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Produced by Kyoritsu Gokin Co., Ltd.& Everloy Shoji Co., Ltd.

Solution cases

Uniform high viscosity liquid spray at 360 degrees for automotive

Industry Automotive Equipment Rust preventive coating equipment
Application Chemical liquid & paint coating Result Even spray distribution
Nozzle - Spray Fluid Chemical liquid

Challenges

Spray nozzles are used in a process for high viscosity rust preventive coating on cars.
In this case, one of our customers requested a 360 degree uniform rust preventive spray at a low cost. In general, any even high viscosity liquid spray is not easy to control, and also a nozzle along the objects is required.

Additionally, 1,600 pieces of nozzles had to be delivered in 6 months. The design, the development, the prototype, the manufacturing and the delivery had to be completed within 6 months. The customer contacted us since their alternative suppliers were not able to meet the customer's requests including the delivery.

Solution

The current nozzle is an orifice type one. This type of nozzle costs more and its lead time is longer since the orifice type nozzle is embedded, which was a factor that their alternative suppliers was not able to meet the customer's requests. Figuring out that rust preventive coating was possible, based on our experiences for high viscosity spray such as seal material, we proposed a slit shape spray nozzle. Compared with the orifice type nozzle, the slit shape spray nozzle is more cost-effective and also its manufacturing lead time is shorter.

Trial

We evaluated the current nozzle with some water since the chemical liquid was not provided. Based on the flow rate from the evaluation, we selected the slit diameter. We made a prototype with a slit on different level on the circumference, and tested the spray. Our first prototype didn't provide an uniform distribution due to the nozzle internal pressure difference. Therefore, we made another prototype, changing the flow passage hole from 1 to 3.

This prototype created the uniform 360 degree spray. After our internal test, the prototype was installed in a customer's test equipment to coat some rust preventive. The test resulted in the uniformity even by some rust preventive. With the uniformity confirmation, we moved on the mass productions.

Result

This project was one of the most difficult ones because of the 360 degree uniform rust preventive spray and the short lead time from design to delivery. However, with our expertise such as design and development, analysis and evolution experiences and our mass production system, this case shows that we were able to meet the customer's requests.


Although we had never had any slit type spray nozzle achievements, trying to change to the slit type spray nozzle, we were able to create the cost-effective slit type nozzle. In general, compared with the orifice type spray nozzles, the slit shape spray nozzle is more cost-effective and its manufacturing lead time is shorter, which made the customer's requested delivery possible.

As this case shows, we are able to design spray nozzles including some prototypes and test the nozzles to meet customer's requests. We are surely able to propose some spray nozzles with some extra benefits.


We devote ourselves to the solutions in any issues, starting from the design and the development even though the other spray nozzle manufacturers decline to work on the issues. Including this, please contact us also for any delivery requests. We will design a nozzle to get it delivered by the requested date. Please do not hesitate to ask us if you have any spray nozzle issues currently.


Other Solution cases

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