Electrostatic Spray Nozzle Stabilization Electrode
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Solution Overview
Problem
Existing electrostatic spray devices face instability in atomization when a large amount of liquid is supplied, leading to uneven particle diameters and difficulties in coating applications, as the increased liquid flow disrupts the formation of a stable Taylor cone and causes non-uniform electrostatic explosions.
Innovation Solution
The introduction of a central rod within the nozzle with a larger opening diameter and a stabilization electrode that adjusts the equipotential curves to concentrate the electrostatic force, ensuring stable atomization even with increased liquid flow by dispersing the electrostatic force and maintaining a uniform charging state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large amount of liquid is supplied to the nozzles, then the application time is shortened and productivity is improved, but the atomization state becomes unstable and manufacturing precision deteriorates
Solution Approach 1:
The electrode is divided into multiple segments (first electrode and second electrode) arranged in sequence along the liquid flow direction. This segmentation allows different regions of the electrode to control different aspects of the electric field, enabling stable atomization even with high liquid flow rates by creating a more distributed and controlled electrostatic force profile along the liquid path.
2Productivity
If a large amount of liquid is supplied to the nozzles, then the coating efficiency is improved, but the particle diameter variation increases and manufacturing precision deteriorates
Solution Approach 1:
The segmented electrode structure distributes the electrostatic force generation along the liquid flow path, with each electrode segment contributing to the atomization process. This ensures that even with increased liquid flow, the electric field acts uniformly across different regions of the liquid stream, maintaining consistent particle diameter throughout the spray.
Solution Approach 2:
Different electrodes are positioned at different locations relative to the nozzle opening, with the first electrode closer to the nozzle and the second electrode further away. This local differentiation allows the electric field to be optimized at different stages of liquid discharge, ensuring uniform atomization quality across the entire liquid flow regardless of the total flow rate.
3Productivity
If a large amount of liquid is supplied to the nozzles, then the application rate is increased, but the liquid fails to atomize properly and manufacturing precision deteriorates
Solution Approach 1:
The segmented electrode arrangement ensures that the electric field is applied progressively along the liquid flow path. The first electrode initiates atomization at the nozzle exit, while the second electrode continues the atomization process further downstream, ensuring complete atomization even for high-volume liquid flows that would overwhelm a single electrode system.
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 configuration allows for stable atomization of liquids with varying viscosities, maintaining particle diameter uniformity and preventing nozzle clogging, even at higher liquid supply rates, thereby enhancing the efficiency and consistency of the electrostatic spray process.
Implementation Method 1
a voltage application unit that applies a voltage between the liquid spray unit and heteropolar portion
Implementation Method 2
atomizes a liquid body by electrohydrodynamics
Implementation Method 3
the liquid is supplied in a state of being pressurized... formation of a stable Taylor cone
Implementation Method 4
causes non-uniform electrostatic explosions
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
There is provided an electrostatic spray device and an electrostatic spray method that ensure stable atomization even when an amount of supplied liquid is large. The electrostatic spray device includes a liquid spray unit including a nozzle configured to spout a liquid; voltage application unit configured to apply a voltage between the liquid spray unit and a heteropolar portion functioning as a pole opposite from a pole of the liquid spray unit to generate an electrostatic force for causing the liquid to separate from a distal end of the nozzle in a charging state; and a stabilization electrode configured to maintain a spraying state of the liquid in a stable state even when a pressure is applied to the liquid to supply the nozzle with the liquid. The stabilization electrode has an electric potential identical to an electric potential of the liquid spray unit, and is disposed near the nozzle such that a jet portion formed at a front of the nozzle by a linear extension of the liquid has a length longer than a length of the jet portion before the stabilization electrode is provided.