment and reduced scrap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If outside diameter grinding is used for pre-orifice inserts, then alignment precision can be improved, but material loss and scrap increase significantly
Solution Approach 1:
The patent replaces the mechanical outside diameter grinding process with a brazing process. Pre-orifice inserts are press-fitted into the stem and secured using silver brazing filler metal, eliminating the need for grinding operations. This substitution maintains alignment precision while significantly reducing material loss and scrap.
2Manufacturing precision
If outside diameter grinding is used for pre-orifice inserts, then alignment precision can be improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces the multi-step mechanical grinding process with a streamlined brazing process. The pre-orifice inserts are press-fitted and secured using silver brazing filler metal, which eliminates time-consuming grinding operations and simplifies the manufacturing workflow, thereby improving productivity.
Solution Approach 2:
The patent changes the manufacturing approach from mechanical removal of material (grinding) to thermal joining (brazing). This parameter change in the manufacturing process allows for achieving alignment precision without the need for precise grinding operations, reducing manufacturing time and complexity.
3Loss of substance
If press fit with brazing is used instead of grinding, then scrap is reduced, but manufacturing precision may be compromised
Solution Approach 1:
The patent replaces the grinding process with a press-fit and brazing process. The pre-orifice inserts are press-fitted into the stem and secured using silver brazing filler metal, which provides strong bonding while maintaining alignment precision without requiring material removal.
Solution Approach 2:
The patent employs a composite joining approach combining press-fit mechanical interference with silver brazing filler metal. This composite method ensures both scrap reduction and maintained manufacturing precision by securing the pre-orifice inserts firmly in place without requiring grinding operations.
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
This approach reduces scrap and ensures proper alignment of pre-orifice inserts, enhancing the consistency and quality of the spray pattern emitted by the spray tip.
Implementation Method 1
secured using silver brazing filler metal or other bonding agents
Data Source
AI summary
A spray tip for a fluid applicator includes a stem configured to be inserted into the fluid applicator. The stem includes a stem pre-orifice portion and an insert receiving portion. The spray tip includes a pre-orifice insert having an inlet and an outlet. The pre-orifice insert is disposed within the insert receiving portion and disposed against a rearward shoulder of the stem.