Internal Conduit Coating Head for On-Demand Mixing and Atomization
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Solution Overview
Problem
Existing coating technologies for internal surfaces of conduits, such as water supply and sewage lines, face challenges including rapid set times for activated coatings, requiring continuous operation and extensive purging systems, which are costly and environmentally cumbersome, especially for small diameter pipes.
Innovation Solution
A coating apparatus combining a high-pressure mixing gun with a rotary atomizer, allowing for efficient mixing and atomization of coating components, enabling smooth and uniform application without the need for purging systems, and allowing for interruptions in the coating process without solvent flushing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a static mixer is used to mix coating components, then the coating can be supplied to a rotating coating application head, but the whole coating operation must be carried out as a single operation due to rapid set time, and extensive purging systems are required
Solution Approach 1:
The patent extracts the mixing function from a static mixer and relocates it to a portable mixing unit with a high-speed rotor that mixes coating components on-demand directly at the application point. This eliminates the need for extensive purging systems required by static mixers that must be discarded and cleaned after use.
Solution Approach 2:
The patent introduces a computer-controlled system as an intermediary that coordinates the mixing, atomization, and application processes. This control system manages the rapid mixing and application timing to ensure complete coating before set occurs, enabling operation continuity without requiring the entire system to run as a single uninterrupted operation.
2Manufacturing precision
If activated coating is applied with rapid set time, then smooth and uniform coating can be achieved, but the coating operation cannot be interrupted and requires immediate retraction and solvent flushing
Solution Approach 1:
The patent performs preliminary mixing of coating components in a portable unit immediately before application, ensuring the coating is ready for application at the exact moment needed. This on-demand mixing allows the coating to be applied smoothly and uniformly while maintaining the ability to pause and resume operations without waste.
Solution Approach 2:
The patent eliminates the need to discard and clean equipment by using a portable mixing unit that can be easily removed and replaced. When interruption is needed, the mixing unit can be swapped out without solvent flushing, and the process can resume with a new mixing unit, maintaining both coating quality and operational flexibility.
3Reliability
If solvent flushing is used to clean equipment after coating operation, then residual activated coating is removed, but environmental hazards increase and operational costs rise
Solution Approach 1:
The patent extracts the mixing and application functions into a portable, self-contained unit that can be completely removed from the system after use. This eliminates the need for in-solvent flushing of fixed equipment, as the portable unit can be disposed of or replaced without environmental cleanup requirements.
Solution Approach 2:
The patent employs a portable mixing unit that can be discarded or replaced after a single use, eliminating the need for expensive and environmentally harmful solvent flushing procedures. The disposable nature of the portable unit makes complete cleanup unnecessary, reducing both environmental impact and operational costs.
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 apparatus provides a seamless and efficient application of activated coatings to internal surfaces of conduits, particularly small diameter pipes, eliminating the need for purging systems and allowing for interruptions in the coating process without solvent use, thereby reducing environmental impact and operational costs.
Implementation Method 1
a high-pressure mix gun for mixing the at least first and second components such that the activated coating is generated
Implementation Method 2
The rotary atomizer cooperates with the activated coating such that the activated coating is atomized so that application of the atomized activated coating onto the internal surface of the conduit is permitted
Implementation Method 3
This atomizes the activated coating and centrifugally delivers it to the pipe wall interior
Data Source
AI summary
A coating apparatus is disclosed for applying an activated coating onto an internal surface of a conduit, the coating being activated by mixing at least a first and a second component. The apparatus includes a high-pressure mix gun for mixing the at least first and second components such that the activated coating is generated. A rotary atomizer is operatively connected to and cooperates with the high pressure mix gun for receiving the activated coating from the high pressure mix gun. The rotary atomizer cooperates with the activated coating such that the activated coating is atomized so that application of the atomized activated coating onto the internal surface of the conduit is permitted.