One-piece actuator with disruptive vortex chamber for spray uniformity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mechanical breakup (MBU) valve actuators for pressurized dispensers do not efficiently generate a uniform and enhanced spray pattern, which is crucial for effective product dispensing.
Innovation Solution
The development of a one-piece DBU valve actuator featuring a disruptive vortex chamber, a ramp structure, and a nozzle that work together to create a vortex swirl spray pattern, enhancing mechanical breakup and spray uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional MBU structures are used, then the device complexity is reduced, but the spray uniformity and mechanical breakup efficiency deteriorate
Solution Approach 1:
The actuator is divided into distinct functional segments: a ramp structure for initial flow direction, a vortex chamber for swirl generation, and a nozzle for spray discharge. This segmentation allows each component to be optimized for its specific function, achieving superior spray uniformity through the vortex chamber while maintaining manufacturing feasibility through modular design approaches
Solution Approach 2:
The ramp structure is positioned at specific angles (20-60 degrees) relative to the chamber axis, introducing a dimensional component to the flow path. This angular configuration creates the vortex swirl motion that enhances mechanical breakup and spray uniformity, transforming simple linear flow into three-dimensional rotational flow patterns
2Productivity
If conventional MBU structures are used, then the manufacturing process is simpler, but the mechanical breakup efficiency deteriorates
Solution Approach 1:
The ramp structure and vortex chamber are merged into a single integrated component in the one-piece embodiment, allowing the complex vortex-generating geometry to be manufactured as one unit. This merging maintains mechanical breakup efficiency while simplifying manufacturing by eliminating the need for precise assembly of multiple parts
Solution Approach 2:
The ramp angle parameter is optimized within the 20-60 degree range to maximize vortex generation and mechanical breakup efficiency. By treating the ramp angle as a variable parameter rather than a fixed value, the design achieves superior breakup performance while the one-piece construction maintains manufacturing ease through standard molding or machining processes
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 DBU valve actuator achieves enhanced mechanical breakup and a more even spray pattern compared to conventional MBU structures, ensuring effective product dispensing and reduced waste.
Implementation Method 1
a chamber structure that generates a vortex and communicates with the ramp structure
Implementation Method 2
The actuator disruptively breaks up product and generates a vortex swirl spray pattern
Data Source
AI summary
A one-piece actuator for a valve includes a ramp structure providing a linear sloping passageway communicating with the valve, a chamber that generates a vortex and communicates with the ramp structure, and a nozzle that communicates with the chamber to dispense and mechanically break apart product upon actuation of the valve from an aerosol container. The ramp structure is angled 20 to 60 degrees relative to the chamber.