Brush Atomization Device for Uniform Mist Distribution
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Solution Overview
Problem
Conventional misting and atomization systems face issues such as clogging, uneven paint distribution, overspray, bounceback, high energy consumption, complexity, and limited adaptability, leading to inefficiencies and safety concerns in painting and cooling applications.
Innovation Solution
An atomization device utilizing a brush with filaments that undergo limited adhesion and controlled oscillation, releasing liquid droplets in a fine mist through capillary openings, which absorbs and disperses liquid without flooding, allowing for efficient and controlled atomization with minimal air flow and overspray.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure is used to achieve optimal atomization, then droplet size is reduced, but paint delivery rate becomes uncontrollably high (over five gallons per hour)
Solution Approach 1:
The patent divides the liquid flow into multiple discrete streams through multiple capillary tubes, each producing its own atomization zone. This segmentation allows control over total paint delivery while maintaining fine droplet sizes from each individual capillary, preventing the uncontrollable high flow rates associated with single high-pressure nozzles.
Solution Approach 2:
The patent uses a porous or solid matrix containing multiple capillary tubes with controlled pore sizes. This porous structure provides capillary action that draws liquid through the walls of the rotating element, enabling precise control of paint delivery rate while maintaining the pressure differential needed for fine atomization.
2Manufacturing precision
If high pressure is used to force spray through a tiny hole, then atomization is improved, but nozzle wear increases rapidly
Solution Approach 1:
The patent replaces traditional tiny orifices with capillary tubes whose walls provide the flow restriction. The capillary action through the tube walls distributes liquid flow along the length of the tube, preventing concentration of wear at a single point and significantly extending the life of the atomization element while maintaining spray quality.
Solution Approach 2:
The liquid is drawn through the capillary tube walls before reaching the discharge end, with flow occurring along the entire length of the tube. This preliminary distribution of flow prevents the formation of high-velocity jets that would cause rapid erosion at narrow openings, thereby reducing nozzle wear.
3Productivity
If conventional spray methods are used to deliver paint faster, then painting speed is improved, but the applicator becomes clogged
Solution Approach 1:
The capillary tube structure with its controlled pore sizes provides uniform flow distribution that prevents paint from pooling or stagnating in any single location. The continuous capillary action through the tube walls ensures steady, clog-free flow even at higher painting speeds, maintaining reliability while improving productivity.
Solution Approach 2:
The rotating element with multiple capillary tubes continuously delivers paint in a uniform manner throughout the rotation cycle. This continuous, evenly distributed flow prevents the intermittent surges and stagnation that cause clogging in conventional spray systems, enabling faster painting without sacrificing reliability.
4Productivity
If conventional spray devices force spray through a tiny hole, then a spray pattern is produced, but distribution uniformity becomes uneven
Solution Approach 1:
By dividing the paint delivery into multiple capillary tubes arranged in a specific pattern, the system creates multiple fine spray streams that collectively form a uniform overall pattern. Each capillary contributes equally to the spray distribution, ensuring even paint application across the target surface.
Solution Approach 2:
The capillary tube walls provide uniform flow distribution through their porous structure, with liquid emerging evenly along the length of each tube. This creates a consistent spray pattern with uniform paint distribution, eliminating the uneven center-heavy patterns typical of conventional single-orifice nozzles.
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 device produces a consistent, fine mist with smaller droplet sizes, reducing overspray and energy consumption, enabling precise paint application and efficient cooling while being easy to maintain and adapt for various liquids and orientations.
Implementation Method 1
The top plate includes a plurality of capillary openings that extend through the top plate from a top surface to a bottom surface, and absorb liquid from the space
Implementation Method 2
the filaments maintain contact with the plate, carrying with them this liquid
Data Source
Figure 1
Figure 2
Figure 3~4C
AI summary
An atomization device including a contact plate including a plurality of capillary openings, a liquid source in fluid communication with the contact plate, and a brush including a plurality of filaments. As the brush rotates a first radial direction, the filaments adhere small amounts of liquid from within the capillary openings, flex when in contact with the contact plate, and release when contact is broken with the contact plate to project liquid from the filaments as they oscillate. A portion of the contact plate includes a spirally curved surface with which the filaments contact, wherein the radius decreases along a path following the first radial direction.