Two-Substance Spray Valve Pneumatic Gap Control
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Solution Overview
Problem
Existing spray devices for applying release agents or antistatic agents to plate-shaped workpieces lack precision and reliability, often resulting in adhesive residues or leaks, and require complex retrofitting, especially in continuous processing machines.
Innovation Solution
A two-substance spray valve with a valve housing and piston that combines air and liquid through adjustable channels and nozzles, allowing for precise control over the mixture and flow, eliminating the need for check valves and enhancing safety and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spray devices with Venturi nozzles are used, then the structure is simple, but the fluid application precision is insufficient and process reliability is poor due to check valve clogging
Solution Approach 1:
The patent removes the check valve from the spray device structure, extracting the problematic component that causes clogging and reliability issues. The simplified structure without check valves eliminates the source of failure while maintaining spray functionality through alternative fluid control mechanisms.
Solution Approach 2:
The patent employs pneumatic principles by using a gas-tight connection system and pressure differential control to regulate fluid flow. The spray device utilizes pneumatic pressure management to achieve precise fluid application without relying on mechanical check valves, thereby improving both precision and reliability.
2Reliability
If check valves are incorporated in spray devices, then fluid flow control is achieved, but the system becomes unreliable due to clogging and improper closing
Solution Approach 1:
The patent eliminates the check valve mechanism entirely, removing the component responsible for clogging and unreliable operation. This extraction simplifies the system while improving reliability by removing the failure-prone element.
Solution Approach 2:
The spray device employs self-regulating fluid flow control through pneumatic pressure differentials and gas-tight connections, eliminating the need for separate check valves. The system automatically maintains proper fluid flow and sealing without additional mechanical components that could fail.
3Manufacturing precision
If complex retrofitting is performed in continuous processing machines, then spray precision is improved, but the implementation difficulty and time increase
Solution Approach 1:
The patent designs the spray device as a modular, self-contained unit that can be independently installed and retrofitted to existing continuous processing machines. This segmentation allows for straightforward integration without requiring complex modifications to the overall machine system, thereby reducing retrofitting time and effort.
Solution Approach 2:
The spray device is designed with universal applicability to various continuous processing machines through standardized connections and pneumatic interfaces. This multi-functionality enables the same device design to be retrofitted across different machine types, significantly reducing the time and complexity required for implementation.
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 two-substance spray valve provides precise and reliable application of fluids, preventing adhesive contamination and ensuring efficient operation in continuous processing machines with improved safety and ease of retrofitting.
Implementation Method 1
The valve piston is mounted for displacement along the axis by an overpressure applied in the first fluid channel
Implementation Method 2
A pressure generator for pumping a gas into the spray container to generate an overpressure in the liquid space
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Two-component spray valve (1), comprising at least a valve housing (2) and a valve piston (3) movable along an axis (4), a first material channel (5) extending through the valve housing (2) and the valve piston (3) to the axis (4), then running along the axis (4) and entering a mixing chamber (6) and extending further to a nozzle outlet (7), and a second material channel (8) opening into the mixing chamber (6) via an adjustable inlet gap (9), wherein the valve piston (3) is displaceably mounted along the axis (4) by an overpressure applied in the first material channel (5) and thereby adjusts the inlet gap (9).