Electrostatic Spray Nozzle Assembly with Modular Segmented Air Cap
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Solution Overview
Problem
Existing electrostatic spray nozzle assemblies with long nozzle bodies and complex configurations face challenges in assembly, installation, and repair, leading to potential high voltage leakage and inefficiencies in liquid particle breakdown and distribution.
Innovation Solution
A pressurized air assisted electrostatic spray nozzle assembly with a modular design, featuring a long nozzle body, a conductive liquid feed tube, and a segmented air cap that allows for easy assembly and maintenance, along with a conductive stinger unit for enhanced electrical charging and particle breakdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the nozzle body is made relatively long to position the spray nozzle far from the liquid inlet and high voltage cable connection, then safety and electrical isolation are improved, but assembly, installation and repair become difficult and improper assembly can result in high voltage leakage
Solution Approach 1:
The spray nozzle assembly is divided into separate modular components including the nozzle body, spray nozzle, charging electrode, and air cap that can be assembled and disassembled independently. This segmentation allows the long nozzle body to maintain electrical isolation while enabling easier assembly and maintenance of individual components.
Solution Approach 2:
A feed tube with integrated liquid passage and electrical conductor is introduced as an intermediary component that simultaneously transports liquid and conducts electrical charge from the charging electrode to the spray nozzle. This mediator ensures proper electrical connection while maintaining the structural integrity of the long nozzle body.
2Reliability
If the spray nozzle is positioned at a relatively long distance from the liquid inlet and pressurized atomizing air inlet, then safety and electrical isolation are improved, but it becomes difficult to properly assemble and install the assembly
Solution Approach 1:
The assembly is segmented into manufacturable sections that can be produced separately and then assembled. The nozzle body, spray nozzle, and air cap are designed as distinct components that can be manufactured using standard processes and then connected through standardized interfaces.
Solution Approach 2:
The feed tube serves multiple functions simultaneously: it acts as a liquid conduit, an electrical conductor, and a structural support element. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly process despite the long nozzle body length.
3Reliability
If a long nozzle body is used to position the spray nozzle far from the inlet, then high voltage leakage is reduced, but repair and maintenance become more difficult
Solution Approach 1:
The modular segmented design allows the spray nozzle, air cap, and feed tube to be removed and replaced independently without replacing the entire long nozzle body. This enables easy maintenance and repair of wear-prone components while maintaining the electrical isolation benefits of the long nozzle body structure.
Solution Approach 2:
The design allows easy replacement of consumable components like the spray nozzle tip and air cap that may wear or become clogged, while the main nozzle body structure remains in place. This facilitates selective replacement of components during maintenance.
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 enables more efficient and reliable operation by ensuring precise electrical charging and easier assembly and repair, reducing the risk of high voltage leakage and improving the distribution of electrostatically charged liquid particles.
Implementation Method 1
The elongated feed tube (74) is disposed within the elongated nozzle body (40) and has a liquid passage (80). The spray tip (94), which is made of electrically conductive material... liquid passing through the feed tube (74) and through the spray tip (94) is electrically charged
Implementation Method 2
The air cap (44) also defines an air flow passage (92) about the spray tip (94) having an air discharge orifice (discharge orifice of 92) from which pressurized air is directed about the pattern of electrostatically charged liquid particles discharging from said spray tip (94)
Data Source
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AI summary
An air assisted electrostatic liquid spray nozzle assembly having a relatively long elongated nozzle body with a spray tip and surrounding air cap disposed at a downstream end of the nozzle body. The spray nozzle assembly includes an upstream electrode for connection to a high voltage electric source, an elongated feed tube, an electrically enhancing stinger, and the spray tip which are secured and retained by the air cap in electrically conductive relation to each other such that liquid passing through liquid passages of the electrode, feed tube, stinger, and spray tip is discharged in an electrostatically charged pattern of liquid particles. The air cap is removable to permit easy removal and replacement of the spray tip, stinger, and liquid feed tube.