Two-Tier Nozzle for Acoustic Tile Edge Coating

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Solution Overview

Problem

Existing vacuum coating technologies for acoustical tiles often result in over-application of paint or coating, leading to ridges on the tiles, which are aesthetically undesirable and wasteful, and require additional post-coating treatments to correct.

Innovation Solution

A vacuum coating machine insert with a two-tier step nozzle design that aligns with the flange height of the tile, featuring a staging chamber, delivery channel, and nozzle with a two-tier step at the exit, allowing precise coating application focused on the edge of the tile to prevent ridge formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional vacuum coating technology is used to apply coating to acoustical tiles, then the coating can be applied to the tile surface, but over-application occurs leading to ridge formation on the tile edges

Engineering Contradiction:

Improvecoating uniformityVSAvoidridge formation

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The nozzle is divided into two distinct tiers: a first tier for applying coating to the upper surface and a second tier for applying coating to the edge. This segmentation allows each tier to be optimized for its specific function, preventing over-application and ridge formation at the edge while maintaining proper coating on the upper surface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each tier of the nozzle is configured with different characteristics tailored to its specific application area. The first tier is optimized for upper surface coating while the second tier is optimized for edge coating, allowing each region to receive the appropriate coating quality without interference from the other.

Inventive Principle:

Principle #3Local quality

2Reliability

If coating is applied to preserve acoustical properties, then the coating must be kept very thin, but this makes it difficult to achieve adequate coverage and protection

Engineering Contradiction:

Improveacoustical property preservationVSAvoidcoating thickness

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

By segmenting the coating application into two tiers, the system can apply thinner coating layers more precisely to each area, ensuring adequate coverage while maintaining the thin coating requirement for preserving acoustical properties.

Inventive Principle:

Principle #1Segmentation

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 solution effectively prevents over-application of paint, reducing waste and maintaining the aesthetic appeal of the tiles by ensuring a uniform coating along the flange without extending beyond the surface, thus enhancing the coating process efficiency.

Implementation Method 1

Vacuum coating is one process that results in a thin coating

Methodology Applied

Scientific EffectVacuum coating: Physical Vapour Deposition

Implementation Method 2

The flow channel has a staging chamber, a delivery channel, and a nozzle

Methodology Applied

Scientific EffectFlow channeling:

Data Source

PatentUS20240238834A1Tile edge coating apparatus and method comprising same

Publication Date: 2024.07.18 KNAUF GIPS KG

AI summary

An insert for a vacuum coating machine includes a body having a flow channel. The flow channel has a staging chamber, a delivery channel, and a nozzle. The nozzle includes a two-tier step proximate a nozzle exit that is configured to application a coating out of the flow channel and onto a surface.