Turn Nozzle Glass Coating for Non-Line-of-Sight Coverage

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Solution Overview

Problem

Conventional spray coating methods for glass pharmaceutical packaging face challenges in achieving uniformity and avoiding defects due to overlapping sprays and complex shapes, leading to mechanical performance issues and product sterility risks.

Innovation Solution

A spray coating apparatus with a turn nozzle assembly that redirects overspray using a pressurized gas to coat non-line of sight areas, utilizing a single atomizer and a turn nozzle to distribute droplets efficiently across glass objects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple spray nozzles are used to coat different areas of glass objects, then coverage is improved, but overlapping sprays cause visible defects and thickness variation

Engineering Contradiction:

Improvecoating uniformityVSAvoidoverlapping spray defects

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

A turn nozzle assembly acts as an intermediary device between the main spray nozzle and the heel area of glass objects. The turn nozzle redirects overspray from the main nozzle to coat the heel area, eliminating the need for direct spraying and preventing overlapping spray defects while ensuring uniform coating thickness

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The coating process is segmented into two distinct paths: the main spray nozzle coats the primary surfaces, while the turn nozzle assembly redirects overspray to specifically coat the heel area. This segmentation allows each nozzle to serve its designated area without overlap, preventing thickness variation and visible defects

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If dip coating is used to coat glass objects, then coating coverage is improved, but material waste increases and product appearance varies

Engineering Contradiction:

Improvecoating coverageVSAvoidcoating material waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The turn nozzle assembly converts the harmful overspray that would normally be wasted into a beneficial coating for the heel area. By redirecting the overspray onto the heel, the system eliminates material waste while ensuring complete coverage of previously inaccessible areas

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The main spray nozzle serves multiple functions: it directly coats the primary surfaces and simultaneously generates overspray that is redirected to coat the heel area. This multi-functionality eliminates the need for separate coating operations, reducing material waste while ensuring comprehensive coverage

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If thicker application of coating material is used, then coating durability is improved, but film mobility increases causing thickness variation

Engineering Contradiction:

Improvecoating durabilityVSAvoidcoating thickness uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The system applies coating material with locally optimized thickness: the main spray nozzle applies an appropriate thickness to primary surfaces, while the turn nozzle redirects overspray to apply a controlled, uniform thickness to the heel area. This local quality control prevents film mobility issues while ensuring adequate durability

Inventive Principle:

Principle #3Local quality

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 apparatus ensures uniform coating on glass objects by redirecting overspray, reducing material waste and variability, and minimizing mechanical defects, thereby enhancing product quality and safety.

Implementation Method 1

A turn nozzle assembly includes a turn nozzle that is arranged and configured to direct a flow of pressurized gas to redirect the coating material onto the non-line of sight area

Methodology Applied

Scientific EffectPressurized gas flow: Jet

Data Source

PatentUS20260008072A1Spray coating apparatuses with turn nozzle assemblies and methods of coating glass objects

Publication Date: 2026.01.08 CORNING INC

AI summary

A spray coating apparatus that applies a coating material onto outer surfaces of glass objects includes a coating material source that includes a coating material. A spray nozzle assembly includes a spray nozzle fluidly connected to the coating material source. The spray nozzle is arranged and configured to direct the coating material in a first direction toward the glass object and provide an overspray amount of the coating material by the glass object such that the overspray amount bypasses a non-line of sight area of the glass object. A turn nozzle assembly includes a turn nozzle fluidly connected to a pressurized gas source. The turn nozzle is arranged and configured to direct pressurized gas in a second direction different than the first direction toward the non-line of sight area of the glass package to redirect the coating material onto the non-line of sight area.