Electronic Ignition and Single Air Manifold for Thermal Spray
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Solution Overview
Problem
Existing thermal spray systems face challenges in ease of operation and efficiency due to complex ignition systems, multiple air supply lines, and fouling issues, which complicate the handling and performance of polymer or polymer composite coatings.
Innovation Solution
The introduction of an electronic ignition system, a single air supply manifold, and an air-shielded powder feed tube simplifies operation, improves ignition reliability, and prevents fouling by creating a controlled air environment for the polymer spray, enhancing the uniformity and efficiency of the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional spark igniter is used to ignite the burner, then ignition can be achieved, but the system becomes complex and difficult to operate due to high voltage cable requirements
Solution Approach 1:
The patent replaces the mechanical/conventional high voltage spark igniter system with an electronic ignition system. This electronic system eliminates the need for heavy high voltage cables and complex mechanical components, providing reliable ignition through electronic control while reducing overall system complexity and improving ease of operation.
Solution Approach 2:
The patent introduces an electronic intermediary system between the power source and the burner ignition. This electronic ignition system acts as a mediator that converts electrical energy into a controlled ignition source, replacing the direct high voltage cable connection and reducing system complexity while maintaining ignition reliability.
2Adaptability or versatility
If multiple individually controlled air lines are used to provide air and fuel mix, then combustion control is achieved, but the system becomes complex with numerous controls and a large bundle of tubes
Solution Approach 1:
The patent merges multiple individually controlled air lines into a single air supply line. This single line incorporates integrated control mechanisms that regulate air flow to both the burner and powder feed systems, reducing the number of separate tubes and controls while maintaining the flexibility needed for proper combustion control.
Solution Approach 2:
The patent creates a universal air supply system where a single air line serves multiple functions - supplying air for combustion, air for powder atomization, and air for cooling. This multi-functional approach eliminates the need for separate dedicated air lines for each function, reducing system complexity while preserving operational versatility.
3Productivity
If the powder feed tube is exposed to the thermal spray environment, then powder delivery is achieved, but the applicator becomes fouled with polymer after extended use
Solution Approach 1:
The patent extracts the powder feed tube from the direct thermal spray environment by positioning it outside the hot gas and flame zones. The tube delivers powder to the spray area without being exposed to the fouling conditions, thereby maintaining consistent performance and eliminating polymer buildup on the feed tube while preserving efficient powder delivery.
Solution Approach 2:
The patent introduces an intermediary mechanism for powder delivery that separates the feed tube from the thermal spray zone. This intermediary approach allows powder to be delivered to the atomization area without the feed tube itself being exposed to high temperatures and molten polymer, preventing fouling while maintaining productivity.
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 solution streamlines the operation of thermal spray systems, ensures reliable ignition, prevents fouling, and achieves a superior spray pattern with even powder distribution, thereby improving the usability and effectiveness of polymer or polymer composite coatings.
Implementation Method 1
an electronic igniter that creates a spark to ignite the combustible gas mixture
Implementation Method 2
The shielding air stream causes the polymer air stream to contract—just downstream of the feed tube exit—and then expand
Data Source
AI summary
An apparatus and method for forming a fusible coating or structure comprising a combustor that is operative to combust a fuel and contain the resulting flame to produce combustion products; components for cooling the combustion products to produce a hot carrier gas stream; and elements for introducing fusible material into the hot carrier gas stream; made lightweight and easier to operate through the addition of a continuous electronic ignition system and a single air manifold.