Coating Torch Local Gas Flow for Overspray Removal
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Solution Overview
Problem
Existing coating devices produce significant overspray, which is inefficiently removed by powerful and costly suction devices, leading to reduced adhesion in subsequent coating layers due to incomplete removal during multi-layer processes.
Innovation Solution
A coating device utilizing a local compressed gas flow to remove overspray, in addition to a compressed gas nozzle for transporting melted coating material, ensures efficient removal by directing a gas flow specifically to the surface, reducing the need for high-capacity suction systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a powerful global suction device is used to remove overspray, then overspray removal capability is improved, but device complexity and cost increase
Solution Approach 1:
The suction device is divided into multiple local suction nozzles distributed around the coating torch, each responsible for a specific local area. This segmentation allows effective overspray removal without requiring a single powerful global suction system, thereby reducing overall device complexity and cost while maintaining effective overspray management.
Solution Approach 2:
Instead of applying uniform suction across the entire coating area, local suction nozzles are positioned strategically to create focused suction zones where overspray occurs. This local quality approach enables effective overspray removal with lower overall suction power requirements, reducing device complexity and operational costs.
2Device complexity
If a less powerful suction device is used, then device complexity and cost are reduced, but overspray removal effectiveness deteriorates leading to reduced adhesion in multi-layer coating
Solution Approach 1:
Local suction nozzles are positioned upstream or at the same level as the coating torch, creating suction zones before overspray can accumulate on the substrate. This preliminary action prevents overspray from settling on the surface, ensuring proper adhesion for subsequent coating layers while using less powerful suction devices.
Solution Approach 2:
The local suction nozzles act as intermediaries between the coating process and the substrate, intercepting overspray particles before they can settle on the surface. This intermediary function maintains coating adhesion reliability while allowing the use of simpler, less powerful suction systems.
3Object-affected harmful factors
If compressed gas flow is used for local overspray removal, then overspray removal efficiency is improved, but energy consumption increases
Solution Approach 1:
The compressed gas system is merged with the existing coating process by using the same gas supply infrastructure for both coating material transport and overspray removal. This integration allows local overspray removal without requiring separate energy-intensive gas generation systems, minimizing additional energy consumption.
Solution Approach 2:
The compressed gas system performs multiple functions: transporting coating material through the torch and simultaneously generating gas flows for local overspray removal. This multi-functionality eliminates the need for dedicated energy-consuming systems for each function, reducing overall energy consumption while maintaining effective overspray management.
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 local removal of overspray enhances adhesion and reduces costs by allowing for a less powerful suction system, ensuring consistent coating quality across multiple layers.
Implementation Method 1
at least one further compressed gas outlet which generates a compressed gas flow directed onto the surface to be coated
Implementation Method 2
the droplets of molten wire are then caught by the compressed air flow and discharged through the nozzle
Implementation Method 3
A radially directed nozzle is provided at the lower end of the torch shaft through which the droplets of molten coating material are discharged
Data Source
Figure 1~5
AI summary
The burner melts coating material and a nozzle directs it onto the workpiece. In novel design, a second compressed gas outlet directs a compressed gas flow onto the surface to be coated. A lengthy main body (1) is arranged on the end face of the distributor. The distributor has a rotary drive turning it about the longitudinal axis of the body. The distributor is carried along the component surface, along its axis of rotation. The compressed gas flow is ahead of the jet of molten material, in the direction of travel. A suction device is included. The suction device is ahead of the compressed gas nozzle and/or the second compressed gas outlet. Inside the main body, the compressed gas supply feeds the compressed nozzle and/or the second compressed gas outlet. The compressed gas nozzle directs the spray jet normally against the surface being coated. Before coating, contaminants on the surface are removed with a compressed gas flow.