Coating Nozzle Clogging Prevention via Upstream Filtration
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Solution Overview
Problem
Nozzle clogging in print heads used for coating applications, such as painting vehicle body components, leads to reduced application efficiency and quality due to solid particles depositing in the nozzles, causing turbulence and potential complete clogging.
Innovation Solution
Incorporating a filter with a specific mesh size adapted to the nozzle diameter upstream of the nozzle to prevent clogging, and using a flushing agent to rinse out residues, along with a sensor system to detect and address nozzle clogging, ensuring continuous operation and high application efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If small nozzle diameter (less than 500 μm or even less than 100 μm) is used in print heads, then application efficiency is improved with minimal overspray, but nozzles are prone to clogging due to paint particle deposition
Solution Approach 1:
The patent applies preliminary action by filtering the coating agent before it reaches the nozzles. A filter with mesh size smaller than the nozzle diameter is positioned upstream to remove paint particles in advance, preventing them from depositing in the nozzles and causing clogging. This allows the system to maintain small nozzle diameters for high application efficiency while protecting against the reliability issue of clogging.
2Manufacturing precision
If small nozzle diameter is used, then coating precision and overspray reduction are improved, but flow stability deteriorates due to turbulence caused by particle deposition
Solution Approach 1:
The filter performs preliminary action by removing paint particles before they can enter the nozzle and disrupt the flow. By filtering the coating agent upstream, the system maintains stable laminar flow through the small nozzle, ensuring both high coating precision and flow stability.
Solution Approach 2:
The filter acts as an intermediary between the coating agent supply and the nozzle. It mediates by selectively removing harmful particles while allowing the coating agent to pass through, thus protecting the nozzle from particle-induced turbulence and maintaining flow stability.
3Reliability
If filter is added upstream of nozzle, then nozzle clogging is prevented, but device complexity increases
Solution Approach 1:
The patent applies the taking out principle by extracting the filtering function from the nozzle itself and placing it upstream in the coating agent supply line. This separation allows the nozzle to remain simple while the filter handles the particle removal, preventing clogging without significantly complicating the nozzle structure.
Solution Approach 2:
The filter serves as an intermediary component that protects the nozzle from particles. By positioning the filter upstream as a separate element in the supply line, the system prevents clogging while maintaining relatively simple nozzle design and ease of maintenance.
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 and detects nozzle clogging, maintaining high application efficiency with minimal overspray, achieving application efficiencies of at least 80% and suitable for large-area coating of automotive body parts with reduced downtime.
Implementation Method 1
Incorporating a filter with a specific mesh size adapted to the nozzle diameter upstream of the nozzle to prevent clogging
Implementation Method 2
using a flushing agent to rinse out residues
Data Source
AI summary
The disclosure relates to a coating installation for coating components with a coating agent, in particular for painting motor vehicle body components, with a nozzle applicator, in particular a print head, with at least one nozzle for delivering a coating agent jet of the coating agent onto the component to be coated. The disclosure provides a device for preventing and/or detecting clogging of the nozzle.