Electrostatic Coating Head Venting for Ozone-Safe Resin Covers
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Solution Overview
Problem
Electrostatic coating devices release ozone from metal components, which can corrode resin parts and cause high voltage leaks, reducing durability.
Innovation Solution
An electrostatic coating device with a resin cover portion and pilot air introduction/exhaust paths to prevent ozone from staying in gaps, using pilot air to flush out ozone from the cylindrical and planar gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high voltage generator is provided to apply high voltage to paint for electrostatic coating, then coating efficiency is improved, but ozone is released from metal components which corrodes resin parts and reduces durability
Solution Approach 1:
The patent extracts and removes ozone from the gaps between components by introducing pilot air flow through the cylindrical gap between the head portion and cover portion, and the planar gap between the arm portion and head portion. This actively removes the harmful ozone before it can corrode the resin components, resolving the contradiction between maintaining electrostatic coating functionality and preventing ozone-induced degradation.
Solution Approach 2:
The patent introduces pilot air as an intermediary substance to carry ozone out of the gaps. The pilot air flow serves as a mediator that transports the harmful ozone from the metal components through the gaps to the exterior, preventing direct contact between ozone and resin components while maintaining the electrostatic coating function.
2Productivity
If metal components such as air motor and rotating shaft are electrically charged with high voltage, then paint particles are attracted to the coated object, but ozone released from these components stays in gaps and corrodes resin components
Solution Approach 1:
The patent converts the harmful effect of ozone into a beneficial outcome by using the existing pilot air system (originally for valve operation) to also serve as an ozone removal mechanism. The pilot air flow, which would otherwise be wasted, is now utilized to actively exhaust ozone from the gaps, transforming a harmful byproduct into a useful cleaning function.
Solution Approach 2:
The patent actively extracts and removes ozone from the gaps between components by introducing pilot air flow through the cylindrical gap between the head portion and cover portion, and the planar gap between the arm portion and head portion. This actively removes the harmful ozone before it can corrode the resin components, resolving the contradiction between maintaining electrostatic coating functionality and preventing ozone-induced degradation.
3Reliability
If a resin cover portion is used to cover the head portion, then component protection is provided, but ozone accumulates in the gap between the cover portion and head portion, causing corrosion
Solution Approach 1:
The patent transforms the static gap between the cover portion and head portion into a dynamic flow path by introducing pilot air circulation. The gap is no longer a stagnant space where ozone accumulates, but becomes an active channel through which pilot air continuously flows, carrying ozone away from the resin components and preventing corrosion.
Solution Approach 2:
The patent actively extracts and removes ozone from the gaps between components by introducing pilot air flow through the cylindrical gap between the head portion and cover portion, and the planar gap between the arm portion and head portion. This actively removes the harmful ozone before it can corrode the resin components, resolving the contradiction between maintaining electrostatic coating functionality and preventing ozone-induced degradation.
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
Prevents ozone from corroding resin components, improving durability and maintaining coating quality by exhausting ozone effectively.
Implementation Method 1
a high voltage generator provided at the arm portion, which applies a high voltage to the paint supplied to the rotary atomizing head through the valve device, the air motor and the rotating shaft
Implementation Method 2
the electrostatic coating device causes the electrically charged paint particles sprayed from the rotary atomizing head to fly toward the grounded coated object
Implementation Method 3
the head portion is provided with a pilot air introduction path guiding the pilot air exhausted from the switching valve to the cylindrical gap
Implementation Method 4
the arm portion is provided with a pilot air exhaust path exhausting the pilot air from the cylindrical gap to the outside
Implementation Method 5
an air motor provided at the head portion and powered by compressed air
Data Source
AI summary
The durability of resin components can be improved by preventing ozone from staying in gaps where there is no air flow. A cylindrical gap is provided around the outer peripheral side of the head portion between the head portion and the resin cover portion covering the outer peripheral side of the head portion. Moreover, the head portion is provided with a pilot air introduction path guiding the pilot air exhausted from the switching valves to the cylindrical gap. In addition, the arm portion is provided with a pilot air exhaust path exhausting the pilot air from the cylindrical gap to the outside.