Compact HVLP Spray Gun Layout Using a High-Speed Brushless Fan
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Solution Overview
Problem
Conventional HVLP-type paint guns are heavy and large due to the use of low-speed brush DC motors, making them difficult for users to handle and increasing workload during coating spraying applications.
Innovation Solution
A spray gun design featuring a high-speed brushless motor with a rated power between 250 W and 500 W and a rotational speed range of 60,000 rpm to 120,000 rpm, integrated with a fan module that reduces the overall size and weight, allowing for a more compact and ergonomic layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a low-speed brush DC motor is used for HVLP-type paint spraying, then the motor can provide sufficient torque for fan rotation, but the motor becomes large and heavy, increasing the overall weight and size of the spray gun
Solution Approach 1:
The patent changes the operating parameters of the motor system by switching from a low-speed high-torque brush DC motor to a high-speed brushless motor. The high-speed motor operates at significantly higher rotational speeds, which allows for a smaller motor size while maintaining the necessary power output for fan rotation and paint atomization.
Solution Approach 2:
The patent replaces the mechanical brush contact system with a brushless motor system that uses electromagnetic fields for commutation. This substitution eliminates the need for carbon brushes and commutators, allowing for a more compact motor design with reduced weight while maintaining reliable torque delivery through electronic control.
2Device complexity
If a low-speed brush DC motor is used, then the motor structure is simpler, but the rotational speed is low requiring a larger fan diameter to achieve sufficient intake air volume
Solution Approach 1:
The patent fundamentally changes the speed parameter of the motor system. The high-speed brushless motor operates at much higher rotational speeds compared to conventional low-speed motors, which directly reduces the required fan diameter to achieve the same air intake volume. This parameter change allows for a more compact overall design.
Solution Approach 2:
The high-speed motor provides preliminary high-velocity airflow that enhances the atomization process at the nozzle. The increased motor speed creates stronger airflow velocities that improve paint atomization quality without requiring larger fan dimensions, thereby reducing the overall device volume.
3Quantity of substance
If a large fan diameter is used to increase intake air volume, then sufficient air flow is achieved, but the tail of the spray gun becomes large and weight is concentrated, making it difficult for the user to hold
Solution Approach 1:
The patent changes the velocity parameter of the airflow system. The high-speed brushless motor generates high-velocity airflow that achieves the required air intake volume with a smaller fan diameter. This velocity-based approach redistributes the weight toward the center of the spray gun, improving balance and user comfort during operation.
Solution Approach 2:
The patent transitions from a low-speed/high-volume approach to a high-speed/high-velocity approach. This dimensional change in the operational parameters allows the same air intake function to be achieved with a more compact fan design, thereby reducing the tail size and improving the center of gravity distribution for better ergonomics.
4Weight of moving object
If a high-speed brushless motor is used, then the size and weight of the fan module are reduced, but the motor generates vibrations that need to be dampened
Solution Approach 1:
The patent applies vibration damping structures and balancing mechanisms to the high-speed brushless motor before deployment. These pre-installed vibration control features attenuate the harmful vibrations generated by high-speed operation, protecting the spray gun structure and reducing user discomfort while maintaining the benefits of the compact high-speed motor design.
Solution Approach 2:
The patent converts the vibrational energy generated by the high-speed motor into useful airflow dynamics. The controlled vibrations are channeled to enhance air mixing and paint atomization at the nozzle, transforming what would be a harmful byproduct into a functional advantage that improves spray quality.
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 use of a high-speed brushless motor in the spray gun reduces the size and weight of the fan module, resulting in a more comfortable and manageable tool for users, with improved ergonomics and reduced user load during operation.
Implementation Method 1
a fan module, received in the first shell and configured to generate an atomization airflow, the fan module comprises a brushless motor and a fan driven to rotate by the brushless motor
Implementation Method 2
a fan driven to rotate by the brushless motor
Implementation Method 3
atomizes and sprays paint at a nozzle by the Venturi principle
Data Source
AI summary
A spray gun includes a first shell, a fan module, a sleeve, a nozzle assembly and a spray bar assembly. The fan module includes a brushless motor. The sleeve is formed or mounted on the first shell. The nozzle assembly is disposed at an end of the sleeve. The spray bar assembly is received in the sleeve and configured to move along a longitudinal axis of the spray bar assembly to open or close the liquid outlet. The fan module has a maximum outer diameter D1 between 30 mm and 80 mm, and a rotation axis of the brushless motor is parallel to or coincident with the longitudinal axis of the spray bar assembly. In this way, the spray gun is more compact and consistent with ergonomics.