Electrostatic Spray Nozzle Assembly for Thin-Line Viscous Lubrication

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Solution Overview

Problem

Existing electrostatic spray nozzle systems are ineffective for spraying high viscosity oils, leading to wasteful overspray, environmental harm, and potential electrical arcing, while pressurized air atomization lacks precision and is costly.

Innovation Solution

A hydraulic electrostatic spray nozzle assembly that directs thin line high viscosity liquids without pressurized air, using a charged electrode with metering orifices and a conical tip for precise targeting, preventing arcing and overspray.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If pressurized air assisted atomization is used to spray high viscosity oils, then atomization of the liquid is improved, but precision of spray targeting deteriorates and overspray increases

Engineering Contradiction:

Improvespray targeting precisionVSAvoidoverspray waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent extracts and removes the pressurized air assistance system from the electrostatic spray nozzle, eliminating the source of poor precision and overspray. The nozzle achieves effective atomization of high viscosity oils through electrostatic forces alone, without relying on compressed air that causes conic spray patterns and wasteful dispersion.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical pressurized air atomization system with an electrostatic field-based atomization system. Instead of using mechanical force from compressed air to break up the liquid, the system uses electrostatic charging and field forces to achieve precise, targeted spray delivery with minimal overspray.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If minimal lubricant flow is used for thin line discharge, then precision of application is improved, but electrical arcing between electrode and metal component occurs

Engineering Contradiction:

Improveapplication precisionVSAvoidelectrical arcing

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent changes the flow rate parameter of the lubricant to an optimized range that prevents both overspray and arcing. By carefully controlling the lubricant flow parameters and matching them with the electrostatic field strength, the system maintains continuous liquid supply to the electrode while achieving precise thin line discharge patterns.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system incorporates flow control mechanisms that respond to operating conditions to maintain optimal lubricant flow rates. This feedback control ensures that the liquid supply to the electrode remains continuous and at the correct rate, preventing the conditions that lead to electrical arcing while maintaining precise application.

Inventive Principle:

Principle #23Feedback

3Duration of action of stationary object

If higher viscosity oil is used for lubrication, then adherence to machine components is improved and equipment life is extended, but sprayability through conventional electrostatic nozzles deteriorates

Engineering Contradiction:

Improveequipment lifeVSAvoidsprayability

Core Design Contradiction:

Duration of action of stationary objectVSEase of operation

Solution Approach 1:

The patent replaces mechanical spray systems with an electrostatic field-based system that can effectively atomize and deliver high viscosity oils. The electrostatic forces are sufficient to overcome the high viscosity of the oil, enabling sprayability of materials that would be too thick for conventional pneumatic or mechanical spray systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical parameters of the spray system, specifically using electrostatic field strength and voltage parameters that are effective for high viscosity liquids. By adjusting these electrostatic parameters, the system achieves proper atomization and spray delivery of high viscosity oils that maintain their adhesive properties for extended equipment protection.

Inventive Principle:

Principle #35Parameter changes

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

Precisely and reliably applies high viscosity lubricants to small targets without wasteful overspray or arcing, enhancing equipment life and reducing environmental impact.

Implementation Method 1

a charged electrode with metering orifices and a conical tip for precise targeting, preventing arcing and overspray

Methodology Applied

Scientific EffectElectrostatic charge: Electrostatics

Implementation Method 2

electrostatic spray nozzle assembly that directs thin line high viscosity liquids without pressurized air

Methodology Applied

Scientific EffectElectrostatic deposition: Electrostatic Deposition

Data Source

PatentUS12551909B2Narrow point electrostatic spray nozzle assembly and lubricant dispensing system

Publication Date: 2026.02.17 SPRAYING SYSTEMS CO

AI summary

A liquid dispensing system for dispensing highly viscous liquids such as lubricating oil. The system includes a nozzle body and elongated electrode that define an annular liquid flow passage communicating with a protruding conically configured terminal end of the electrode. An end cap of the nozzle body defines a plurality of circumferentially spaced discharge orifices about the electrode for controlling the discharge of electrically charged liquid onto the terminal end of the electrode for direction therefrom in a thin line, having a width of less than 0.06 inches.