Electrostatic Rotary Cup Glaze Spraying for Large Ceramic Tiles
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Solution Overview
Problem
The existing equipment in the building ceramic industry struggles to stably and evenly distribute thin-layer water-based glaze with a specific gravity between 1.20 and 1.50 and a glaze amount between 0 g/m2 and 120 g/m2 on large-scale products.
Innovation Solution
The electrostatic spraying equipment includes a glaze storage and adjustment device, a transfer isolation device, an electrostatic rotary cup spray gun, a PLC intelligent controller, and a high-voltage electrostatic generator, which work together to uniformly atomize and coat the glaze on large-scale products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional glaze throwing cabinet or high-pressure automatic glaze spraying system is used, then large-area glazing can be achieved, but the working specific gravity is lower than 1.55 and glaze flatness cannot meet requirements when glazing amount is less than 300 g/m2
Solution Approach 1:
The patent replaces traditional mechanical glaze spraying systems with an electrostatic spraying system. The electrostatic rotary cup spray gun uses electrostatic field forces to atomize and distribute glaze, substituting mechanical high-pressure spraying. This enables precise control of thin-layer glaze application (0-120 g/m2) while maintaining high flatness standards, resolving the contradiction between large-area coverage and glaze flatness precision.
Solution Approach 2:
The patent changes the working specific gravity parameter to between 1.60 and 1.80, optimized for electrostatic spraying. This parameter adjustment enables the system to achieve both large-area coverage and high glaze flatness, as the optimized specific gravity allows proper atomization and distribution of thin-layer glaze without the limitations of traditional systems.
2Manufacturing precision
If bell jar glaze spraying is used to achieve specific gravity exceeding 1.70, then flatness is high, but glaze spraying is easy to break and bifurcate when glazing amount is less than 300 g/m2
Solution Approach 1:
The patent employs a rotary cup design that rotates at controlled speeds to dynamically atomize glaze. This dynamic atomization process creates fine, uniform glaze particles that are electrostatically charged and distributed evenly. The rotation mechanism prevents glaze breakage and bifurcation by maintaining continuous, controlled flow, thereby improving spraying stability while achieving high flatness.
Solution Approach 2:
The patent replaces static bell jar spraying with dynamic electrostatic rotary cup spraying. The electrostatic field combined with rotational motion creates a more stable and controllable atomization process, eliminating the glaze breakage and bifurcation issues inherent in traditional bell jar systems while maintaining high flatness standards.
3Manufacturing precision
If screen plate printing or rotary screen printing machine is used, then glazing can be achieved, but specification problem occurs when specification exceeds 1.2 m and accuracy of equipment is difficult to meet
Solution Approach 1:
The electrostatic rotary cup spray gun is designed as a universal glazing device that can handle various product sizes and specifications. The electrostatic field and rotary atomization mechanism adapt to different product dimensions, eliminating the specification limitations of screen printing equipment. This enables accurate glazing on large-scale products exceeding 1.2 m without compromising equipment accuracy.
Solution Approach 2:
The patent replaces mechanical screen printing systems with electrostatic spraying. The electrostatic field provides precise control over glaze distribution regardless of product size, eliminating the accuracy degradation that occurs with large specifications in mechanical printing systems. This enables consistent glazing accuracy across various product scales.
4Adaptability or versatility
If ink-jet printing is used for glazing, then digital glaze can be implemented, but working specific gravity is less than 1.40 and glazing amount in a single channel is difficult to exceed 40 g/m2
Solution Approach 1:
The patent merges the advantages of digital control with electrostatic rotary cup spraying. The PLC intelligent controller provides digital precision control over the rotary cup speed, rotation angle, and glaze flow rate. This combination enables the system to achieve both the adaptability of digital glazing and the high glazing amount capacity of rotary cup spraying, exceeding 120 g/m2 per channel while maintaining digital precision.
Solution Approach 2:
The patent uses composite water-based glaze materials with optimized specific gravity (1.60-1.80) formulated specifically for electrostatic spraying. This composite glaze formulation enables the system to achieve high glazing amounts while maintaining proper atomization and distribution, overcoming the limited glazing capacity of ink-jet systems that use different material compositions.
5Manufacturing precision
If traditional equipment is used for thin-layer water-based glaze with specific gravity between 1.20 and 1.50, then glazing can be applied, but uniform distribution on large-scale products cannot be achieved
Solution Approach 1:
The patent replaces traditional mechanical spraying systems with electrostatic spraying. The electrostatic field forces charged glaze particles to distribute uniformly across the product surface, regardless of scale. This electrostatic distribution mechanism overcomes the limitations of mechanical systems that cannot achieve uniform distribution on large-scale products, enabling consistent glaze application across the entire product surface.
Solution Approach 2:
The patent optimizes the working specific gravity parameter to between 1.60 and 1.80, which is specifically suited for electrostatic spraying of thin-layer glaze. This parameter change enables proper atomization and electrostatic distribution, achieving uniform glaze distribution on large-scale products that cannot be accomplished with traditional equipment using lower specific gravity glazes.
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
This solution effectively addresses the issues of rotary cup glaze accumulation, glaze dropping, electric leakage, and uneven glaze distribution, achieving uniform atomization and coating of all-water thin-layer glaze on large-size products in the building ceramic industry.
Implementation Method 1
a high-voltage electrostatic generator connected with the electrostatic rotary cup spray gun and used for electrifying the electrostatic rotary cup spray gun
Implementation Method 2
an electrostatic rotary cup spray gun connected with a transfer isolation glaze barrel and used for receiving the glaze in the transfer isolation glaze barrel and spraying the glaze to a body to be glazed
Data Source
AI summary
Electrostatic spraying equipment and an electrostatic spraying method. The electrostatic spraying equipment includes a glaze storage and adjustment device used for storing and stirring glaze, a transfer isolation device used for receiving the glaze in the glaze storage and adjustment device, an electrostatic rotary cup spray gun used for receiving the glaze in a transfer isolation glaze barrel and spraying the glaze to a body to be glazed on a glaze line, a PLC (programmable logic controller) intelligent controller connected with the glaze storage and adjustment device, the transfer isolation device and the electrostatic rotary cup spray gun, and a high-voltage electrostatic generator connected with the electrostatic rotary cup spray gun and used for electrifying the electrostatic rotary cup spray gun. The glaze is stored and stirred through the glaze storage and adjustment device.