Granular Coating Mass Airless Spraying Nozzle Clogging
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Solution Overview
Problem
Conventional grain-containing coating compositions for thermal insulation composite systems face issues with viscosity, nozzle clogging, and high rebound losses when applied using airless spraying, leading to material waste and contamination risks, especially on elastic substrates like polystyrene boards.
Innovation Solution
A coating composition with fillers of maximum grain size ≤250 µm, combined with organic/inorganic binders, water, additives, and reinforcing fibers, allowing for airless spraying without nozzle clogging and reduced kinetic energy, enabling focused application and reduced material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional granular coating compositions are applied using airless spraying, then application efficiency is improved, but nozzle clogging occurs and material losses increase due to high kinetic energy
Solution Approach 1:
The patent changes the particle size parameter of fillers from conventional coarse granular sizes to fine-grained particles with a maximum particle size of ≤250 µm. This parameter change reduces the kinetic energy of the coating material upon impact with the substrate, thereby minimizing rebound losses while still enabling efficient airless spraying application.
2Productivity
If conventional granular coating compositions are applied using airless spraying, then application efficiency is improved, but nozzle clogging occurs
Solution Approach 1:
The patent specifies that the maximum particle size of fillers should be ≤250 µm, which is a critical parameter change compared to conventional coarse granular compositions. This fine-grained specification prevents nozzle clogging during airless spraying while maintaining application efficiency, as the smaller particles can pass through nozzle openings without causing blockages.
3Productivity
If compressed air is used to convey coating material, then application speed is improved, but material losses increase due to rebound effect on elastic substrates
Solution Approach 1:
The patent changes the particle size parameter to ≤250 µm, which reduces the kinetic energy of the coating material. This parameter change mitigates the rebound effect on elastic substrates like polystyrene boards, thereby reducing material losses while maintaining acceptable application speed through airless spraying.
Solution Approach 2:
The patent replaces the compressed air-based mechanical conveying system with an airless spraying system that uses a pump to generate material pressure. This substitution eliminates the high-speed airflow that causes rebound losses on elastic substrates, while the pump-based system provides controlled material delivery.
4Productivity
If compressed air spraying is used, then application speed is improved, but mist and turbulence occur causing contamination
Solution Approach 1:
The patent replaces the compressed air-based spraying system with an airless pump-based system. This substitution eliminates the high-speed airflow that generates mist and turbulence, thereby preventing contamination of adjacent components and the surrounding area while maintaining application speed.
Solution Approach 2:
The patent changes the material pressure parameter generated by the pump to achieve optimal atomization without excessive kinetic energy. This parameter change produces a controlled spray pattern that minimizes mist and turbulence, reducing contamination risks while maintaining efficient application.
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 composition facilitates efficient, clean, and cost-effective application with reduced material waste and environmental protection, suitable for various application methods, including mechanical and airless spraying, ensuring excellent adhesion and layer formation in thermal insulation composite systems.
Implementation Method 1
After application, the coating compound hardens and forms a rigid plaster layer
Implementation Method 2
The stresses that regularly occur within the plaster layer during the hardening process due to shrinkage are absorbed by a reinforcing mesh embedded in the reinforcing layer
Data Source
AI summary
Viscous, particle containing curing coating mass, comprises: fillers comprising carbonates, magnesium hydrosilicates, layer silicates and/or barium sulfate; organic and/or inorganic binders comprising polymer dispersions, dispersible powder, cement, water glass and/or calcium hydroxide; water; various additives comprising film formers, defoamers, thixotropic agent, hydrophobic agent, crosslinking agent, preservatives and/or flame retardants; and organic and/or inorganic reinforcing fibers comprising cellulose fibers and/or glass filaments. Viscous, particle containing curing coating mass, comprises: 30-75 mass% of fillers comprising carbonates, magnesium hydrosilicates, layer silicates and/or barium sulfate, in a particle distribution with a maximum particle size of >= 500, preferably 150 mu m; 5-30 mass% of organic and/or inorganic binders comprising polymer dispersions, dispersible powder, cement, water glass and/or calcium hydroxide; 5-45 mass% of water; 0.3-25 mass% of various additives comprising film formers, defoamers, thixotropic agent, hydrophobic agent, crosslinking agent, preservatives and/or flame retardants; and >= 4 mass% of organic and/or inorganic reinforcing fibers comprising cellulose fibers and/or glass filaments, where a fine coating mass is obtained and is discharged by airless spraying process.