Atomiser Head Flat Air Cap Reduces Overspray
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Solution Overview
Problem
Conventional pneumatic atomization methods for paint and similar liquids result in high overspray and fluid loss, leading to inefficient paint application and increased material consumption, as well as contamination and cleaning challenges.
Innovation Solution
An atomizer head design featuring a circular liquid nozzle with an air cap having atomizing air nozzles arranged in a ring around the nozzle, where shaping air is directed via nozzles that open obliquely into a flat end face, rather than protruding horns, to achieve uniform atomization and reduce overspray.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional pneumatic atomization methods with protruding horns are used to shape the spray jet, then the spray jet can be formed, but overspray and fluid loss increase significantly
Solution Approach 1:
Instead of having the air cap end face protrude forward to shape the spray jet (conventional design), the invention inverts the approach by having the end face be flat or recessed relative to the spray axis. The shaping air nozzles are arranged on this flat end face, directing air jets that converge to form the spray pattern without the need for protruding horns, thereby reducing overspray and fluid loss.
Solution Approach 2:
The invention transitions from a three-dimensional protruding horn structure to a two-dimensional flat end face arrangement. The shaping air nozzles are positioned on the flat end face plane, and their air jets converge in space to achieve the desired spray shaping effect, eliminating the need for axial protrusion and reducing the associated overspray problems.
2Quantity of substance
If high energy compressed air jets are used for atomization, then effective paint atomization is achieved, but turbulence increases and disperses color in ambient air
Solution Approach 1:
The air cap is designed with different regions having different functions: atomizing air nozzles for paint atomization and shaping air nozzles for spray pattern formation. The shaping air nozzles are positioned to create a controlled air flow field that confines the atomized paint particles, reducing turbulence-induced dispersion while maintaining effective atomization in the local region.
Solution Approach 2:
The shaping air jets act as an intermediary between the atomizing air jets and the ambient environment. They create a controlled boundary layer that guides the atomized paint particles toward the target surface, reducing chaotic turbulence and improving deposition efficiency while minimizing color dispersion in the surrounding air.
3Ease of operation
If protruding horns are used to direct shaping air onto the spray jet, then spray shaping is achieved, but cleaning effort and contamination increase
Solution Approach 1:
Instead of protruding horns that extend forward and are difficult to clean, the invention inverts the design by using a flat or recessed end face. The shaping air nozzles are positioned on this accessible surface, allowing easy access for cleaning and maintenance without requiring disassembly or special tools, thereby reducing cleaning effort and contamination risk.
Solution Approach 2:
The flat end face design allows the air cap to be easily cleaned by the operator without requiring specialized equipment or complex procedures. The smooth, accessible surface enables self-service cleaning, reducing maintenance time and contamination from prolonged exposure to paint residues.
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
This design reduces overspray and paint consumption by up to 30%, minimizes contamination, and lowers cleaning effort, resulting in more uniform paint application and extended equipment lifespan.
Implementation Method 1
In the pneumatic atomization of liquids, which are used, for example, in paint shops, a compressed air jet is used to atomize a jet of liquid.
Implementation Method 2
Such a jet carries a lot of color with it, which is not deposited on the object to be coated, but is dispersed in the ambient air with strong turbulence.
Data Source
Figure 1a~2
Figure 3~4
Figure 5~6
AI summary
The head (1) has a fluid nozzle for discharging fluid, and an air cap (3) with an even front surface (9), in which several atomizer air nozzles (5) are arranged, where form air nozzles (8) are arranged radially outside the atomizer air nozzles. The form air nozzles are subjectable with compressed air for atomizing the fluid discharged via the fluid nozzle, where both nozzles are arranged in a same level. The form air nozzles are designed as boreholes in the front surface of the air cap, where the front surface is arranged perpendicular to the symmetrical axis of the fluid nozzle and the cap.