Electrostatic Sprayer Dual Electrode Ionization Stability
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Solution Overview
Problem
Existing electrostatic spraying installations for coating products are prone to dirtying and reduced efficiency due to sensitivity to environmental changes and the Corona effect, leading to frequent interruptions for maintenance and costly recovery procedures.
Innovation Solution
An electrostatic sprayer with a rotating bowl and dual electrode configurations, where the second electrodes emit ions towards the bowl edge, creating a more stable ionization phenomenon and reducing the risk of dirtying by maintaining a consistent electrostatic field, even in varying environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external charging with single electrode configuration is used, then coating product can be kept at earth potential without short-circuiting, but electrodes become dirty and ionization current decreases leading to runaway dirtying phenomenon
Solution Approach 1:
The single electrode is divided into multiple electrodes (first electrodes and second electrodes) arranged in different spatial configurations. The first electrodes are distributed around the rotation axis and the second electrodes are positioned at different radial distances, creating segmented ionization zones that reduce mutual interference and dirtying.
Solution Approach 2:
The patent introduces a multi-dimensional electrode arrangement where electrodes are positioned at different radial distances from the rotation axis (different circles centered on the axis). This spatial dimensionality creates diverse ionization pathways and reduces the concentration of coating product on individual electrodes.
2Productivity
If electrode is positioned close to bowl for effective charging, then charging efficiency improves, but electrode is more exposed to coating product cloud and becomes dirty faster
Solution Approach 1:
Multiple electrodes are positioned at different radial distances from the rotation axis, creating segmented charging zones. This allows the system to maintain effective charging while distributing the exposure to coating product across multiple electrodes rather than concentrating it on a single electrode.
Solution Approach 2:
Different electrodes are positioned in different locations relative to the bowl and coating product cloud. The first electrodes are distributed around the rotation axis while second electrodes are at different radial distances, creating local variations in exposure and ionization effectiveness.
3Adaptability or versatility
If ionization current intensity varies due to environmental changes, then charging consistency deteriorates, but system continues operation without intervention
Solution Approach 1:
Multiple electrodes create segmented ionization zones that are less sensitive to environmental variations. If one zone is affected by environmental changes, other zones continue to provide stable ionization, maintaining overall charging consistency.
Solution Approach 2:
The patent uses multiple electrodes at different positions to create a more robust ionization system that can adapt to environmental changes. The distributed electrode configuration allows the system to maintain stable ionization current through parameter diversity in spatial arrangement.
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 dual electrode configuration enhances the stability of the ionization process, reducing the risk of electrode dirtying and maintaining consistent electrostatic charging, thereby ensuring reliable and efficient coating operations with reduced downtime and maintenance costs.
Implementation Method 1
emit, when the sprayer is operating and at least partially toward an object to be coated, a first stream of ions from a first tip
Implementation Method 2
encounter ions bombarded by these electrodes and end up being electrostatically charged
Implementation Method 3
When such a droplet or particle thus charged is subjected to an electrostatic field, it undergoes a Coulomb force proportional to its charge and the intensity of this field
Implementation Method 4
a rotating bowl and several electrodes distributed around the rotation axis of the bowl
Data Source
AI summary
This electrostatic sprayer of coating products with external load, comprises a bowl rotatable about an axis, a turbine for rotating the bowl around this axis, and a plurality of first electrodes distributed around the axis and each capable of emitting, when the sprayer is operating and is at least partly in the direction on an object to be coated, a first ion flux from a first point. The first points are arranged in a first circle centered on and perpendicular to the axis. The sprayer comprises second electrodes each capable of emitting, when the sprayer is operating and mainly or exclusively in the direction of an edge of the bowl, a second ion flux, of the same sign as the first ion flux, from second points arranged in a second circle centered on and perpendicular to the axis, and having a different radius than the first circle.