Spray Tip Brazed Pre-Orifice Insert Assembly Without OD Grinding
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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 to secure pre-orifice inserts within the stem, allowing for different formation methods of the channel and internal geometry, such as machining, casting, or molding, and utilizing a silver brazing filler metal or other bonding agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If outside diameter grinding is used to secure pre-orifice inserts, then alignment precision can be improved, but material waste and scrap increase significantly
Solution Approach 1:
A brazing material is introduced as an intermediary substance between the pre-orifice insert and the spray tip body. This brazing material facilitates secure attachment while eliminating the need for outside diameter grinding, thus preventing material waste while achieving proper alignment and secure attachment.
Solution Approach 2:
The mechanical grinding process is replaced with a thermal bonding process (brazing). Instead of using mechanical removal of material (grinding) to achieve alignment and attachment, the patent uses thermal energy to melt and bond the brazing material, securing the insert without material removal.
2Strength
If outside diameter grinding is used to secure pre-orifice inserts, then attachment strength can be improved, but assembly time and productivity decrease
Solution Approach 1:
The mechanical grinding process is replaced with a thermal bonding process (brazing). Instead of using mechanical removal of material (grinding) to achieve alignment and attachment, the patent uses thermal energy to melt and bond the brazing material, securing the insert without material removal.
Solution Approach 2:
The patent changes the bonding mechanism from mechanical (grinding) to thermal (brazing). By changing the physical parameter from mechanical force to thermal energy, the process achieves both strong attachment and improved efficiency, as brazing can be performed in a single continuous operation.
3Device complexity
If pre-orifice inserts are secured without brazing, then manufacturing complexity is reduced, but spray pattern consistency deteriorates
Solution Approach 1:
A brazing material is introduced as an intermediary substance between the pre-orifice insert and the spray tip body. This brazing material facilitates secure attachment while eliminating the need for outside diameter grinding, thus preventing material waste while achieving proper alignment and secure attachment.
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 alignment failures, enabling consistent and precise spray patterns with improved assembly efficiency and reduced material waste.
Implementation Method 1
using a slip fit with a filler metal in a brazing process to secure pre-orifice inserts within the stem
Implementation Method 2
utilizing a 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.